Unlock Peak Performance and Efficiency in UNIPOL^® Polypropylene Process Technology using CONSISTA^® Catalysts

CONSISTA^® catalysts provide optimal performance in PP resin production.

Manufacturers of food containers want a polypropylene that does not impart a taste or odor to the contents of the package. Companies making medical syringes and IV bags need polypropylene that is resistant to chemicals and stable in the sterilization process. Makers of automotive parts need a product that is lightweight and impact resistant. In making household products, the polypropylene needs to be durable and aesthetically appealing.

Grace developed CONSISTA^® catalysts to meet these requirements. The catalyst enhances polymer resin properties such as high melt rate, impact resistance, clarity, and stiffness for homopolymers, random copolymers, and impact copolymers. These catalysts are designed as drop-in solutions for existing UNIPOL^® PP technology plants, requiring no additional capital investment. They also minimize raw material operating costs due to their greater productivity and reduced need for peroxide additives.

These sixth-generation Ziegler-Natta catalysts offer several key advantages:

• Improved Reactor Operability: Traditional catalysts may cause polymer buildup (fouling) on reactor walls, leading to frequent shutdowns for cleaning. CONSISTA^® catalysts and donors significantly reduce this issue, ensuring smoother operations. Less fouling also means more stable process conditions, reducing the risk of reactor disruptions.
• Better Flowability of Catalyst Particles: The CONSISTA^® catalysts are engineered for uniform morphology, improving their dispersion and reaction consistency inside the reactor. This helps maintain a steady production throughput and prevent process upsets.
• Less Need for Peroxide Additives: Many polypropylene production processes require peroxide additives to adjust final polymer properties. Because CONSISTA^® catalysts enable production of high melt flow rate (MFR) polymers, they minimize the need for peroxides, streamlining production and reducing costs.
• Superior Product Properties: These catalysts and donors deliver high melt flow rates, improved stiffness, enhanced clarity, reduced volatile organic compounds (VOCs), and better taste and odor profiles – allowing for a broad range of PP products to be produced.

Grace has licensed its UNIPOL^® polypropylene technology at more than one hundred PP resin reactors worldwide, manufacturing the broadest range of homopolymers, random and impact copolymers, plus terpolymers. Together, these reactors produce close to three hundred standard grades of polypropylene resins that are used to manufacture a wide variety of consumer and industrial products, including food and industrial packaging, automotive parts, medical accessories, appliances, and range of consumer goods.

The efficiency and productivity of UNIPOL^® PP technology results from the unique combination of Grace’s proprietary process technology, CONSISTA^® catalysts and donors, and the global technical service and support that our experts provide. UNIPOL^® PP process technology licensees enjoy Grace’s Plant Lifetime Performance™ commitment and better outcomes because CONSISTA^® catalysts were made specifically with UNIPOL^® polypropylene process technology mind.