BASF Ultrason PPSU: Premium Material for Injection & Blow Molding of Baby & Adult Bottles

The two polyphenylsulfone (PPSU) grades Ultrason P 2010 and P 3010, newly introduced by BASF, Florham Park, N.J., are engineered for injection‑stretch blow molding, extrusion blow molding and injection molding, delivering adult and baby bottles that are safe, robust, and chemically resistant, available in a wide array of designs, shapes, and colors.

All three processing routes benefit from the tailored properties of this high‑temperature thermoplastic: it contains no harmful substances, is approved for food contact, and exhibits exceptional strength, chemical resistance, and long‑term stability at temperatures up to 180 °C (356 °F). Transparent, slightly honey‑colored bottles made from BASF PPSU can easily withstand sterilization in a microwave or in very hot water—regardless of the manufacturing method.

During extrusion blow molding, the plastic melt is extruded from top to bottom through a circular die to form a tube‑shaped parison. Internal pressure then inflates the parison within a mold, giving the part its final shape. The medium‑viscosity Ultrason P 3010 is especially well suited for this process because its high melt strength keeps the elongated parison stable near the die, ensuring uniform blow molding. For complex geometries with varying wall thicknesses, a programmed parison‑control system can be employed, preventing elongation caused by the parison’s weight and guaranteeing consistent wall thickness along the entire bottle.

When injection molding is used, the bottle body can be formed with or without a cap thread and base, offering great flexibility in bottle design and venting strategies for baby bottles. Today, manufacturing with single and multi‑cavity molds combined with an upstream hot‑runner system represents the state of the art. The high‑flow, low‑viscosity Ultrason P 2010 is particularly effective, enabling thin walls even over long flow paths without compromising impact or chemical resistance.

The most widespread method, especially for baby bottles in Asia, is injection‑stretch blow molding. A parison resembling a test tube with a cap thread is first produced in an injection mold, then reheated, stretched, and finally inflated in a blow mold that shapes the bottle as a negative. Ultrason P 3010 delivers rapid cycle times and precise molding of the bottle cap thread, making it ideal for this application.

Both Ultrason P grades are highly processable with hot‑runner systems, minimizing scrap losses. This allows the production of long‑lasting, versatile bottles that maintain superior mechanical and optical properties across a broad range of applications.

Said Georg Grässel from BASF’s Ultrason global business development, “The production of high‑quality, safe, and stylish bottles for adults and babies presents a challenge that cannot be compared to that of conventional PET, PP, or co‑polyester bottles. The globally widespread processing methods all have their own specific requirements of the material used—and this is where Ultrason P has proven its value to customers in many different countries. They can choose the most suitable material from our portfolio and can also benefit from our on‑site technical application support and the global availability of the different grades.”