After peaking up in 1999, PP business has been adversely affected due to huge over capacity (38 million tonnes vs. 30-31 million tonnes consumption in 2001), falling prices (as low as US$450/t) and rising feedstock costs. To provide stimulus to the growth, PP_R&D teams have developed several new grades, either using newer and modified catalyst systems or better polymerization processes.

Metallocene catalysts that have introduced several newer and enhanced PE grades are finally getting more importance in the bulk markets, compared to niche markets of fibers earlier. Several isostatic grades, ranging from a very low (fractional MFR) to a very high (40 MFR) in homopolymer, random copolymers and impact copolymer grade range for blow moulding, injection moulding as well as film extrusion have been commercially introduced. These metallocene PP (mPP) grades offer higher melt strength for low MFR grades, better clarity, higher impact and most importantly - lower extractables. They are therefore more suitable for food packaging. Atofina has introduced Syndiotechtic PP copolymer grades that have lower melting points, lower crystallinity and exceptionally good gloss compared to the conventional PP grades. Their excellent flexibility make them a suitable replacement to flexible PVC.

In addition to Atofina, ExxonMobil also has introduced Achieve mPP homopolymers for injection moulding applications.

Basell - the largest PP supplier globally, has now introduced high flow nucleated homopolymers for thin wall moulding. DOW - a relatively later entrant to PP business has commercially introduced 'Inspire' grades. Some of the inspire PP grades have expectionally higher melt strength and excellent dart impact strength. This makes them ideally suitable for heavy duty films.

The developments are not restricted to Metallocene catalysts alone. Several new developments with new and better Z-N heterogeneous catalysts have also been introduced into the markets. High crystallinity grades with better mechanical strength have been offered by Atofina and BP. With its new gas phase loop process called Multi Zone Circulating Reactor (MCZR), Basell is expected to produce more uniform products. This process has the capability to also produce bimodal MWD that will have enhanced performance characteristics. These new products are expected to increase the scope of PP applications and are therefore expected to provide stimulus to growth of PP.