PolyAl vs recycled PP: which to spec?
Short answer
PolyAl is an LDPE-dominated recycled polyolefin (~66% LDPE, 18% HDPE, 6% PP, ~10% aluminium) from post-consumer packaging, aimed at profiles, pallets, crates and urban furniture. Recycled PP (rPP) is stiffer and holds up to higher temperatures, making it better for hot-fill packaging, automotive interiors and living-hinge parts, but its supply and price are more volatile and it lacks PolyAl's aluminium-driven stiffness boost at a comparable recycled-polyolefin cost.
Recycled PP is sourced mainly from post-industrial and post-consumer packaging (yoghurt pots, caps, automotive) and inherits PP's higher heat resistance and rigidity. PolyAl comes from a single, large, well-characterised post-consumer stream and is reinforced by the aluminium barrier layer rather than by polymer chemistry alone. The choice usually comes down to operating temperature, impact requirements and how much you value feedstock consistency versus polymer-family stiffness.
Side-by-side comparison
| Property | PolyAl | recycled PP |
|---|---|---|
| Origin | 100% post-consumer recycled, EU origin | Post-consumer/post-industrial PP (pots, caps, automotive) |
| Polymer composition | ~66% LDPE, 18% HDPE, 6% PP + ~10% aluminium | Predominantly PP, variable contamination |
| Density | 950 – 1050 kg/m³ | 900 – 920 kg/m³ |
| Melt flow index (230 °C / 2.16 kg, PP basis) | n/a (tested at 190 °C, 2–4 g/10 min) | 5 – 25 g/10 min, batch-dependent |
| Heat/temperature resistance (Vicat) | 90 – 100 °C | 140 – 155 °C |
| Stiffness / flexural modulus | 220 – 520 MPa (aluminium-reinforced) | 900 – 1300 MPa (typical, grade-dependent) |
| Impact resistance / toughness | Good, LDPE-driven flexibility | Lower, more brittle especially at low temp |
| Odour | Low after washing/pelletising | Can retain odour from prior use (food, automotive) |
| Feedstock consistency | High — single, large, characterised waste stream | Variable — many source streams and grades |
| Supply/price volatility | Lower, decoupled from oil markets | Higher, subject to rPP scarcity and demand spikes |
| Aluminium reinforcement | Up to 10-13% (natural, from carton barrier) | None |
| Embodied CO₂ | Very low (~0.3 t CO₂/t) | Low but variable (~0.4 – 0.7 t CO₂/t) |
Choose PolyAl when…
- You need consistent feedstock quality batch after batch, sourced from one well-characterised stream.
- Your part needs impact toughness and flexibility more than pure rigidity.
- You manufacture pallets, crates, profiles, urban furniture or panels for ambient-temperature service.
- You want to reduce exposure to rPP price and availability volatility.
Stick with recycled PP when…
- Your part must withstand sustained temperatures above 100–120 °C.
- You need higher flexural stiffness without adding fillers (e.g. thin-wall rigid parts, living hinges).
- You are targeting automotive or hot-fill packaging applications where PP's chemistry is the industry default.
FAQ — PolyAl vs recycled PP
Is PolyAl a type of recycled PP?
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No. PolyAl is an LDPE-dominated recycled polyolefin (roughly 66% LDPE, 18% HDPE, 6% PP) reclaimed from beverage cartons, plus about 10% aluminium from the carton's barrier layer. It only contains a small PP fraction, so it should not be marketed or specified as recycled PP.
Which is stiffer, PolyAl or recycled PP?
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Recycled PP, typically 900–1300 MPa flexural modulus versus PolyAl's 220–520 MPa. PP's semi-crystalline chemistry is inherently stiffer than PolyAl's LDPE-dominated, aluminium-reinforced matrix, so PP suits thin, rigid, self-supporting parts better.
Can PolyAl handle the same temperatures as recycled PP?
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No. PolyAl's Vicat softening point is around 90–100 °C, while recycled PP typically holds up to 140–155 °C. For hot-fill, autoclave or engine-bay applications, recycled PP is the better choice.
Is recycled PP's supply more volatile than PolyAl's?
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Generally yes. rPP is aggregated from many disparate sources (packaging, automotive, industrial scrap) with fluctuating quality and price. PolyAl is drawn from a single, large, structurally consistent waste stream — beverage cartons — which tends to give more predictable availability and pricing.
Why would I pick PolyAl over recycled PP for outdoor furniture or pallets?
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For ambient-temperature, impact-exposed applications like pallets, crates and outdoor furniture, PolyAl's greater flexibility and toughness (from its LDPE-dominated matrix) resist cracking better than the more brittle recycled PP, while its aluminium content adds stiffness that pure LDPE lacks.
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