Plastics History

Before the invention of plastic, the only substances that could be molded were clays (pottery)
and glass. Hardened clay and glass were used for storage, but they were heavy and brittle. Some
natural substances, like tree gums and rubber, were sticky and moldable. Rubber wasn't very
useful for storage because it eventually lost its ability to bounce back into shape and became
sticky when heated.
In 1839, Charles Goodyear accidentally discovered a process in which sulfur reacted with crude
rubber when heated and then cooled. The rubber became resilient upon cooling -- it could
stretch, but it snapped back to its original shape. It also retained its resilience when heated. We
now know that the sulfur forms chemical bonds between adjacent rubber polymer strands. The
bonds cross-link the polymer strands, allowing them to "snap back" when stretched. Charles
Goodyear had discovered the process now known as vulcanization, which made rubber more
durable.
In 1846, Charles Schonbein, a Swiss chemist, accidentally discovered another polymer when he
spilled a nitric acid-sulfuric acid mixture on some cotton. A chemical reaction occurred in which
the hydroxyl groups of the cellulose fibers in the cotton were converted to nitrate groups
catalyzed by the sulfur. The resultant polymer, nitrocellulose, could burst into a smokeless flame
and was used by the military in place of gunpowder. In 1870, chemist John Hyatt reacted
nitrocellulose with camphor to make celluloid, a plastic polymer that was used in photographic
film, billiard balls, dental plates and Ping-Pong balls.
In 1909, a chemist named Leo Baekeland synthesized Bakelite, the first truly synthetic polymer,
from a mixture of phenol and formaldehyde. The condensation reaction between these monomers
allows the formaldehyde to bind the phenol rings into rigid three-dimensional polymers. So,
Bakelite can be molded when hot and solidified into a hard plastic that can be used for handles,
phones, auto parts, furniture and even jewelry. Bakelite is hard, resistant to heat and electricity,
and can't be easily melted or scorched once cooled. The invention of Bakelite led to a whole
class of plastics with similar properties, known as phenolic resins.
In the 1930s, a Dupont chemist named Wallace Carruthers invented a plastic polymer made from
the condensation of adipic acid and a certain type of diaminohexane monomers that could be
drawn out into strong fibers, like silk. This plastic became known as nylon. Nylon is lightweight,
strong and durable and became the basis of many types of clothing, coverings (tents), luggage,
bags and ropes.
The use of these early polymers became widespread following World War II and continues
today. They lead to the creation of many other plastics, like Dacron, Styrofoam, polystyrene,
polyethylene and vinyl.

Types of Plastics
Plastics can be divided into two major categories:
1. Thermoset or thermosetting plastics. Once cooled and hardened, these plastics retain their
shapes and cannot return to their original form. They are hard and durable. Thermosets can be
used for auto parts, aircraft parts and tires. Examples include polyurethanes, polyesters, epoxy
resins and phenolic resins.
2. Thermoplastics. Less rigid than thermosets, thermoplastics can soften upon heating and
return to their original form. They are easily molded and extruded into films, fibers and
packaging. Examples include polyethylene (PE), polypropylene (PP) and polyvinyl chloride
(PVC).
Let's look at some common plastics.
Polyethylene terephthalate (PET or PETE): John Rex Whinfield invented a new polymer in
1941 when he condensed ethylene glycol with terephthalic acid. The condensate was
polyethylene terephthalate (PET or PETE). PET is a thermoplastic that can be drawn into fibers
(like Dacron) and films (like Mylar). It's the main plastic in ziplock food storage bags.
Polystyrene (Styrofoam): Polystyrene is formed by styrene molecules. The double bond
between the CH2 and CH parts of the molecule rearranges to form a bond with adjacent styrene
molecules, thereby producing polystyrene. It can form a hard impact-resistant plastic for
furniture, cabinets (for computer monitors and TVs), glasses and utensils. When polystyrene is
heated and air blown through the mixture, it forms Styrofoam. Styrofoam is lightweight,
moldable and an excellent insulator.
Polyvinyl Chloride (PVC): PVC is a thermoplastic that is formed when vinyl chloride
(CH2=CH-Cl) polymerizes. When made, it's brittle, so manufacturers add a plasticizer liquid to
make it soft and moldable. PVC is commonly used for pipes and plumbing because it's durable,
can't be corroded and is cheaper than metal pipes. Over long periods of time, however, the
plasticizer may leach out of it, rendering it brittle and breakable.
Polytetrafluoroethylene (Teflon): Teflon was made in 1938 by DuPont. It's created by
polymerization of tetrafluoroethylene molecules (CF2=CF2). The polymer is stable, heatresistant, strong, resistant to many chemicals and has a nearly frictionless surface. Teflon is used
in plumbing tape, cookware, tubing, waterproof coatings, films and bearings.
Polyvinylidine Chloride (Saran): Dow makes Saran resins, which are synthesized by
polymerization of vinylidine chloride molecules (CH2=CCl2). The polymer can be drawn into
films and wraps that are impermeable to food odors. Saran wrap is a popular plastic for
packaging foods.

Polyethylene, LDPE and HDPE: The most common polymer in plastics is polyethylene, which
is made from ethylene monomers (CH2=CH2). The first polyethylene was made in 1934. Today,
we call it low-density polyethylene (LDPE) because it will float in a mixture of alcohol and
water. In LDPE, the polymer strands are entangled and loosely organized, so it's soft and
flexible. It was first used to insulate electrical wires, but today it's used in films, wraps, bottles,
disposable gloves and garbage bags.
In the 1950s, Karl Ziegler polymerized ethylene in the presence of various metals. The resulting
polyethylene polymer was composed of mostly linear polymers. This linear form produced
tighter, denser, more organized structures and is now called high-density polyethylene (HDPE).
HDPE is a harder plastic with a higher melting point than LDPE, and it sinks in an alcohol-water
mixture. HDPE was first introduced in the hula hoop, but today it's mostly used in containers.
Polypropylene (PP): In 1953, Karl Ziegler and Giulio Natta, working independently, prepared
polypropylene from propylene monomers (CH2=CHCH3) and received the Nobel Prize in
Chemistry in 1963. The various forms of polypropylene have different melting points and
hardnesses. Polypropylene is used in car trim, battery cases, bottles, tubes, filaments and bags.

Making Plastics
To make plastics, chemists and chemical engineers must do the following on an industrial scale:
1.
2.
3.
4.

Prepare raw materials and monomers

Carry out polymerization reactions
Process the polymers into final polymer resins
Produce finished products

First, they must start with various raw materials that make up the monomers. Ethylene and
propylene, for example, come from crude oil, which contains the hydrocarbons that make up the
monomers. The hydrocarbon raw materials are obtained from the "cracking process" used in
refining oil and natural gas (see How Oil Refining Works). Once various hydrocarbons are
obtained from cracking, they are chemically processed to make hydrocarbon monomers and
other carbon monomers (like styrene, vinyl chloride, acrylonitrile) used in plastics.
Next, the monomers carry out polymerization reactions in large polymerization plants. The
reactions produce polymer resins, which are collected and further processed. Processing can
include the addition of plasticizers, dyes and flame-retardant chemicals. The final polymer resins
are usually in the forms of pellets or beads.
Finally, the polymer resins are processed into final plastic products. Generally, they are heated,
molded and allowed to cool. There are several processes involved in this stage, depending upon
the type of product.
Extrusion: Pellets are heated and mechanically mixed in a long chamber, forced through a small
opening and cooled with air or water. This method is used to make plastic films.

Injection molding: The resin pellets are heated and mechanically mixed in a chamber and then
forced under high pressure into a cooled mold. This process is used for containers like butter and
yogurt tubs. (Custompart.net has a great lesson on injection molding.)
Blow molding: This technique is used in conjunction with extrusion or injection molding. The
resin pellets are heated and compressed into a liquid tube, like toothpaste. The resin goes into the
chilled mold, and compressed air gets blown into the resin tube. The air expands the resin against
the walls of the mold. This process is used to make plastic bottles.
Rotational molding: The resin pellets are heated and cooled in a mold that can be rotated in
three dimensions. The rotation evenly distributes the plastic along the walls of the mold. This
technique is used to make large, hollow plastic items (toys, furniture, sporting equipment, septic
tanks, garbage cans and kayaks).

Making Plastics
To make plastics, chemists and chemical engineers must do the following on an industrial scale:
1.
2.
3.
4.

Prepare raw materials and monomers

Carry out polymerization reactions
Process the polymers into final polymer resins
Produce finished products

First, they must start with various raw materials that make up the monomers. Ethylene and
propylene, for example, come from crude oil, which contains the hydrocarbons that make up the
monomers. The hydrocarbon raw materials are obtained from the "cracking process" used in
refining oil and natural gas (see How Oil Refining Works). Once various hydrocarbons are
obtained from cracking, they are chemically processed to make hydrocarbon monomers and
other carbon monomers (like styrene, vinyl chloride, acrylonitrile) used in plastics.
Next, the monomers carry out polymerization reactions in large polymerization plants. The
reactions produce polymer resins, which are collected and further processed. Processing can
include the addition of plasticizers, dyes and flame-retardant chemicals. The final polymer resins
are usually in the forms of pellets or beads.
Finally, the polymer resins are processed into final plastic products. Generally, they are heated,
molded and allowed to cool. There are several processes involved in this stage, depending upon
the type of product.
Extrusion: Pellets are heated and mechanically mixed in a long chamber, forced through a small
opening and cooled with air or water. This method is used to make plastic films.
Injection molding: The resin pellets are heated and mechanically mixed in a chamber and then
forced under high pressure into a cooled mold. This process is used for containers like butter and
yogurt tubs. (Custompart.net has a great lesson on injection molding.)

Blow molding: This technique is used in conjunction with extrusion or injection molding. The
resin pellets are heated and compressed into a liquid tube, like toothpaste. The resin goes into the
chilled mold, and compressed air gets blown into the resin tube. The air expands the resin against
the walls of the mold. This process is used to make plastic bottles.
Rotational molding: The resin pellets are heated and cooled in a mold that can be rotated in
three dimensions. The rotation evenly distributes the plastic along the walls of the mold. This
technique is used to make large, hollow plastic items (toys, furniture, sporting equipment, septic
tanks, garbage cans and kayaks).

Biopolymers and Recycling

As we mentioned earlier, there are other polymers besides plastics. Naturally occurring
polymers, such as starches, cellulose, soy protein, vegetable oil, triglycerides and bacterial
polyesters, can be extracted from crops and bacteria. Furthermore, plants and microorganisms
can produce substances like lactic acid, which can be polymerized into bioplastics (polylactic
acid, for example). There are two strategies for producing bioplastics.
Fermentation: Bacteria or other microorganisms mass-produce the biopolymers in bioreactors
(fermentation tanks). The biopolymers (lactic acid, polyesters) are extracted from the bioreactors
and chemically processed into plastics.
Genetic engineering plants as bioreactors: Biotechnologists introduce bacterial genes into
plants. These genes code for the enzymes to make bacterial plastics. The plants are grown and
harvested, and the plastics are extracted from the plant material.
In 1997, Cargille Dow made a clear plastic (polylactide) from corn. The polylactide fibers were
woven into sports apparel, upholstery fabrics and bioplastic wraps.
Bioplastics have the advantage of being produced from renewable resources (bacteria, plants)
rather than nonrenewable resources (oil, natural gas). Furthermore, bioplastics are biodegradable
-- they can break down in the environment (see How Landfills Work). Bioplastics is a potentially
important industry. With current technology, bioplastics might be more expensive to produce,
but biotechnology is rapidly advancing and production may become more economical in the
future.
Recycling Plastics

Oil-based plastics don't degrade, but many types (including PP, LDPE, HDPE, PET, and PVC)
can be recycled. Each type has a code and identifying number, but some plastics aren't as
economically feasible to recycle. So it's important to check with your recycler or municipality
about which types of plastics will be accepted.
Once collected, plastics go through the following steps

Inspection to weed out contaminants and inappropriate types of plastic

Shredding and washing
Separation based on density
Drying
Melting
Draining through fine screens to remove more contaminants
Cooling and shredding into pellets
Selling back to plastic companies

The discovery of plastics revolutionized our society by introducing a huge variety of lightweight,
strong, flexible products with many uses. Although plastics do pose disposal problems, recycling
is always a possibility. Furthermore, new research into biopolymers may produce new bioplastic
products from renewable resources that are biodegradable and easier on our environment.

Types of plastic
The following table illustrates the most common types of plastics used, their applications and the
symbol which is often used to identify them on forms of plastic packaging.
Polymer
Types

Examples of applications Symbol

Polyethylene Fizzy drink and

Terephthalate water bottles. Salad trays.

null

High Density
Polyethylene

Milk bottles, bleach, cleaners

and most
null
shampoo bottles.

Polyvinyl
Chloride

Pipes, fittings, window and

door frames
(rigid PVC). Thermal
insulation (PVC foam)
and automotive parts.

Low Density
Polyethylene

Carrier bags, bin liners and

packaging films.

Margarine tubs,
microwaveable meal trays,
also produced as fibres and
Polypropylene
filaments for carpets, wall
coverings and vehicle
upholstery.

null

null

null

Polystyrene

Unallocated
References

Yoghurt pots, foam

hamburger boxes and egg
cartons, plastic cutlery,
protective packaging for
electronic goods and toys.
null
Insulating material in the
building and construction
industry.
Any other plastics that do
not fall into any of the above
categories - for example
polycarbonate which is often
null
used in glazing for the
aircraft industry

The 6 Most Common Plastics & the Plastic

Identification Code

Symbol

Type of
Plastic

Properties

Common
Uses

Recyled In

PET
Polyethylene
Terephthalate

Clear, tough
solvent resistant,
barrier to gas and
moisture, softens
at 80C

Soft drink and

water bottles,
salad domes,
biscuit trays,
salad dressing
and peanut
butter containers

Pillow and
sleeping bag
filling, clothing,
soft drink bottles
carpet

PE-HD
High Density
Polyethylene

Hard to semiflexible, resistant

to chemicals and
moisture, waxy
surface, opaque,
softens at 75C,

Crinkly shopping
bags, freezer
bags, milk
bottles, ice cream
containers, juice
bottles,

Recycling bins,
compost bins,
buckets,
detergent
containers, posts,

easily coloured,
processed and
formed

PVC
Unplasticised
Polyvinyl Chloride
PVC-U
Plasticised
Polyvinyl Chloride
PCV-P

PE-LD
Low density
Polyethylene

PP
Polypropylene

Strong, tough,
can be clear, can
be solvent
welded, softens
at 80C
Flexible, clear,
elastic, can be
solvent welded

shampoo,
chemical and
detergent
bottles, buckets,
rigid agricultural
pipe, milk crates

Cosmetic
containers,
electrical
conduit,
plumbing pipes
and fittings,
blister packs,
wall cladding,
roof sheeting,
bottles

fencing, pipes

Flooring, film and

sheets, cables,
speed bumps,
packaging,
binders, mud
flaps and mats

garden hose,
shoe soles, cable
sheathing, blood
bags and tubing,
watch straps

Soft, flexible,
waxy surface,
translucent,
softens at 70C,
scratches easily

Plastic Food
wrap, garbage
bags, squeeze
bottles, black
irrigation tube,
garbage bins

Rubbish bin
liners, pallet
sheets

Hard but still

flexible, waxy
surface, softens
at 140C,
translucent,
withstands
solvents, versatile

Dip bottles and

ice cream tubs,
potato chip bags,
straws,
microwave
dishes, kettles,
garden furniture,
lunch boxes, blue
packing tape

Pegs, bins, pipes,

pallet sheets, oil
funnels, car
battery cases,
trays

PS
Polystyrene
PS-E
Expanded
Polystyrene

OTHER
Letters below
indicate ISO code
for plastic type
e.g SAN, ABS, PC,
Nylon

Clear, glassy,
rigid, brittle,
opaque, semitough, softens at
95C. Affected
by fats and
solvents

CD cases,
plastic cutlery,
imitation
'crystal
glassware', low
cost brittle toys,
video cases

Foamed,
lightweight,
energy
absorbing, heat
insulating

Foamed
polystyrene hot
drink cups,
hamburger
takeaway
clamshells,
foamed meat
trays, protective
packaging for
fragile items

Includes all other

resins and multi
materials (e.g.
laminates).
Properties
depend on plastic
or combination of
plastics

Car parts,
appliance parts,
electronics, water
cooler bottles,
packaging

Coat hangers,
coasters, white
ware
components,
stationery trays
and accessories

Car parts,
concrete
aggregate, plastic
timber

THE DIFFERENT TYPES OF PLASTICS AND CLASSIFICATION

Resource Center The Different Types of

Plastic and Their Number Classifications
(Codes)
Many consumer products, such as water bottles and product containers, are made from various
types of plastic. The Society of the Plastics Industry (SPI) established a classification system in
1988 to allow consumers and recyclers to properly recycle and dispose of different types of
plastic. Manufacturers follow a coding system and place an SPI code, or number, on each plastic
product, which is usually molded into the bottom. Although you should always verify the plastic

classification number of each product you use, this guide provides a basic outline of the different
plastic types associated with each code number.
Plastic marked with an SPI code of 1 is made with
Polyethylene Terephthalate, which is also known
as PETE or PET. Containers made from this
plastic sometimes absorb odors and flavors from
foods and drinks that are stored in them. Items
made from this plastic are commonly recycled.
PETE plastic is used to make many common
household items like beverage bottles, medicine
jars, peanut butter jars, combs, bean bags, and
rope. Recycled PETE is used to make tote bags,
carpet, fiberfill material in winter clothing, and
more.
Plastic marked with an SPI code of 2 is made with
High-Density Polyethylene, or HDPE. HDPE
products are very safe and they are not known to
transmit any chemicals into foods or drinks. HDPE
products are commonly recycled. Items made
from this plastic include containers for milk, motor
oil, shampoos and conditioners, soap bottles,
detergents, and bleaches. Many personalized toys
are made from this plastic as well. (Please note: it
is NEVER safe to reuse an HDPE bottle as a food
or drink container if it didnt originally contain
food or drink!) Recycled HDPE is used to make
plastic crates, plastic lumber, fencing, and more.
Plastic labeled with an SPI code of 3 is made with
Polyvinyl Chloride, or PVC. PVC is not often
recycled and it can be harmful if ingested. PVC is
used for all kinds of pipes and tiles, but it's most
commonly found in plumbing pipes. This kind of
plastic should not come in contact with food
items. Recycled PVC is used to make flooring,
mobile home skirting, and more.

Plastic marked with an SPI code of 4 is made with

Low-Density Polyethylene, or LDPE. LDPE is not
commonly recycled, but it is recyclable in
certain areas. It is a very healthy plastic that tends
to be both durable and flexible. Plastic cling wrap,
sandwich bags, squeezable bottles, and plastic
grocery bags are all made from LDPE. Recycled
LDPE is used to make garbage cans, lumber,
furniture, and more.
Plastic marked with an SPI code of 5 is made with
Polypropylene, or PP. PP is not commonly
recycled, but it is accepted in many areas. This
type of plastic is strong and can usually withstand
higher temperatures. Among many other products,
it is used to make plastic diapers, Tupperware,
margarine containers, yogurt boxes, syrup bottles,
prescription bottles, and some stadium cups.
Plastic bottle caps are often made from PP as well.
Recycled PP is used to make ice scrapers, rakes,
battery cables, and more.
Plastic marked with an SPI code of 6 is made with
Polystyrene, also known as PS and most
commonly known as Styrofoam. It is commonly
recycled, but it is difficult to do so and often ends
up in landfills anyway. Disposable coffee cups,
plastic food boxes, plastic cutlery, packing foam,
and packing peanuts are made from PS. Recycled
PS is used to make insulation, license plate
frames, rulers, and more.
The SPI code of 7 is used to designate
miscellaneous types of plastic that are not defined
by the other six codes. Polycarbonate and
Polylactide are included in this category. These
types of plastics are difficult to recycle.
Polycarbonate, or PC, is used in baby bottles, large
water bottles (multiple-gallon capacity), compact
discs, and medical storage containers. Recycled
plastics in this category are used to make plastic
lumber, among other products.
Read more: http://www.qualitylogoproducts.com/lib/different-types-ofplastic.htm#ixzz3DXujpRxO