Abstract Polyethylene is a versatile polymer suitable for a large variety of flexible and rigid packaging applications. Its mechanical and rheological properties can be tuned across a wide range by controlling its molecular architecture, such as the amount and distribution of olefinic comonomers (short chain branching), long chain branching, and molecular weight distribution. Linear low‐density polyethylene (LLDPE) is known for its high toughness which enables downgauged film structures and low‐density polyethylene (LDPE) is known for its excellent shear thinning and melt strength which enables enhanced processability and high throughput, such as on blown film lines. In order to obtain a balance of toughness and processability on films produced on blown film lines, blends of LLDPE and LDPE are commonly used. In this paper, we describe additive‐based approaches, including a new product, DOWLEX™ (TM = trademark of the Dow Chemical Company (“Dow”) or an affiliated company of Dow) GM AX01, which enhances melt strength and other rheological properties of polyethylene, enabling fabrication of films with lower LDPE content while still maintaining excellent rheological properties and higher toughness versus conventional LLDPE/LDPE blends. The higher toughness enables downgauging without loss of mechanical properties, which in turn reduces consumption of polymer resulting in a more sustainable solution.
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