PolyAl vs virgin HDPE: which to spec?
Short answer
PolyAl is not a one-for-one substitute for virgin HDPE: it always goes into the blend with the resin you already run, on your existing injection and extrusion lines for pallets, profiles, urban furniture and crates. It matches HDPE on density, Vicat point and chemical resistance while cutting embedded CO₂ by ~1.6 t per tonne and providing 100% post-consumer recycled content traceable to post-consumer packaging.
Virgin HDPE is the industry workhorse for durable plastic goods, but it carries a fossil footprint and zero recycled content. PolyAl is engineered to match the technical performance HDPE buyers expect — same processing window, similar mechanical envelope — while turning a hard-to-recycle waste stream (polylaminated cartons) into ISCC PLUS certified pellets ready for your existing lines.
Side-by-side comparison
| Property | PolyAl | virgin HDPE |
|---|---|---|
| Origin | 100% post-consumer recycled, EU origin | Fossil-based, virgin |
| Recycled content | 100% | 0% |
| Density | 950 – 1050 kg/m³ | 940 – 970 kg/m³ |
| Melt flow index (190 °C / 2.16 kg) | 2 – 4 g/10 min | 0.3 – 8 g/10 min (grade-dependent) |
| Vicat softening point | 90 – 100 °C | 120 – 130 °C |
| Tensile strength | 10 – 15 MPa | 20 – 30 MPa |
| Chemical resistance (cleaning agents) | UNE 56875:2021 intensive use | Excellent |
| Embodied CO₂ | Very low (~0.3 t CO₂/t) | High (~1.9 t CO₂/t) |
| PPWR recycled-content compliance | Yes | No |
| Aluminium reinforcement | ≈10% (natural) | None |
| Price stability | Decoupled from oil markets | Tied to crude & gas prices |
Choose PolyAl when…
- You manufacture pallets, crates, profiles, urban furniture or fencing.
- You need to hit PPWR recycled-content quotas before 2030.
- You report Scope 3 and want a verifiable category-1 reduction.
- You want price stability decoupled from oil markets.
Stick with virgin HDPE when…
- Your part is load-bearing and needs Vicat > 110 °C.
- You require food-contact-grade material.
- You need very high tensile strength (> 20 MPa) without redesign.
FAQ — PolyAl vs virgin HDPE
Can PolyAl be used instead of virgin HDPE?
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Not one-for-one. PolyAl is blended with the resin you already run, on the same injection and extrusion lines, with melt temperatures of 180–220 °C and an MFI of 2–4 g/10min. The share is set by the converter for the part and process, and we help you tune it.
How much CO₂ do I save by switching from virgin HDPE to PolyAl?
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Roughly 1.6 tonnes of CO₂ equivalent per tonne of pellets — the difference between the embodied emissions of fossil HDPE production (~1.9 t CO₂/t) and PolyAl recycling (~0.3 t CO₂/t).
Does PolyAl count toward PPWR recycled-content targets?
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Yes. PolyAl provides ISCC PLUS certified post-consumer recycled content traceable back to the sorting facility, which is exactly what the EU Packaging and Packaging Waste Regulation requires.
Can I blend PolyAl with virgin HDPE?
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Yes. Many converters start with 30–50% PolyAl in their HDPE blend to validate parts before going to 100% recycled content.
What's the price difference?
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PolyAl is typically priced at or below virgin HDPE depending on oil markets, with the added benefit of decoupling your input cost from crude oil volatility.
Run the numbers on your application
Send us your spec and target volume — we'll come back with a tailored quote and a comparative environmental impact estimate within 48 hours.
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