Applications of Versalis Greenflex ML 31 EVA in Industrial Manufacturing

Versalis Greenflex ML 31 EVA serves as a key polymeric raw material for a variety of industrial downstream applications. Due to its defined vinyl acetate content and molecular weight, it supports demanding processes in specialized segments. Below are industry-specific uses with detailed standards, formulation ratios, integration steps, and end products.

1. Solar Panel Encapsulation Films Production

EVA copolymers play a central role in the lamination of photovoltaic cells, ensuring durability, transparency, and UV resistance for extended field life. Consistent performance under moisture and temperature stress is crucial for large-scale solar module manufacturing. Technical integration requires precise melt flow properties and clarity in optical transmission layers.

Industry compliance standards

• IEC 61215:2021 (Crystalline silicon terrestrial PV modules)
• UL 1703 (Flat-plate photovoltaic modules and panels)
• REACH regulation (EC No 1907/2006) for materials safety
• RoHS Directive (EU 2015/863) on hazardous substances

Typical usage ratio

• 60–75% by weight in the encapsulant resin blend, adjusted for cell type and optical requirements

Downstream process integration

• Granules or pellets fed to twin-screw extruders
• Sheet extrusion and film casting post-compounding with crosslinking agents, UV stabilizers
• Laminated with tempered glass sheets around photovoltaic cells prior to final module assembly

Final product types

• Photovoltaic encapsulant films
• Semi-finished module laminates
• Full solar PV modules
• BIPV (building-integrated photovoltaic) panels

2. Hot Melt Adhesive Formulation

EVA resins provide the main elastomeric and tackifying base for industrial hot melt adhesives. Used in packaging, bookbinding, and product assembly lines, the material balances cohesion, open time, and set speed. The consistent reactivity and flexibility profile allow for automated high-throughput production lines and precise bond strength control.

Industry compliance standards

• FDA 21 CFR 175.105 for indirect food contact adhesives
• EN 923:2005 terminology for hot-melt adhesives
• ISO 9001:2015 for quality management in adhesive plants
• GB/T 2793 testing for peel strength in adhesives (China)

Typical usage ratio

• 30–50% by weight in adhesive batch, blended with waxes, resins, and functional additives depending on application (carton sealing vs. woodworking)

Downstream process integration

• Direct pellet loading to hot melt tanks
• Blending with tackifiers and wax in heated reactors
• Extrusion onto substrates or production of ready-to-use adhesive blocks/granules

Final product types

• Case and carton sealing glues
• Perfect binding adhesives for books
• Pressure-sensitive labels
• Furniture edge banding adhesives

3. Footwear Injection Molding Compounds

EVA is widely processed into injection-molded foam compounds for midsoles, outsoles, and sandal units. Its fine cell structure and variable hardness enable cushioning and shock absorption properties essential for athletic and casual footwear. Material consistency supports both direct injection and compression molding, ensuring high-volume productivity with strict quality control.

Industry compliance standards

• SATRA TM77 for bond strength in footwear soles
• ISO 20871:2018 (Footwear—Outsole abrasion)
• REACH Annex XVII for restricted substances
• ISO 14001 for environmental management in shoe manufacturing

Typical usage ratio

• 45–90% in foam blends, adjusted based on density, hardness, and resilience required for sports or comfort ranges

Downstream process integration

• Blended with blowing agents, crosslinkers, and fillers in a pelletizing line
• Fed into injection or compression molding machines
• Secondary finishing (trimming, coating) after demolding

Final product types

• Running shoe midsoles
• Children’s EVA sandals
• Work boot outsoles
• Comfort slippers

4. Flexible Packaging Films Manufacturing

In multilayer co-extruded packaging films, EVA is incorporated to provide sealing performance, clarity, and impact resistance. The material supports heat-seal layers and improves film puncture strength, especially for food, pharmaceutical, and fast-moving consumer goods packaging lines operating at commercial scale.

Industry compliance standards

• FDA 21 CFR 177.1350 (Ethylene-vinyl acetate copolymers for food contact)
• EU Regulation 10/2011 (Plastic materials for food contact)
• ISO 22000:2018 (Food safety in packaging)
• GMP EC No 2023/2006 (Good manufacturing practice for food-contact materials)

Typical usage ratio

• 5–25% of film structure, depending on sealing temperature, transparency, and mechanical property targets; higher loading for peelable seals

Downstream process integration

• Metered as individual layer in multilayer co-extrusion
• Extrusion into blown or cast film lines
• Integrated as sealing or peelable layer before lamination or printing

Final product types

• Dairy and meat packaging films
• Flexible pouches
• Pharmaceutical blister lidding
• Heat-sealable wrap films

5. Wire and Cable Sheathing Compounds

EVA-based compounds act as insulating and sheathing layers in low voltage and communication cables. These grades must ensure dielectric strength, weatherability, and mechanical protection for both indoor and outdoor installations. Processing requires stable melting behavior and compatibility with crosslinking agents or flame retardants.

Industry compliance standards

• IEC 60502-1 (Power cables with extruded insulation)
• UL 1581 (Electrical wires, cables, and flexible cords)
• RoHS Directive (EU 2015/863)
• REACH Regulation (EC No 1907/2006)

Typical usage ratio

• 40–85% in cable compound formulations, tuned for flame resistance, flexibility, and required insulation thickness

Downstream process integration

• Dry blending with flame retardants and stabilizers
• Pelletizing via twin-screw extrusion
• Extrusion directly over metallic wire core as insulation or jacketing

Final product types

• Power cable insulation
• Data cable sheaths
• Flexible appliance cords
• Outdoor telecom cable jackets

6. Toy and Sporting Goods Molding

The softness and impact cushioning properties of EVA enable safe production of toys, sports mats, and protective gear. Compounding must address color retention, age resistance, and non-toxicity criteria for child-contact and sports use. Advanced molding processes enable complex shapes and multi-color assemblies, essential for modern design requirements.

Industry compliance standards

• EN 71 Part 3: Migration of certain elements (Toy safety)
• ASTM F963 (Standard Consumer Safety Specification for Toy Safety)
• CPSIA (Consumer Product Safety Improvement Act, USA)
• ISO 8124:2018 (Safety of toys)

Typical usage ratio

• Up to 100% for foam mats, 60–85% for injection-molded toys, ratio reduced when blending with PE or color masterbatches

Downstream process integration

• Blended with pigments and foaming agents
• Fed into injection or expansion molding units
• Heat-press treatment for large-area sheets (e.g., gym mats)

Final product types

• EVA foam play mats
• Safe sports flooring
• Protective helmets and pads
• Soft molded children’s toys