LDPE and HDPE are thermoplastic materials under the family of polyolefins, which are

petrochemical-based plastics that include polypropylene (PP) and polyethylene

(PE). Polyethylene is the most common plastic material in the world and is known for its
simple structure, the simplest of all polymers commercially available.
Collectively under the polyethylene class of materials, LDPE (low-density
polyethylene) and HDPE (high-density polyethylene) have shaped the landscape of the
packaging and manufacturing industry. LDPE is well known for being widely used in plastic
bags as its low density makes it light and flexible, rendering it perfect for this kind of
application. HDPE, on the other hand, is harder and offers higher strength and better
resistance to heat. Recently, it has become very popular as a source material for 3D
printing filaments, used instead of ABS material. It is also used to produce durable plastic
parts such as HDPE pipes, toys and plastic chairs.
Although LDPE and HDPE are both thermoplastic ethylene polymers, they differ in several
properties and uses. One stark contrast is that LDPE has more branching than HDPE.
Branching takes place during polymerisation, where polymer chains have secondary
polymer chains attached to them by replacing an atom in the primary chain with a monomer
group. This weakens the intermolecular forces in the polymer. That is why HDPE have a
higher strength-to-density ratio than LDPE with increased tensile strength.
The varying uses of LDPE and HDPE are based on this fundamental structural difference,
among many other properties.
Here, you will learn about:
• The divergence in properties between LDPE and HDPE
• The advantages and disadvantages of using each polyethylene material
• How each of them is produced and processed
• The different applications of LDPE and HDPE
LDPE plastic bags
Properties of LDPE and HDPE
Although both materials come from the same ethylene monomer, the difference in chemical
structure yields a wide variety of unique properties.
As its name suggests, low-density polyethylene (LDPE) has a lower density, strength, and
temperature resistance. Meanwhile, high-density polyethylene (HDPE) is characterized by
higher specific strength and heat resistance.
Table 1. Comparison of the material properties of LDPE and HDPE
Property LDPE HDPE
Chemical structure More branching Less branching, more linear

Low density High density

Density
0.91-0.94 g/cm3 0.95-0.97 g/cm3
High crystallinity (>90%),
Low crystallinity (50-60%),
Flexibility which makes it tougher and
and therefore more flexible
more rigid
 Drastic decrease in density Able to withstand heat with
Heat resistance when subjected to temperatures more than
temperatures beyond 20°C 100°C

Melting point ~115°C ~135°C

Resistant to most alcohols,

Chemical resistance
Superior resistance to
acids, and alkalis; low
solvents, alcohols, acids, and
resistance to oxidising
alkalis; low resistance to
agents and selected
most hydrocarbons
hydrocarbons

Relatively increased impact High tensile and specific

Strength
strength in cold conditions strength

High, due to amorphous Low, due to increased level

Transparency
condition of crystallinity

Maximum allowable stress at

6–17 MPa 14–32 MPa
20°C

Pros and cons of using LDPE and HDPE

While both materials have their respective benefits, they also carry with them a number of
disadvantages. Here's a list of the pros and cons of each of LDPE and HDPE.
Table 2. Advantages and disadvantages of using LDPE vs HDPE
LDPE HDPE
Wide variety of uses Wide variety of uses
Low cost Low cost
Resistant to acids and bases High tensile strength

Advantages Easy to process and mould Able to resist low temperature

Good electrical insulation Relatively strong and stiff
Waterproof property Waterproof property
May be processed as transparent Good electrical insulation

More prone to crack stress May crack under stress

Not useful in extremely high or low Higher risk of mould shrinking
Disadvantages temperatures
Little to no UV resistance
High permeability to carbon dioxide
and other gases
 Little to no UV resistance

Production and processing of LDPE and HDPE

How is LDPE produced?
LDPE is made through either a stirred autoclave or tubular reactor. Its general manufacture
involves the compression of ethylene gas, polymerisation using an initiator, and gas
separation.

How is HDPE produced?

Most HDPE materials are produced by either slurry polymerisation or gas phase
polymerisation. The process starts with polymerisation from a solution of ethylene
monomers, followed by separation and drying.

How are those two polyethylene materials processed?

Once produced, the thermoplastic material may be processed for consumer or industrial
use by the following methods:
Injection moulding
This rapid process converts LDPE and HDPE pellets or granules into custom shapes and
sizes defined by the mould. The thermoplastic pellets are sent to a hot barrel, from which
the materials are melted through a screw barrel and heater bands. The molten plastic is
then injected to a pre-configured mould cavity, which also cools down the material. After
solidifying, the plastic material is ejected out of the moulding machine.
• Injection Moulding of Plastics: An Overview

Extrusion
Similar to injection moulding, this also makes use of heat to melt the plastic granules. The
difference comes at the final section of the machine – in this case, the melted plastic goes
through a pre-designed opening and is then cooled down to solidify.
Blow moulding
This type of processing is usually carried out to manufacture hollow-shaped plastic goods.
Instead of injecting the molten plastic, the process uses compressed air to blow the material
into the mould.
• Blow Moulding: History, Process, and Types

HDPE pipes
Applications of LDPE and HDPE
LDPE applications include:
• LDPE plastic bags
• Light packaging materials: Six-pack rings, waterproof carton lining, plastic wraps,
snap-on lids
• Wash bottles
• Corrosion protection layer for work surfaces
• Computer hardware covers and packaging
HDPE applications include:
• HDPE filament for 3D printers
• Strong packaging materials: bottle caps, plastic milk bottles, drums, bulk containers
for industrial use
• Fibres for ropes, nets, and industrial fabrics
• Vehicle fuel tanks
• Boat parts
• HDPE pipes and tubing
• HDPE plastic chairs and tables
• Playground structures: slides, swing seats
• Consumer products: trash and recycling bins, ice cube containers, toys, ice chests