PolyAl vs virgin LDPE: which to spec?
Short answer
PolyAl is an LDPE-dominated recycled polyolefin (~66% LDPE, 18% HDPE, 6% PP, ~10% aluminium) reclaimed from post-consumer packaging, which makes virgin LDPE its closest technical reference. PolyAl is the right call for moulded and extruded parts — profiles, crates, pallets, panels — where the aluminium micro-reinforcement adds stiffness and the recycled content cuts embodied CO₂. Virgin LDPE still wins for thin blown film, clarity and food-contact packaging, where PolyAl's aluminium filler and opacity rule it out.
Virgin LDPE is the benchmark polyolefin for flexible film, squeeze bottles and coatings — low density, high elongation, excellent clarity. PolyAl starts from the same polymer family (it's LDPE-dominated) but is reinforced with aluminium fines left over from carton recycling, so it behaves like a stiffer, more opaque, more filled version of LDPE. That makes it a strong substitute in moulding and profile applications, and a poor one in thin transparent film.
Side-by-side comparison
| Property | PolyAl | virgin LDPE |
|---|---|---|
| Origin | 100% post-consumer recycled, EU origin | Fossil-based, virgin |
| Polymer composition | ~66% LDPE, 18% HDPE, 6% PP + ~10% aluminium | 100% LDPE |
| Density | 950 – 1050 kg/m³ (aluminium-loaded) | 915 – 935 kg/m³ |
| Melt flow index (190 °C / 2.16 kg) | 2 – 4 g/10 min | 0.3 – 20 g/10 min (grade-dependent) |
| Vicat softening point | 90 – 100 °C | 85 – 95 °C |
| Tensile strength | 10 – 15 MPa | 8 – 15 MPa |
| Flexibility / elongation at break | Moderate (filler reduces stretch) | Very high, ideal for film |
| Clarity / transparency | Opaque (aluminium content) | Transparent to translucent |
| Thin blown film suitability (< 100 µm) | Not suitable | Excellent |
| Injection moulding / profile stiffness | Higher, thanks to aluminium reinforcement | Lower, needs fillers or blending |
| Food-contact approval | Not applicable | Available in food-grade resins |
| Embodied CO₂ | Very low (~0.3 t CO₂/t) | High (~1.8 – 2.0 t CO₂/t) |
| PPWR recycled-content compliance | Yes | No |
| Price stability | Decoupled from oil markets | Tied to crude & ethylene prices |
Choose PolyAl when…
- You mould or extrude rigid-to-semi-rigid parts: crates, panels, profiles, pallets, urban furniture.
- You want the stiffness bump aluminium gives over pure LDPE without adding fillers yourself.
- You need to hit PPWR recycled-content quotas or report a Scope 3 reduction.
- You want a raw-material cost decoupled from crude oil and ethylene price swings.
Stick with virgin LDPE when…
- You need thin blown film (bags, wraps, liners) with high clarity and stretch.
- Your application requires food-contact or medical-grade certification.
- You need a precisely tunable, filler-free MFI across a wide range for demanding film or coating lines.
- Transparency or very light weight (low density) is a hard requirement.
FAQ — PolyAl vs virgin LDPE
Is PolyAl the same thing as recycled LDPE?
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Not exactly. PolyAl is an LDPE-dominated recycled polyolefin (roughly 66% LDPE, 18% HDPE, 6% PP) reclaimed from the plastic-aluminium layer of beverage cartons, plus about 10% residual aluminium. It behaves like a reinforced LDPE rather than a pure single-polymer recyclate.
Can PolyAl replace virgin LDPE in my application?
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Yes for injection-moulded and extruded rigid or semi-rigid parts — profiles, crates, pallets, panels, urban furniture — where its higher stiffness and opacity aren't a drawback. No for thin blown film, clarity-critical parts, or food-contact packaging, where virgin LDPE's purity and transparency are required.
Why does PolyAl have a higher density than virgin LDPE?
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The ~10% aluminium content left over from the carton's barrier layer adds mass without a proportional volume increase, pushing density from LDPE's typical 915–935 kg/m³ up to 950–1050 kg/m³ for PolyAl.
Does PolyAl reduce embodied CO₂ compared to virgin LDPE?
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Yes, substantially. Virgin LDPE production carries roughly 1.8–2.0 t CO₂ per tonne from fossil feedstock and cracking; PolyAl's recycling route is closer to 0.3 t CO₂ per tonne, a reduction of roughly 1.5 t CO₂ per tonne switched.
Is PolyAl's price more stable than virgin LDPE?
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Yes. Virgin LDPE pricing tracks crude oil and ethylene markets closely. PolyAl is sourced from a recycled waste stream, so its cost base is decoupled from those fossil feedstock cycles, giving buyers more predictable input costs.
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