Sumika Polymer Compounds has introduced a new grade of glass-fibre-reinforced polypropylene under the name ThermofilXP. This material, containing 30% glass fibre, has been developed to achieve both reduced injection moulding cycle time and high mechanical properties. The solution is intended to optimise not only the production of individual parts but the entire value chain from European OEMs to the end user. ThermofilXP addresses two key market challenges: increasing requirements for material performance in innovative products and the pressure to improve cost competitiveness and industrial efficiency.
Cycle time reduction of up to 10%
According to the manufacturer, the applied modifications make it possible to achieve up to a 10% reduction in cycle time compared with typical PP-GF materials. On an annual basis, this can correspond to an additional month of available production capacity without the need for extra capital expenditure on machinery.
For plastics processors this translates directly into benefits in several areas:
- measurable productivity increase,
- optimisation of unit part costs,
- higher machine availability thanks to shorter cycles,
- combining high technical performance with sustainability objectives.
Enhanced mechanical properties
Within the Thermofil range, ThermofilXP sets a new level for mechanical performance. According to the manufacturer, key material parameters include:
- tensile modulus up to 8,700 MPa,
- tensile strength up to 129 MPa,
- Charpy notched impact strength at 23°C of 11 kJ/m²,
- CO₂ equivalent emissions of 1.8 (value declared by the manufacturer).
The combination of high stiffness, strength and impact resistance, together with a limited carbon footprint, is intended to enable the material to be used in demanding applications where both durability and cost efficiency are required.
Designed for competitiveness
According to Sumika Polymer Compounds, ThermofilXP has been developed as a material that supports the competitiveness of industrial customers. The company highlights the combination of mechanical robustness, processing benefits resulting from shorter cycle time, and reduced environmental impact.
From the company’s perspective, this configuration of properties is meant to respond to the current challenges of the plastics processing industry, where not only performance and production cost are important, but also environmental indicators, including the carbon footprint of materials.
Bruno Pendélio, marketing manager and new product development manager at Sumika Polymer Compounds Europe, emphasises the importance of the new grade for customers: "ThermofilXP is not just a new product developed for a specific application, it is a real innovation designed to strengthen the competitiveness of our customers and open up new opportunities for industrial efficiency."
Verification in independent SKZ tests
To verify the declared benefits under representative industrial conditions, Sumika Polymer Compounds commissioned tests at the independent SKZ laboratory in Würzburg, Germany. A comprehensive test campaign was carried out to confirm the initial estimates regarding cycle time.
Injection trials were performed on a KraussMaffei PX160 injection moulding machine with a clamping force of 1,600 kN and a screw diameter of 35 mm. The following mould and part configuration was used:
- test part: box-shaped moulding with dimensions 158 × 100 × 50 mm,
- nominal wall thickness: 2.3 mm,
- part volume: 114 cm³,
- runner system: cold runner.
Under these conditions, ThermofilXP achieved a 12.5% reduction in cycle time compared with ThermofilHP, fully confirming the manufacturer’s initial forecast that the new grade can deliver cycle time reductions of around 10% versus typical PP-GF grades.
A new milestone in high-performance material portfolio
Sumika Polymer Compounds describes ThermofilXP as a new milestone in the development of high-performance materials tailored to current requirements of the plastics processing industry. The combination of significant cycle time reduction, high-level mechanical properties and a low carbon footprint is intended to provide European manufacturers with a tangible lever for improving competitiveness.
According to the company, the properties of the new grade, confirmed by independent tests, reflect both the original design targets and the potential for long-term changes in production practices. ThermofilXP is presented as a solution that combines reliability and efficiency with a focus on future market requirements, supporting manufacturers in meeting their technical, economic and environmental objectives.
