Clariant (Muttenz / Switzerland; www.clariant.com) has newer “Hydrocerol” chemical foaming agents that it says allow less plastic to be used to create a bottle without significant loss in its mechanical properties. The foaming agents decompose and produce bubbles in the polymer matrix when pressure is reduced as the resin enters the mould or exits the extrusion die.

Material reductions of 10% or more have been reported in monolayer and coextruded bottles and sheet. Clariant says less heat is needed to melt the resin and cycle times are reduced by as much as 10-15%. Hydrocerol is available in mini pellets, which are less than half the size of standard pellets, making it possible to achieve a more homogeneous and finer foam structure at low dosages.