RPI International
Inc.
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PLASTICS GUIDE

How Plastic Resin Is Made, Graded, and Traded.

A plain-English guide to the plastics industry — from the gas fields and crackers of the Gulf Coast to the factories that turn pellets into everyday products.

IN THIS GUIDE
01The BasicsWhat plastic really is02A Short HistoryKey moments since 190703From Well to PelletHow resin is made04The ResinsSeven key resins05Reading a Spec SheetMFI, density, IV, and more06Grades and QualityPrime to plant sweep07From Pellet to ProductHow factories shape resin08RecyclingHow plastic is reused09Shipping and TradeShipping terms and customs10Acronyms and TermsWords used in the trade
01 · THE BASICS

What Is Plastic?

Plastics are polymers — very long chains made by linking thousands of small molecules, called monomers, end to end.

Ethylene links into polyethylene, propylene into polypropylene, and so on. How long the chains are, how much they branch, and what is blended in decide whether the finished material is soft and stretchy, clear and rigid, or tough enough for a water pipe.

In the trade, raw plastic is called resin. It is usually sold as small pellets (also called granules or nurdles), which factories melt and shape into film, bottles, pipe, fiber, and thousands of other everyday products.

431M
Metric tons of plastic made globally in 2024, per Plastics Europe.
1 in 4
Share of all plastic that is polyethylene, the largest family.
80%+
U.S. ethylene made from ethane, found in natural gas.
~95%
U.S. ethylene capacity located in Texas and Louisiana.

Two Families: Thermoplastics and Thermosets

THERMOPLASTICS
Melt, Shape, and Melt Again
Thermoplastics soften when heated and harden when cooled — again and again. That is what lets them be molded, reground, and recycled. PE, PP, PET, and EVA are all thermoplastics.
MOST PLASTICS TRADED WORLDWIDE
THERMOSETS
Cure Once, Set for Good
Thermosets harden through a permanent chemical reaction and cannot be remelted or reshaped. Epoxy is a thermoset: it cures with a hardener, a reaction that heat triggers in powder coatings.
EPOXY, PHENOLICS, AND UNSATURATED POLYESTERS
02 · A SHORT HISTORY

A Century of Plastics.

Plastic went from a lab discovery to an everyday material in under a century, thanks to these breakthroughs.

1907
Bakelite
Baekeland invents Bakelite, the first all-synthetic plastic.
1933
Polyethylene
ICI chemists in England stumble on polyethylene.
1941
PET
Whinfield and Dickson file a patent for PET polyester.
1951
Phillips Catalyst
Hogan and Banks find a chromium catalyst for HDPE.
1953
Ziegler Catalyst
Ziegler's catalyst makes low-pressure PE possible.
1954
Polypropylene
Giulio Natta makes the first ordered polypropylene.
1973
The PET Bottle
Nathaniel Wyeth of DuPont patents the PET bottle.
03 · FROM WELL TO PELLET

How Oil and Gas Become Resin.

Almost all plastic starts as oil or natural gas. It takes six broad steps to turn a hydrocarbon into a bag of resin pellets.

STEP 1
Feedstock
Ethane and propane from natural gas — or naphtha from crude oil — are the starting point. U.S. plants mostly use ethane.
STEP 2
Cracking
In a steam cracker, feedstock is heated above 800°C for a split second, breaking it into smaller molecules.
STEP 3
Monomers
The gas is cooled and separated into pure ethylene and propylene. Propylene also comes from refineries and PDH plants.
STEP 4
Polymerization
In a reactor, catalysts or very high pressure link the monomers into long chains. The recipe sets the grade.
STEP 5
Pelletizing
Molten polymer is blended with additives, pushed through an extruder, and cut into small, uniform pellets.
STEP 6
Packing
Pellets are packed in 25 kg bags, boxes, or bulk bags, or blown into hopper railcars holding about 200,000 lb.
Refinery towers and storage tanks at golden hour
WHY HOUSTON

The Heart of American Plastics.

About 95% of U.S. ethylene capacity sits in Texas and Louisiana, close to shale gas supplies and deep-water ports. The Houston Ship Channel is one of the largest petrochemical complexes in the world.

Because U.S. crackers run mostly on low-cost ethane, America makes large amounts of polyethylene — much of it exported through Gulf Coast ports to buyers in Asia, Latin America, and beyond.

04 · THE RESINS

Seven Resins, Seven Personalities.

Each resin has its own strengths. Values are typical and vary by grade. Codes are explained below; epoxy falls under 7, Other.

RESIN
CODE
DENSITY (G/CM³)
MELTING POINT
KNOWN FOR
COMMON PRODUCTS
LDPE
4
0.910–0.940
105–115°C
Soft, flexible, and clear
Film, bags, liners, and coatings
LLDPE
4
0.915–0.925
120–125°C
Tough and puncture-resistant
Stretch film, sacks, and liners
HDPE
2
0.941–0.965
130–137°C
Stiff and chemical-resistant
Jugs, crates, pipe, and drums
PP
5
0.895–0.920
160–166°C
Light, rigid, and heat-resistant
Containers, caps, and auto parts
PET
1
About 1.38
250–260°C
Clear and a strong gas barrier
Bottles, trays, fiber, and strapping
EVA
7
0.92–0.96
45–100°C
Soft, rubbery, and sticks well
Foam, shoe soles, and glue
Epoxy
7
1.1–1.4 (cured)
Does not melt
Hard, adhesive, and durable
Coatings and adhesives

The Polyethylene Family

Low-, linear low-, and high-density PE are all made from ethylene. They differ in how the chains branch, set by pressure, catalyst, and comonomer.

HIGH PRESSURE
LDPE
Made at very high pressure, roughly 1,000 to 3,000 bar. Long branches keep its chains apart, so LDPE is soft and clear.
LOW PRESSURE + COMONOMER
LLDPE
Low pressure plus a little butene, hexene, or octene. Short branches give film that stretches without tearing.
LOW PRESSURE
HDPE
Made at low pressure with catalysts and very few branches, so chains pack tightly into a stiffer, stronger plastic.

Other Common Resins

PROPYLENE
PP
Sold as homopolymer (stiffest), random copolymer (clearer), or impact copolymer (tougher in cold). Made with Ziegler-Natta or metallocene catalysts.
PTA + MEG
PET
Polyethylene terephthalate, made from purified terephthalic acid and ethylene glycol. Bottle grades get solid-state polymerization for strength.
ETHYLENE + VA
EVA
Ethylene plus vinyl acetate, made in high-pressure reactors. More VA makes it softer, clearer, and stickier — from film at low VA to adhesives at high VA.
RESIN + HARDENER
Epoxy
Usually made from bisphenol A and epichlorohydrin. It stays a liquid or powder until its hardener cures it, often with heat, into a hard, lasting solid.

Resin Identification Codes

The number inside the triangle on a product shows which resin it is made of — not whether it can be recycled. The system is set by ASTM International (standard D7611), which now uses a solid triangle instead of chasing arrows.

PET
HDPE
PVC
LDPE/LLDPE
PP
PS
Other
05 · READING A SPEC SHEET

The Numbers That Define a Grade.

Each resin comes in many grades, each with a data sheet. A handful of numbers tell a buyer most of what they need to know.

MFI · MFR
Melt Flow Index
How easily molten resin flows, in g/10 min. PE is tested at 190°C and PP at 230°C (ASTM D1238). Low MFI suits film and pipe; high MFI suits injection molding.
G/CM³
Density
Mass per volume. For polyethylene, density shows how tightly the chains pack — and places it in the LDPE, LLDPE, MDPE, or HDPE range. Higher density means stiffer plastic.
DL/G
Intrinsic Viscosity (IV)
The key number for PET. Higher IV means longer chains and a stronger bottle or fiber — typically about 0.78–0.85 for water and soft-drink bottles, and lower for fiber.
% VA
VA Content
The share of vinyl acetate in EVA. Low-VA grades go into film, mid-range grades into foam, and high-VA grades — up to about 40% — into hot-melt adhesives.
HOMO · CO
Homopolymer vs. Copolymer
A homopolymer uses one monomer. A copolymer adds a second — like hexene in LLDPE or ethylene in PP — to change the plastic's toughness, clarity, or flexibility.
TDS · COA
Additives and Paperwork
Grades may add slip, antiblock, antioxidants, or UV stabilizers. A technical data sheet (TDS) lists typical values; a certificate of analysis (COA) shows one lot's results.
06 · GRADES AND QUALITY

Not All Resin Is Prime.

In the trade, grade also describes quality. Much resin is sold below first quality, priced to match, giving buyers a cheaper option.

GRADE
WHAT IT IS
WHERE IT USUALLY COMES FROM
Prime
Virgin resin that meets the producer's full specification
Normal, on-spec production runs
Wide-Spec
Virgin resin outside prime tolerances for MFI, density, or color
Bulk plant runs, often sold by railcar
Off-Grade
Virgin resin that missed spec — often used to mean wide-spec
Start-ups, upsets, and off-target runs
Transition
Resin made while a reactor switches from one grade to another
Grade changes at the resin plant
Regrind
Scrap that has been ground into flakes but not re-pelletized
Factory trim, rejects, or used products
Repro
Scrap that has been melted, filtered, and re-pelletized
Recyclers and compounders
Purge
Clean resin with no set specification, often a mix of grades
Resin plants and processors, sold as mixed lots
Lumps & Chunks
Solid masses of resin, ground or remelted for reuse
Start-ups, changeovers, and spills
Plant Sweep
Pellets recovered from plant floors and rail yards
Resin plants and packaging lines
PIR
Post-Industrial Recycled
Scrap that never reached a consumer — trim, rejects, and purge from factories. It is usually cleaner and more consistent.
PCR
Post-Consumer Recycled
Plastic that was used by a consumer and then collected — bottles, jugs, and film. It needs more sorting and washing.
07 · FROM PELLET TO PRODUCT

How Factories Shape Resin.

Once a grade is chosen, converters (or processors) turn it into products. Most use one of these eight methods.

Blown Film
Resin is pushed through a round die and blown into a bubble, then flattened.
RESINS: LDPE · LLDPE · HDPE
Cast Film
Resin is extruded through a flat die onto chilled rollers to make clear, even film.
RESINS: LLDPE · PP
Injection Molding
Melted resin is shot into a steel mold under pressure, cooled, and ejected.
RESINS: PP · HDPE
Blow Molding
A hot tube or preform is inflated in a mold to make jugs, bottles, and more.
RESINS: HDPE · PET
Extrusion
Resin is pushed through a shaped die to make pipe, profiles, tubing, and sheet.
RESINS: HDPE · PP
Rotational Molding
Powdered resin tumbles in a hot, rotating mold to form big hollow parts like tanks.
RESINS: LLDPE · MDPE
Thermoforming
Heated plastic sheet is pressed over a mold to make trays, cups, and clamshells.
RESINS: PET · PP
Fiber Spinning
Molten resin is forced through tiny holes to make fibers for textiles and carpet.
RESINS: PET · PP
08 · RECYCLING

Giving Plastic a Second Life.

Mechanical recycling, the source of repro, keeps the polymer intact and turns used plastic back into pellets.

Bales of crushed clear plastic bottles stacked for recycling
Collect
Used plastic is gathered from homes, businesses, and factories.
Sort
Near-infrared (NIR) scanners and workers separate it by resin and color.
Bale
Sorted plastic is pressed into dense bales for easy shipping.
Grind
Bales are broken open and shredded or ground into small flakes.
Wash
Flakes are washed to remove labels, dirt, glue, and food residue.
Dry
Clean flakes are dried so moisture does not damage the melt.
Extrude and Filter
Flakes are melted and pushed through fine screens to catch debris.
Pelletize
The filtered melt is cut into pellets, ready to be used again.
CHEMICAL RECYCLING

A newer route breaks plastic back down into chemicals. Pyrolysis heats polyolefins like PE and PP into oils, while depolymerization (glycolysis, methanolysis, or hydrolysis) turns PET back into its building blocks.

09 · SHIPPING AND TRADE

How Resin Moves Around the World.

Most export resin travels in sea containers. A few standard units, terms, and documents come up on every deal.

Container ship being loaded by cranes at a port

Packaging and Load Sizes

25 kg
Standard Bag
About 55 lb. The standard unit for resin.
1.0–1.4 t
Pallet
Typically 40 or 55 bags, shrink-wrapped.
~1,000 kg
Bulk Bag (FIBC)
A woven super-sack with lifting loops.
1,000+ lb
Gaylord
A large corrugated box on a pallet.
~200,000 lb
Hopper Railcar
How U.S. plants ship resin in bulk.
~24.75 t
40-ft Container
Bagged resin; a 20-ft holds about 16.75 t.

Incoterms

Incoterms are standard trade terms, published by the International Chamber of Commerce (ICC), that spell out where the seller's job ends and the buyer's begins. These are the ones most used for resin.

TERM
STANDS FOR
WHAT IT MEANS
EXW
Ex Works
Buyer collects the goods at the seller's site and handles everything after.
FCA
Free Carrier
Seller delivers to the buyer's carrier. Recommended by the ICC for containers.
FAS
Free Alongside Ship
Seller delivers the goods beside the ship at the port of loading.
FOB
Free on Board
Seller loads the goods on board; risk passes to the buyer there.
CFR
Cost and Freight
Seller pays freight to the destination port; risk passes at loading.
CIF
Cost, Insurance, and Freight
Like CFR — risk passes at loading — plus the seller buys insurance.
DAP
Delivered at Place
Seller delivers to a named place, ready for unloading.

Common Export Documents

Commercial Invoice
The bill of sale — value, terms, and goods.
Packing List
What is in each container, bag, or pallet.
Bill of Lading
The carrier's receipt — and title, if negotiable.
Certificate of Origin
Where the goods were produced.
COA
Lab results for a specific lot of resin.
SDS and TDS
Safety data and typical technical values.

HS Codes for Resin

Customs around the world classify goods with Harmonized System (HS) codes. The first six digits are shared by the 200-plus countries that use the system. Single-resin repro pellets are usually classed as resin, not scrap — a customs broker makes the final call.

HS CODE
DESCRIPTION
TYPICALLY COVERS
3901.10
Polyethylene, specific gravity below 0.94
LDPE and many LLDPE grades
3901.20
Polyethylene, specific gravity 0.94 or higher
HDPE
3901.30
Ethylene-vinyl acetate copolymers
EVA
3901.40
Ethylene-alpha-olefin copolymers, below 0.94
Many LLDPE grades
3902.10
Polypropylene
PP homopolymer
3902.30
Propylene copolymers
Random and impact PP
3907.30
Epoxide resins
Epoxy
3907.61 / .69
Polyethylene terephthalate
PET, split by viscosity
3915
Waste, parings, and scrap of plastics
Scrap and regrind
A NOTE ON IMPORT RULES

Rules for plastic scrap have tightened worldwide. China stopped accepting most plastic scrap in 2018 and banned solid waste imports in 2021, though recycled pellets that meet national standards can still enter. India bans most plastic scrap imports. Since 2021, the Basel Convention has required prior consent for mixed or contaminated plastic waste.

Prime and off-grade virgin resin is generally traded as ordinary goods. Rules change often, so always confirm current requirements with a licensed customs broker before shipping.

10 · ACRONYMS AND TERMS

Speak the Language of Resin.

The plastics trade runs on acronyms. Here are the ones you will hear most, followed by common terms.

ASTM
ASTM International, a standards body
BOPP
Biaxially Oriented Polypropylene (film)
COA
Certificate of Analysis
EVA
Ethylene-Vinyl Acetate
FIBC
Flexible Intermediate Bulk Container
HDPE
High-Density Polyethylene
HS
Harmonized System (customs codes)
ICC
International Chamber of Commerce
IV
Intrinsic Viscosity
LDPE
Low-Density Polyethylene
LLDPE
Linear Low-Density Polyethylene
MDPE
Medium-Density Polyethylene
MEG
Monoethylene Glycol
MFI / MFR
Melt Flow Index / Melt Flow Rate
mLLDPE
Metallocene LLDPE
MT
Metric Ton (1,000 kg, about 2,205 lb)
NGL
Natural Gas Liquids
NIR
Near-Infrared (used in sorting)
PC
Polycarbonate
PCR
Post-Consumer Recycled
PDH
Propane Dehydrogenation
PE
Polyethylene
PET
Polyethylene Terephthalate
PIR
Post-Industrial Recycled
PP
Polypropylene
PS
Polystyrene
PTA
Purified Terephthalic Acid
PVC
Polyvinyl Chloride
RIC
Resin Identification Code
rPET
Recycled PET
SDS
Safety Data Sheet
SSP
Solid-State Polymerization
TDS
Technical Data Sheet
UHMW
Ultra-High Molecular Weight PE
VA
Vinyl Acetate
VLDPE
Very-Low-Density Polyethylene

Common Terms

Catalyst
Speeds up polymerization and shapes how the chains grow.
Comonomer
A second monomer, like butene or hexene, added to tune a polymer.
Compounding
Blending resin with additives, fillers, or color into a custom material.
Converter
A factory that turns resin into products — also called a processor or molder.
Cracker
Breaks ethane, propane, or naphtha into ethylene and propylene.
Fractional Melt
A resin with an MFI below 1, typical of film, pipe, and blow-molding grades.
Masterbatch
Concentrated color or additive pellets mixed into natural resin.
Monomer
A small molecule, like ethylene or propylene, that links up into a polymer.
Natural
Resin with no added color — usually clear, white, or translucent.
Pellet
The small bead that resin is sold in, also called a granule or nurdle.
Polymer
A long molecule made of many repeating monomer units linked end to end.
Specific Gravity
Density compared with water. Customs codes use it to split PE grades.
SOURCES
Plastics Europe — Plastics: The Fast Facts 2025 · U.S. Energy Information Administration (EIA) · ASTM International — D1238 and D7611 · U.S. EPA — Basel Convention plastic waste amendments · World Customs Organization — HS Nomenclature 2022 · International Chamber of Commerce — Incoterms 2020 · Producer technical literature (LyondellBasell, EQUATE, Celanese). Figures are typical values for general education; always check a specific grade's data sheet.
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