| HS Code | 503485 |
| Product Name | Soarnol GH3804B |
| Resin Type | Ethylene-vinyl alcohol copolymer (EVOH) |
| Ethylene Content | 38 mol% |
| Density | 1.14 g/cm³ |
| Melt Flow Rate | 4.0 g/10 min (190 °C, 2.16 kg) |
| Melting Point | 175 °C |
| Glass Transition Temperature | 60 °C |
| Oxygen Transmission Rate | 1.0 cm³/m²·day·atm (20 μm film, 20 °C, 65% RH) |
| Tensile Strength At Break | 80 MPa (film) |
| Elongation At Break | 300% (film) |
As an accredited Soarnol GH3804B factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Soarnol GH3804B is supplied in 25 kg polyethylene-lined paper bags, sealed to protect against moisture and contamination. |
| Container Loading (20′ FCL) | 20′ FCL container loading of Soarnol GH3804B: 25 kg bags on pallets, shrink-wrapped, moisture-protected, securely stowed for safe transport. |
| Shipping | Soarnol GH3804B is an EVOH resin supplied as moisture-sensitive pellets. For shipping, keep original packaging sealed and dry, ideally in a ventilated, covered container. It is not classified as dangerous cargo under standard regulations, but protect from humidity, heat, and direct sunlight to maintain quality. |
| Storage | Store Soarnol GH3804B in a cool, dry, well-ventilated area away from direct sunlight, heat, and excessive humidity. Keep containers or bags tightly sealed when not in use to prevent moisture absorption and contamination. Avoid stacking under severe conditions. Under proper conditions, shelf life typically extends for several years without significant degradation. |
| Shelf Life | Store in original, unopened packaging in a cool, dry place. Shelf life is 12 months from date of manufacture. |
Soarnol GH3804B is converted as a discrete oxygen barrier layer in three-layer and five-layer polypropylene-based sheet for thermoformed food-service and shelf-stable ready-meal packaging. In a typical three-layer structure, the PP/EVOH/PP sheet is coextruded with an EVOH layer at 5–8 wt% of total sheet mass and a nominal sheet gauge of 800–1,000 µm, placing the EVOH core at 30–50 µm. The adjacent tie layers are maintained at 3–5 µm, and the EVOH melt is processed at 205–225°C; die-head temperatures above 240°C produce crosslinked gel specks that appear as longitudinal die lines on production-scale machines. Resin viscosity is tracked on receipt by melt mass-flow rate under ISO 1133-1:2022 at 210°C and 2.16 kg load, because a shift of more than ±10% changes layer gauge stability. Drying is performed at 80–90°C for 4–6 h to reduce residual moisture below 0.1%, and when ambient relative humidity exceeds 60% the resin is not left in the feed hopper for more than 30 min without closed-loop drying. On sheet lines with a 75 mm PP main extruder and a 35 mm EVOH extruder at 24:1 L/D, the EVOH layer is typically combined in a feedblock before a 1,200 mm flex-lip die, and melt pressure upstream of the die is held in the range of 50–70 bar. After chill-roll polishing at 30–50°C, the sheet is thermoformed into cups, trays, and ready-meal containers. Compliance is assessed under EU 10/2011 for plastic food-contact materials and 21 CFR 177.1360 for the EVOH copolymer, with overall migration testing per EN 1186-1:2002, resin property testing per ISO 14663-2:2004, and oxygen transmission testing per ASTM D3985 at 23°C and 65% RH. Production failures observed on high-output lines include interlayer waviness in thermoformed corner sections when tie layer thickness drops below 2 µm, and batch-to-batch melt-flow drift requires closed-loop melt pump correction to hold the EVOH layer gauge tolerance at ±5%.
On a five-layer blown film line running PE/tie/EVOH/tie/PE for modified-atmosphere meat and cheese packaging, Soarnol GH3804B is introduced as a 4–6 µm core inside a total film gauge of 45–60 µm, which corresponds to 7–10 wt% of the structure. The EVOH extruder is sized at 35–45 mm with a 24:1 screw, and the barrier layer is combined in a spiral mandrel die of 200–300 mm diameter at a blow-up ratio of 2.0–2.5. Melt temperatures are kept at 205–220°C because lower settings raise backpressure and higher settings increase gel formation at the spiral gaps. The tie layers are extruded at 3–5 µm each, and film edge trim containing EVOH is limited to 20–25 wt% in the polyethylene skin layers to prevent haze bands in the bubble. Pre-drying at 80–90°C to residual moisture below 0.1% is mandatory; on humid days at ambient relative humidity above 60%, blister defects in the EVOH layer appear if the material remains open to atmosphere for more than 30 min. Barrier performance is quantified by ASTM D3985 oxygen transmission testing at 23°C and 65% RH, and food-contact compliance is documented under EU 10/2011 and 21 CFR 177.1360. The finished film is fabricated into vacuum skin packages, flow-pack wrappers, and MAP lidding for fresh meat, smoked meat, and cheese. On production lines with internal bubble cooling, operators observe that EVOH layer gauge variation exceeding ±10% creates intermittent barrier failure in package corners, detectable only after the film is thermoformed or peeled; therefore inline thickness profiling is used during start-up and after each film-width change.
In multi-layer oxygen barrier pipe, Soarnol GH3804B is coextruded as a buried layer between polyethylene of raised temperature resistance or crosslinked polyethylene to block oxygen ingress into closed-loop heating water. The EVOH layer is dimensioned at 0.10–0.15 mm in a 2.0 mm wall, equivalent to 5–7.5% of wall thickness. The pipe line is configured with a five-layer or three-layer die head and vacuum calibration; EVOH melt entering the die is held at 210–225°C, and processing above 230°C generates microgels that create local thinning at the pipe circumference. Drying before extrusion at 80–90°C to below 0.1% residual moisture is required because moisture in EVOH manifests as radial bubble voids in the barrier layer after vacuum sizing. The oxygen barrier of completed pipe is evaluated according to ISO 17455-1:2007 for oxygen permeability of barrier pipes, and the finished system is assessed for mechanical and thermal performance under EN 1264-1 and DIN 4726 where radiant heating installation is specified. Potable-water suitability is documented under national approvals, commonly referencing NSF/ANSI 14 or equivalent plumbing code listings. The terminal products are floor-heating pipe, radiator connection pipe, and district heating distribution lines. Production experience on in-line pipe corrugators and vacuum calibration troughs indicates that degradation begins at the EVOH layer first because it is buried between PE layers that act as thermal insulation; after extended interruptions, purging with LDPE at 190–200°C before re-start prevents crosslinked gel accumulation in the spiral channels. The EVOH layer is not suitable as a continuous hot-water contact layer above 80°C when oxygen barrier retention is critical, because the plasticizing effect of water at elevated temperature raises oxygen transmission and must be factored into wall-thickness calculations.
Across six-layer coextrusion blow molding lines for agricultural chemical containers, Soarnol GH3804B is positioned as an internal barrier layer in HDPE/regrind/tie/EVOH/tie/HDPE structures. The EVOH layer is calibrated to 3–5 wt% of total container mass, with typical barrier-layer thickness between 40–80 µm for a 1.0–2.5 L bottle wall of 1.0–1.5 mm. The blow molder uses an accumulator head with 150–190 mm die diameter and parison programming to maintain wall thickness at the pinch-off and shoulder corners; barrier-layer thinning below 20 µm in the lower chime has caused permeation failure in production qualification tests under the UN packaging regime. Processing temperatures for EVOH are set at 210–225°C, and the resin is dried at 80–90°C for 4–6 h to below 0.1% moisture. Compliance is addressed through the UN Model Regulations and ADR/RID packaging requirements for hazardous substances, with additional company-specific permeation protocols using ASTM D3985 at 23°C and 65% RH. Container types include round and rectangular jerrycans, F-style bottles, and closures for pesticide and solvent-based formulations. On high-output shuttles with 50–60 s cycle times, the EVOH layer is more heat-sensitive than the HDPE matrix; shutdown of the EVOH extruder without HDPE purge leads to gel deposits in the die-head spiral section. The barrier structure is not recommended for highly polar solvents that plasticize EVOH; for such products, additional fluorination or a different barrier layer is required.
In multi-layer blow molded fuel tanks, Soarnol GH3804B is incorporated into a six-layer construction of HDPE/regrind/tie/EVOH/tie/HDPE to reduce hydrocarbon permeation from gasoline, ethanol-blended fuels, and diesel. The EVOH layer is placed at 2–4% of total wall thickness, typically 80–120 µm in a 4 mm tank wall, and the regrind layer may contain up to 30 wt% of ground tank material without eliminating the continuous EVOH barrier. Accumulator-head blow molding machines with 10-point parison programming are used because the parison sag behavior of EVOH differs from that of HDPE; insufficient programming causes barrier-layer thinning in the pinch seam and around the filler spout. EVOH melt temperature is controlled at 215–230°C, with the die head maintained within ±5°C to avoid viscosity mismatch at the layer interfaces. Drying to less than 0.1% residual moisture at 80–90°C is required before extrusion, and all regrind is kept below 0.05% moisture. Compliance testing for fuel permeation is carried out according to SAE J1737 or vehicle-manufacturer specifications, and evaporative emissions are evaluated under EPA 40 CFR 86 and CARB LEV III protocols where applicable. Terminal components include gasoline and diesel fuel tanks, filler pipes, and small-engine fuel reservoirs. Production experience on multi-layer accumulator machines shows that EVOH layer interruptions occur if the head tooling gap is set below 1.5 mm or if the EVOH melt pressure drops below 30 bar during parison ejection; therefore melt pumps are often used on the EVOH extruder. The barrier layer must not be directly exposed to fuel on the inner tank surface because ethanol-blended fuels can swell and disrupt the EVOH layer, so a continuous HDPE inner layer of at least 0.5 mm is maintained.
Because pharmaceutical blister lidding requires a flat, die-stable EVOH layer with tight gauge control, Soarnol GH3804B is coextruded in a three-layer film with polyethylene and tie resin and then adhesive-laminated to foil or polyester. The EVOH core is normally 3–5 µm in a 50–60 µm lidding structure, corresponding to 5–8 wt% of the total film. The film line uses a 35–45 mm EVOH extruder at 24:1 L/D and a slot die with internal deckle adjustment; melt temperature is held at 210–225°C, and die build-up is controlled by purging with LDPE at 190–200°C during stoppages. Drying is done at 80–90°C for 4–6 h to below 0.1% residual moisture, and QC records the oxygen transmission of the finished lidding by ASTM D3985 at 23°C and 65% RH. The compliance path for pharmaceutical packaging uses USP <661.1> for plastic materials and component suitability, with additional testing per 21 CFR 177.1360 where food-like or oral dosage contact is assessed. The terminal products are push-through and peelable lidding for tablets, capsules, and transdermal backing films. On production-scale laminators, tension control at the EVOH-containing web is critical; elongation differences between the EVOH film and foil substrate cause tunneling and delamination in the blister track when adhesive cure is incomplete. Published data for GH3804B in high-pH or amine-containing pharmaceutical formulations is limited, so compatibility testing with the specific drug product is required before use.
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Soarnol GH3804B is a pelletized ethylene-vinyl alcohol copolymer supplied under the Soarnol trade name by Mitsubishi Chemical Corporation. The resin belongs to the 38 mol% ethylene class and is intended for use as the oxygen-barrier core in coextruded polyolefin structures such as rigid sheet, blow-molded containers, and coextruded film. The grade designation follows the manufacturer’s nomenclature convention: the 38 denotes nominal ethylene comonomer content of 38 mol%, and the terminal digit identifies a nominal melt flow rate of 4 g/10 min measured at 210 °C under a 2160 g load in accordance with ISO 1133-1:2022. Manufacturer technical data list density at 1.17 g/cm³ using ISO 1183-1:2019, melting point at 173 °C using ISO 11357-3:2018, glass transition at 58 °C using ISO 11357-2:2020, and crystallization temperature at 157 °C using ISO 11357-3:2018. Oxygen transmission rate for a 20 μm monolayer film conditioned at 20 °C and 65% relative humidity is typically reported at 1.5 cm³·20 μm/(m²·day·atm) under ASTM D3985. These values are family-representative and not lot-release specifications; they shift with orientation, layer thickness, moisture history, and downstream thermal treatment.
EVOH grades with 38 mol% ethylene are processed at melt temperatures between 210 °C and 230 °C at the die adapter. Extended exposure above 240 °C initiates thermochemical decomposition; the observable production symptoms are acetic acid evolution, yellow gel particles, and die-lip deposit formation. The resin must be dried to below 0.01 wt% (100 ppm) water before melting. Desiccant drying at 80 °C for 4 h to 6 h with a dew point of -40 °C is used in production. At plant relative humidity above 60%, closed hopper loading with dried-air purge is required because EVOH surface moisture uptake occurs within minutes and residual moisture causes bubble voids in cast film and sheet.
Rheologically, the nominal melt flow rate of 4 g/10 min is lower than the 8 g/10 min flow of the 38 mol% grade identified as E3808; this gives GH3804B higher melt strength and improves parison stability in coextrusion blow molding but increases pressure drop in narrow sheet dies. Screw configurations should use a low-shear barrier mixing section with a compression ratio between 2.8:1 and 3.2:1 and a length-to-diameter ratio of at least 24:1. Gear-pump-assisted extrusion is preferred; it stabilizes pressure and reduces residence-time variation. Total residence time in the melt should not exceed 10 min at 230 °C; at 215 °C, a residence window of 15 min to 20 min is available before gel particle density increases. Melt temperatures should be confirmed with an immersion probe because infrared sensors are affected by EVOH surface emissivity changes during heating.
Direct melt contact with polyvinyl chloride, polyvinylidene chloride, or carbon-black-containing regrind that can generate acidic degradation products during stoppages is incompatible. Purging with a low-density polyethylene having a melt flow rate of 2 g/10 min to 4 g/10 min before and after extrusion is recommended. Transition-metal stearates and certain amine-containing processing aids should be excluded because they accelerate thermal degradation at processing temperature. At the feedblock shear-rate range of 50 s⁻¹ to 200 s⁻¹, the apparent melt viscosity of GH3804B is matched to anhydride-modified tie resins by selecting a tie resin with a melt flow rate within 1 g/10 min of the EVOH. A greater mismatch produces wavy interlayer interfaces and local thickness nonuniformity.
On a production-scale coextrusion sheet line using a 75 mm single-screw barrier extruder with 30:1 L/D, a 60/100/60 mesh screen pack, and a gear pump, GH3804B is processed as the central layer between polypropylene skins and anhydride-modified tie layers. Die adaptor melt temperature is held at 215 °C to 225 °C; a thermocouple excursion to 230 °C for more than 20 min has been associated with oxidized gel streaks in sheet and increased die-lip deposit frequency. Die gaps in the 0.4 mm to 0.8 mm range are used for sheet gauges from 300 μm to 1200 μm. The barrier layer thickness is controlled to 3 μm to 8 μm in most rigid barrier packaging. Excessively thin layers below 3 μm risk layer breakup and incipient gel-induced holes; layers above 12 μm increase scrap cost and may reduce sheet impact properties.
During sheet extrusion, the die temperature profile should be set to maintain an EVOH melt viscosity close to that of the adjacent tie layers; a mismatch greater than 10% in apparent viscosity at the shear rate of the coextrusion feedblock causes interfacial flow instabilities. The feedblock and die should use streamlined flow channels without dead spots. On thermoforming lines, the sheet surface temperature is maintained below 80 °C before entering the oven to prevent surface moisture absorption that would generate microvoids during heating. Regrind incorporation is limited in polyolefin skins; EVOH regrind is typically kept below 10 wt% in the skin layers to avoid visible gels and maintain impact strength. On cast film lines, layer thickness is monitored with beta gauges; EVOH thickness variation should not exceed ±5% of the nominal core thickness, and line speed is adjusted to keep the thickness deviation within ±0.5 μm for a 6 μm barrier layer.
The barrier performance of GH3804B is governed by the inverse relationship between ethylene content and dry oxygen barrier. Table 1 lists published typical oxygen transmission values for monolayer films at 20 μm thickness tested under ASTM D3985 at 20 °C and 65% relative humidity. These values are family-representative and not lot-release specifications.
| Product designation | Nominal ethylene content (mol%) | Nominal melt flow rate (g/10 min at 210 °C, 2160 g) | Oxygen transmission rate (cm³·20 μm/(m²·day·atm)) |
|---|---|---|---|
| Soarnol D2908 | 29 | 8 | 0.4 |
| Soarnol DC3203F | 32 | 3 | 0.6 |
| Soarnol GH3804B | 38 | 4 | 1.5 |
| Soarnol A4412 | 44 | 12 | 3.0 |
At 20 °C and 65% RH, the oxygen transmission rate of GH3804B is approximately 3.8 times higher than that of Soarnol D2908 and approximately 2.0 times lower than that of Soarnol A4412. The intermediate ethylene content reduces the number of vinyl alcohol units available for hydrogen bonding with permeating water, which lowers equilibrium moisture uptake relative to 29–32 mol% grades. As external relative humidity increases, monolayer lower-ethylene EVOH films show a larger relative loss in barrier than 38 mol% films. In coextruded polyolefin structures the skin layers act as moisture shields; the local relative humidity at the EVOH layer may remain below 70% even when the package exterior is at 90% RH, depending on skin thickness and exposure time. Therefore, GH3804B is specified in humid environments where a 29 mol% grade would require thicker skins or a second barrier layer.
Oxygen permeation through EVOH is an activated process. For the 38 mol% class, published data indicate that oxygen transmission at 40 °C is approximately 2.0 to 2.5 times the value measured at 20 °C under the same relative humidity; this corresponds to an apparent activation energy near 40 kJ/mol. Package designers using ASTM D3985 data at 20 °C must therefore correct for distribution and hot-fill temperatures when predicting shelf life. Barrier thermal history is also relevant. After thermoforming at 130 °C to 150 °C sheet surface temperature, the oxygen transmission of EVOH can increase by 10% to 25% relative to the preformed sheet because thinning and orientation distribution alter the layer thickness and free volume. The 38 mol% grade generally shows less orientation-induced microcracking than 44 mol% grades in deep-draw trays.
Retortable polypropylene/tie/EVOH/tie/polypropylene structures expose the barrier layer to saturated steam at 121 °C for 30 min to 60 min and overpressure cycles of 0.15 MPa to 0.20 MPa. Under these conditions, a 29 mol% EVOH layer provides superior initial oxygen barrier but absorbs water rapidly, which can reduce interfacial adhesion and increase post-retort oxygen permeability. GH3804B, with its higher ethylene content, exhibits lower water uptake and improved resistance to process-induced delamination at the tie interfaces, but a lower initial barrier. Direct substitution without recalculating the barrier layer thickness increases oxygen ingress after retort. Production trials therefore evaluate post-retort oxygen transmission on the finished tray using ASTM D3985 at 23 °C and 50% RH after retort conditioning, and adhesion is measured according to ASTM F904 or ISO 11339:2022. A typical start-point adjustment is to increase the nominal EVOH layer thickness by 20% to 40% relative to the 29 mol% design, then verify oxygen transmission and bond strength. Published data for this specific retort configuration is limited; process validation on the target packaging line is required because fill weight, headspace, and retort rack loading alter the humidity history of the EVOH layer.
If the package has a polypropylene skin thickness above 300 μm, moisture penetration is slower, and the difference between 29 mol% and 38 mol% during retort narrows. In thin-wall trays with skin thickness below 150 μm, the 38 mol% grade may be preferred for its resistance to post-retort delamination despite higher oxygen transmission. In all cases, the EVOH layer must not be allowed to exceed 90% internal relative humidity during processing because barrier recovery after drying is incomplete once microcracks form. The tie layers must be selected with melt flow rates within 15% of the EVOH and skin resin to limit interfacial slip in thin layers.
Regulatory status must be confirmed for the finished structure, not the neat resin alone. Table 2 lists the standard designations commonly referenced in supplier compliance documentation for EVOH barrier layers.
| Parameter | Standard or regulation | Test condition / remark |
|---|---|---|
| Food-contact resin status | FDA 21 CFR 177.1360 | Subject to migration and use-level limitations in the finished food-contact article. |
| Food-contact compliance in EU | Regulation (EU) 10/2011 | Verification of specific migration limits required for final multilayer structure. |
| Melt mass-flow rate | ISO 1133-1:2022 | 210 °C, 2160 g; reported typical 4 g/10 min. |
| Density | ISO 1183-1:2019 | 1.17 g/cm³ typical. |
| Oxygen transmission rate | ASTM D3985 | Film sample 20 μm, 20 °C, 65% RH; typical 1.5 cm³·20 μm/(m²·day·atm). |
| Melting point | ISO 11357-3:2018 | DSC second heating; typical 173 °C. |
Because EVOH barrier performance is not a single-point material constant, users should request lot-specific certificates of analysis for melt flow rate, density, and residual moisture. The residual moisture specification is particularly critical for extrusion lines without vacuum venting; material that has been exposed to plant air above 60% relative humidity for more than 30 min before hopper loading may require re-drying. For coextrusion blow molding, the melt temperature at the die head should be re-validated after every screw pull because barrel temperature overshoot above 240 °C creates carbonized deposits in the accumulator head. Off-spec film containing oxidized gels should not be ground into direct-food-contact layers.
