Application of Polypropylene in Technical Textiles

Muhammad Mushtaq Mangat1

Abstract
Polypropylene (PP) is a thermoplastic polymer with unique characteristics. It has various
applications. Technical textiles is one area where PP is used to produce numerous products. Its
growth rate is higher than any other synthetic fibers. Textile industry is using it to produce jackets
for outwears for protection from snow and rain. At the same time, it is used to produce
undergarments and diapers for kids. It is equally good for filters to separate fine particles from any
solution and much preferred by designers to make pipes to transport various types of solutions.
Surgeons also prefer PP for stitching purpose and it is also used to make patches in surgery. It is
believed that PP is one of the fibers which will help textile industry to develop new technical
textiles.

Introduction
In current era it seems impossible to think life without plastics and man-made fibers. Virtually there
is no filed were plastics are not contributing. There is a long list of products which are part of
plastic family. Polypropylene is one of the key members of plastic family. It has highest growth rate
and more applications than any other member. Technical textile is one the major recipient of the
polypropylene finer.

Polypropylene or polypropene (PP) is a thermoplastic polymer and has unique characteristics. After
passing through preliminary working which started in 1954, its large scale production was started in
1957 (Morris, 1989). There are divers’ fields where it is used and people are developing different
products and improving processes with its help. Growth in demand of PP is much higher than other
synthetic fibers. It is mainly due to its distinct technical functions. It is much liked by designers in
all fields, due to its light weight, strong, hydrophobic, flexible and as well as rigid, having low
thermal conductivity qualities. There are many technical textile products, where PP is regularly
used. It is widely used to make undergarments, jackets for outerwear, swimming suits, filters, bags,
diapers etc. This study is an effort to discuss salient features of PP and its application in technical
textiles.

1 Author is a student of PhD at Technical University Liberec Czech Republic (mushtaq.mangat@gmail.com

Hearle (2001) divides the man-made fibers development into three generations. Introduction of
polyamides, polyester, PP etc are considered the first generation of man-made fibers. Such fibers
were invented till mid of the twentieth century. In last quarter of the twentieth century, high-
modulus and high tenacity fibers were invented and made available in market. These are polymeric
and inorganic fibers. These fibers are considered second generation of the man-made fibers. By the
end of twentieth century, we see smart and intelligent fibers, which act in a different way. They are
also called Phase Changing Materials. This is the third generation of man-made fibers. Keeping the
history of the man-made fibers, PP belongs to the first generation.

History of Polypropylene
PP has gained much popularity just after its large scale production in 1954 and is used in numerous
fields. Its application area is much broader than any other synthetic fiber. Polypropylene (PP) has
more than one name. It is also called Polypropene; Polypropene; Propene polymers; Propylene
polymers. Most commonly it is called polypropylene.

As reported by American Chemical Society (ACS)2 in 1951, Paul Hogan and Robert Banks of
Phillips Petroleum invented High Density Polyethylene and Crystalline Polypropylene.
J.Paul Hogan and Robert L. Banks were searching a way to convert ethylene and propylene into
components of gasoline. During this process they found that by adding a certain catalyst, these
products can be converted into a solid material. They finally developed high density polyethylene
and crystalline polypropylene. It is considered a big achievement of the company.

History of PP invention and getting it patent is quite interesting. During 1951-53, three application
by Hogan and Banks; A. Zletz of Standard Oil; and Karl Ziegler of the Max Planck Institute were
filed to get patent of PP. It took more than 30 years to decide that who was the real inventor and
finally in 1989, appellate court ruled that J. Paul Hogan and Robert L. Banks are the owners of the
patent.

Market Size of PP
Alberta Economic Development, Williams Energy and Alberta Industrial Heartland Association
have prepared a report. They foresee 5.8% growth rate from 2004-9. They further report that in

2 ACS is a congressionally chartered independent membership organization which represents professionals at all degree
levels and in all fields of chemistry and sciences that involve chemistry.
2004 total world demand of PP was 28.6 Million, MT and it was expected that in 2009, it will be
51.3 Million, MT. In value terms it is more than 80 US $ billion.

Chemistry of PP
PP is an isotactic in nature. Macromolecules are the building blocks of isotactic polymers. Isotactic
polymers have a unique structure. In this structure all substituent are on one side of the
macromolecules. Additionally such compounds are less crystalline; mainly it is due to its structure.

Chemical formula of PP is (C3H6)n. Its density depends upon the rigidity. It ranges from 0.855 g/
cm3 (in amorphous region) to 0.946 g/cm3, (in crystalline region)

Tacticity is an important feature of PP and properties of PP are highly linked with its isotactic
structure. Particularly it plays an important role in making it crystal. It is mainly due to the
orientation of methyl groups. There are many catalysts available which make it isotactic. Most
commonly used is Ziegler-Natta catalyst. This catalyst produces isotactic PP. Through this process
a helical shape is produced which is arranged in a line. Through this arrangement, a crystal form is
produced. It is important to note that there are many more catalysts available which can modify the
nature and properties of PP. Such products can make it rigid or soft. Addition of catalyst depends
upon the end user requirements.
Kleinschmidt et al (2000) have discussed in detail polymerization of PP by using different
techniques to improve its isotacticity. They have used different solvents and successfully
incorporated different parameters which have improved its usability in various fields

PP manufacturing
PP is produced in three different ways called; homopolymers, copolymers, and block polymers. All
three have different characteristics. This variation has increased its application horizon. Extrusion
and molding are two methods which are commonly used in PP manufacturing. It depends upon the
final application. PP fiber is produced by using extrusion method, whereas, injection molding
technique is used to produce PP sheets which is used to make different parts. There are possibilities
to modify its properties during production. For example, colors and antistatic agents can be added
and certain polymers can be introduced to increase moisture transfer properties, etc.

In technical textiles, mainly PP fiber is used. PP fiber is produced by using melt spinning technique.
In this process polymer is converted into a liquid by using heat and then this liquid is passed
through spinnerets. Spinnerets of various diameter of the fiber ranging from micro to macro are
available. In addition, different shapes of the fiber, oral, round can be produced by using different
spinnerets. Material coming from spinnerets is cooled down immediately and reeled.

Forms of polypropylene

There are eight different types of polypropylene:

1. Polymer chip,
2. Staple fiber,
3. Spun staple yarn,
4. Textile multifilament,
5. High tenacity multifilament,
6. Bulked Continuous Filament (BCF),
7. Monofilament
8. Tape/slit film
Salient Features of Polypropylene
PP has some unique characteristics, which are making it much useful in various fields.
PP is semi crystalline in nature and lies between low density and high density polyethylene
structures. Its young modulus is also moderate and it demonstrates different picture when it is
copolymerized with polyethylene. PP is flexible as well as strong in nature. Its cost of production is
comparatively low as compared to other filaments, which is an added advantage and playing a
significant role in its growth in demand.

PP is one of the fibers which are quite difficult to dye. They are colored during extrusion process. It
is originally opaque and has the ability to withstand against fatigue. However, its melting point is
lower than polyester and higher than polyethylene. Its melting point is 160 C, which limits its
applications in clothing since this temperature is lower than the ironing temperature which is always
near to 200 C.

Density of PP is quite less when it is compared with other fibers (See Table 01). Due to its less
density, it covers more than 50% area as compared to polyester. In other words, we need less weight
of PP fiber to weave a certain length of fabric as compared to other natural and man made fibers.

Thermal conductivity is another salient feature of fibers when they are used to make clothing.
Human body generates thermal energy, which is necessary to keep it warm. In case of high thermal
conductivity lot of heat is transferred from the body which reduces the temperature of human body.
PP has lowest thermal conductivity among the man made fibers which helps undergarments to keep
human body temperature intact and provides a warm feel.

Resiliency is another property which is highly demanded by the clothing manufactures and users. It
is interesting to note that PP has resiliency better than most commonly used fibers and equal to
wool (see Table 4).

Laning (1992) reports that PP is widely used in ready mix concrete in USA. It serves various
purposes and much preferred by designers and users. Due to its hydrophobic nature, it is quite easy
to convert into a mesh which is easy to interconnect and disperse throughout the concrete mixture.
Laning (1992) concludes that PP has many advantages over other synthetic fibers.
Application of polypropylene

After reviewing the long list of PP products, we can divide it into two main categories; products
which are made by using PP fiber and products which are made by using thick or thin PP sheets. We
have given here a long list of PP applications and we also believe that this list is not exhaustive.
There are many more areas where PP is used. Demand of PP has highest growth rate among other
man made fibers. It is mainly due to unique characteristics of PP.

Application of PP starts from pipes and goes to ultrafine filament which is used in under garments
manufacturing. It is equally good in construction and widely used to make babies comfort by
providing them dry diapers since PP has almost 0% absorbency. PP is very strongly resistant to
acids and alkalies and can withstand under many sever conditions. It is used to make highly strong
and solid piping system, since it has a very strong resistance to corrosion. Furthermore, it is not
affected under freezing climate. In addition it has the ability to join by melting process rather than
by applying glue. It is mainly due to its lower melting point.

PP is widely used in filters and gives excellent results. Ultrafine PP fiber (less than 1.00 denier) is
affective filter for various matters like, oil particles, dust etc. Its inert ability provides extra benefits
in filtration process.

We can make crystal clear PP sheets for packing purposes. It is mainly due to biaxial property of PP.
Nevertheless we can produce colored PP by adding different colors during extrusion. PP is used for
packing of medicines and other liquids since it is quite inert in general. We can find chairs made by
PP. Such chairs are more suitable under some extreme climatic conditions.

PP is warmly welcomed by people interested to produce warm under garments. It is much liked by
people who have to experience very cold atmosphere. Its acceptance increased due to its property to
transport moisture from human body to environment.
Due to high strength, PP is also used in making ropes and sheets where there a high stretch or stress
is experienced. It is also replacing PVC in insulation process. People are using it in making water
proof roofs and sheets to cover places or installation.

PP has been accepted by medicine industry and is used where total non-absorbent material is
required. Suture made of PP is one example. Another example is use of PP is hernia and pelvic
organ prolapse repair operations. It is mainly to stop another attack of hernia.

PP in molded form has more application than in filament form. Such sheets are used to make
different parts or even complete products like chairs, tables, stationary folders, boxes etc. It can be
said that PP is first choice of designers who want to use colorful, solid, inert, light weight and
strong product.

Polypropylene is most commonly used for plastic moldings where it is injected into a mold while
molten, forming complex shapes at relatively low cost and high volume, examples include bottle
tops, bottles and fittings.

Fashion industry is another emerging avenue for PP products. People are making jewelry from PP,
which is much liked due to its various properties. Expanded Polypropylene (EPP) is another form of
PP which has significant advantages over other foams. It is well liked and most suitable in aircrafts
due to its low stiffness and high resilience characteristics.

PP shows quite considerable resistance towards heat in any autoclave. For this reason it is used to
make consumer grade kettles. Furthermore, food containers are mostly made of PP since it is quite
rigid and does not change its shaper during filling, etc. PP is commonly used to make disposable
bottles, juice or liquids bottles, coolers. Due to its strong resistance towards acids, it is commonly
used in batteries. It can be concluded that we see PP in every filed of life due to its versatile
properties.
Table 01
Technical Data of Different Natural and Man Made Fibers
Density Elongation % Tenacity Elastic recovery Initial modulus
g/cm3 cN/tex % N/Tex
Cotton 1.50-1.54 6-15 25-50 75 3-6
Wool 1.32 25-50 10-20 95-99 1.5-3
Silk 1.25 10-30 25-50 95 7-10
Viscose 1.52-1.54 10-30 16-45 70-100 2-3
Cellulose acetate 1.29-1.32 20-45 10-15 90-95 2-3.5
Nylon 6 1.14 30-70 30-40 96-100 0.5-3
P o l y e t h y l e n e1.36-1.41 20-30 25-60 90-98 2.5-4
terephthalate
(polyester)
Polyethylene 0.95-0.97 10-45 30-70 95-100 0.25-5
Polypropylene 0.90-.92 15-50 25-60 95-100 0.5-5

Source: Fritz (2008)

Table 02
Technical Data of Different Natural and Man Made Fibers
S p e c i fi c h e a tT h e r m a lDecomposition I r o n i n gW a t e rWater retention
capacity conductivity Temperature Ctemperature absorption
W/M K (Melting)
Cotton 1.3 0.3 to 0.5 400 180-220 7-11 40-50
Wool 1.3-1.6 0.2-0.4 16-170 15-17 40-45
Silk 0.2-0.4 0.2-0.4 170-180 140-165 9-11 40-45
Viscose 1.3-1.5 0.3-0.6 150-180 12-14 85-120
C e l l u l o s e1.3-1.5 0.3 180 6-7 20-28
acetate
Nylon 6 1.5-1.8 0.2.03 90-95 150 3.5-4.5 10-15
Poly ethylene0.4-1.9 0.2-0.3 250-260 150-200 0.2-0.5 3-5
terephthalate
(polyester)
Polyethylene 1.4-2 0.2-0.4 124-138 0 0
Polypropylene 1.6 0.2-0.3 160-175 130 0 0

Source: Fritz (2008)

Table 01 and 02 tell about different properties of PP, above average elongation, high tensile
strength, excellent elastic recovery, low initial modulus, above average specific heat capacity,
average thermal conductivity, low decomposition temperature and the lowest water absorbency and
water retention. Above mentioned properties are indicators, which help to understand the
significance of PP.

Vengsarkar (2010) has elaborated different properties of PP. One of the major properties of PP is its
resistance towards strong alkalis and acids. Table 03 depicts the standing of PP.
Table 03
Comparison of resistance towards alkalis, acids and microbial of different fibers

Resistance of PP towards Acids and Alkalies

Fiber Strong Alkalies Strong Acids Mildew/Moths/Insects

Polypropylene E E E

Polyester P A E

Nylon G P E

Acrylic G P E

Viscose D D A

E: Excellent; G: Good; D: Dissolves; A: Average; P: Poor

Source: Vengsarkar (2010)

Table o4
Resiliency % of Different Fibers

Fiber Resiliency
(%)

Polypropylene 280

Polyester 225

Polyamide 265

Acrylic 280

Rayon 40

Wool 282
 Fiber Resiliency
(%)

Cotton 30-85

Source: Vengsarkar (2010)

Vengsarkar (2010) concludes that isotactic nature of PP provides excellent resistance against many
mineral acids, alkalis, aqueous solutions of inorganic salts, detergents, oils, and greases at room
temperature. Vengsarkar (2010) has also discussed the moisture absorbency behavior of PP, which
is highly appreciated by active sportswear manufacturers and users. Due to high surface expansion,
it wicks away moisture quite quickly. PP does not retain at all any type of moisture, which gives
protection from the germination of bacteria or fungi. In addition it does not catch stain ultimately it
needs less effort in washing in shape of detergent and water.

Application of PP

Here is a short list of products where PP is used. This list provides an insight of PP application.

• Agriculture and Landscaping (Crop Covers, Turf Protections, Nursery Over wintering, Weed
Control Fabrics, Root Bags, Containers, Capillary Matting, Other types of covers)

• Personal Care and Hygiene (Diapers, Sanitary Napkins, Tampons, Training Pants, Incontinence
Products, Dry Wipes, Wet Wipes, Cosmetic Applications, Removers , Lens Tissue)

• Construction, Furniture and Bedding (Roofing and Tile Underlayment , Acoustical Ceilings ,
Insulation, House wrap, Pipe wrap, Sofa and Mattress Lining)

• Bags and Ladies Purses (Sleeping Bags, Tarpaulins, Tents Artificial Leather, Luggage, Vacuum
Cleaner Bags, Tea and Coffee Bags, Buff Pads)

• Apparel and Accessories (Coveralls, Pillow cases, Airline Headrests, Interlinings, Clothing and
Glove insulation, Bra and Shoulder Padding, pants, trousers, snow jackets, undergarments, socks)

Conclusion
Since 1954, PP is available in market and has a growth rate more than 5%. It has unique
characteristic which have made it versatile and its application horizon is much wider as compared to
other plastic materials. It is available in molded form and in filament form. PP filament is much
suitable for the production of technical textiles. It is used to make clothing, sheets, filters, napkins,
pillow cases and many more. Considering its strength, resistance to acids/alkalis, hydrophobic
qualities, flexibility, low thermal conductivity and many other technical parameters, it is presumed
that its demand will increase in coming years.

References

Fritz Schultze-Gebhardt (2008). Ullmann's Fibers. Ed. Wiley VCH. USA

Hearle, J. W. S. (2001). Introduction. In J. W. S. Hearle (Ed.), High Perfrmance Fibers: Woodhead

Publishing

Kleinschmidt, R., Griebenow, Y., & Fink, G. (2000). Stereospecific propylene polymerization using
half-sandwich metallocene/MAO systems: a mechanistic insight. Journal of Molecular
Catalysis 157(1-2), 83-90.

Laning, A. (1992). Primarily used to reduce shrinkage cracking, polypropylene, nylon, and
polyester fibers offer other benefits as well. Retrieved from ftp://imgs.ebuild.com/woc/
C920525.pdf

Vengsarker, D. S. R. (2010). POLYPROPYLENE STAPLE FIBRE FOR SPECIALLIZED

TECHNICAL TEXTILES APPLICATION. Retrieved from http://www.fibre2fashion.com/
industry-article/23/2282/polypropylene-staple-fibre-for-specialized-technical-textiles-
application1.asp