p.1 

OAR Box 1413 

Prepped by Ollie Stewart 

Document Number: 

100)11-1-101 

Docket Number: 

A-94-52 

Printed 7/9/2008 3:11:24 PM Sheet 100 of J14 
P.2 

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P.3 

S£_ 

General Statistics 

Development of Today's Plastics 3 

Introduction of Plastic Resins 6 

Plastics Monomer Derivatives 7 

Ethylene 7 

Methane 8 

Acetylene 9 

Butadiene 10 

Propylene 11 

Benzene 12 

Naphthalene, Toluene and Xylenes 13 

Plastics SIC/NAICS Codes 14 

Plastics Materials and Products Industry Trends 16 

Plastics Materials and Resins (SIC 2821 or NAICS 325211) 16 

Miscellaneous Plastics Products (SIC 308) 16 

Plastics Compared to Other Manufacturing Industries 17 

Financial and Operating Ratios - Processing Industry 18 

Balance Sheet 18 

Income Statement . 18 

Statistical Data 19 

Major Markets 

Definitions of Major Market Categories 23 

Total Sales & Captive Use by Major Market (1993-1997) 25 

Percentage Distribution of Resins by Major Market 26 

All Resins (1993-1997) 26 

Thermoset Resins 28 

Thermoplastic Resins 28 

Major Market Report 29 

Total Thermoset Resins 29 

Total Thermoplastic Resins 29 

Individual Plastics Resins 30 

Resin Statistics 

Production and Sales & Captive Use 35 

All Resins (1972-1997) 35 

Individual Plastics Resins (1988-1997) 36 

Domestic Merchant Sales by Plastics Resins 39 

Apparent U.S. Consumption of Selected Plastics Resins 40 
P.4 

t

 ' Manufacturers 44 

Production and Sales & Captive Use 44 

Domestic Consumption by End-Use 44 

Distribution by Major Market ...' 45 

Typical Applications ; 45 

Phenolic 46 

Manufacturers 46 

Production and Sales & Captive Use 46 

Typical Applications 46 

Domestic Consumption by End-Use 47 

Distribution by Major Market . 47 

Unsaturated Polyester 48 

Manufacturers 48 

Production and Sales &T Captive Use 48 

Typical Applications 48 

Domestic Consumption by End-Use 49 

Distribution by Major Market 49 

Urea and Melamine .. : 50 

Manufacturers . .., 50 

Production and Sales & Captive Use 50 

Domestic Consumption by End-Use 52 

Distribution by Major Market 52 

Typical Applications .5 2 

Isocyanates 53 

Manufacturers • 53 

Production and Sales & Captive Use 53 

Polyether Polyols 54 

Manufacturers ..'. 54 

Production and Sales & Captive Use 54 

Polyester Polyols , 55 

Manufacturers 55 

Production and Sales & Captive Use 55 

Polyurethane 56 

Sales by Material 56 

Domestic Consumption by End-Use 56 

Thermoplastic Resins 

Summary Statistics 59 

Latex Materials 61 

ABS and SAN 62 

Manufacturers 62 

Production and Sales & Captive Use 62 

Distribution by Major Market . 63 

Typical Applications 63 

^^^^^^^^sm^mi^M^"-^'' 
P.5 

Distribution by Major Market 65 

High Density Polyethylene 66 

Manufacturers 66 

Capacity and Utilization 66 

Production and Sales & Qptive Use 66 

Domestic Consumption by End-Use 67 

Distribution by Major Market.. , 67 

Typical Applications 67 

Distribution by Selected End-Uses 69 

Low Density Polyethylene 70 

Manufacturers 70 

Capacity and Utilization 70 

Production and Sales 6r Captive Use 70 

Domestic Consumption by End-Use 70 

Distribution by Selected End-Uses 71 

Linear Low Density Polyethylene 72 

Manufacturers 72 

Capacity and Utilization 72 

Production and Sales & Captive Use , 72 

Domestic Consumption by End-Use 72 

Distribution by Selected End-Uses '. 73 

Nylon 74 

Manufacturers 74 

Capacity and Utilization 74 

Production and Sales 6*r Captive Use 74 

Domestic Consumption by End-Use 75 

Distribution by Major Market 75 

Typical Applications 75 

Material Flow Chan 76 

Polystyrene 77 

Material Flow Chart 77 

Manufacturers 78 

Capacity and Utilization 78 

Production and Sales & Captive Use 78 

Domestic Consumption by End-Use 79 

Distribution by Major Market _ 79 

Typical Applications 79 

&^£S^g-^^^^£^^^§^^^^^0Sr^^^^W^^'P^: 
P.6 

Domestic Consumption by End-Use 81 

Distribution by Major Market 81 

Typical Applications 81 

Polyvinyl Chloride 82 

Manufacturers - 82 

Capacity and Utilization r 82 

Production and Sales & Captive Use 82 

Typical Applications 82 

Domestic Consumption by End-Use 83 

Distribution by Major Market 83 

Thermoplastic Polyester 84 

Manufacturers 84 

Capacity and Utilization 84 

Production and Sales & Captive Use 84 

Domestic Consumption by End-Use 85 

Distribution by Major Market . . .: 85 

Typical Applications 85 

Material Flow Diagram 88 

Domestic Sales and Captive Use of Selected Thermoplastics 

by Process Grade . 86 

Integrated Solid Waste Management 

The American Plastics Council 90 

Plastics Recycling 91 

Resource Conservation 91 

Fabricated Plastic Products 

Flow Chart: Raw Material to Finished Product : 94 

Composites 95 

Overview 95 

Shipments by Market 95 

Vinyl Siding and Soffit 96 

Participating Producers .... . 96 

U.S. Shipments 96 

-i>'^;x%H^-^ ^ ^^s^ss^ ^ J: 
P.7 

Uossary 

Additives for Plastics 103 

Definitions of Resins . . . 105 

Definitions of Selected Plastics Properties 112 

Other Sources of Plastics Information 

Business Consulting Groups 119 

Government Publications 119 

Newspapers 120 

Trade Associations and Professional Organizations 120 

Trade Publications 120 

Order Forms 

Monthly Statistical Report - Resins 123 

Facts & Figures of the U.S: Plastics Industry 127 

Index 

Index ..131 

c n m B__B 
Production and Sales & Captive Use COIlt. (millions of xranus) 

RESIN 

Epoxy 

Phenolic 

Polyester (Unsaturated) 

Urea 

Melamine 

Total Selected 

Thermoscis 

ADS 

SAN 

HDPr. 

LDPE. 

LDPE 

l.LDPr; 

Nvlon 

Polypropylene 

Polvsivrcnc 

PVC 

Thermoplastic 

Polyester 

Total Selected 

Thermoplastics 

Total Selected Plastics 

All Other Plastics 

Grand Total 

1993 

P 

...51? . 

. 3.078 

. 1.264 

. 1,744 ' 

270 

. 6.868 

. 1.462 

.. . 105. 

.9.941 

12 GOT 

. 7 12'.:x 

. 4.84] 

7f\H 

. 8.62S 

. 5.382 

10.257 

. .2.540 

51.159 

. 5S.027 

10.777 

68.854 

S&CU 

535 

3,081 

1.280 

1,743 

26! 

6.900 

1.373 

118 

10,604 

13.140 

7.4? 4 

5.716 

794 

SO 38 

5.494 

10.540 

2.540 

5V556 

K\45 6 

10.650 

71,094 

1994 

P 

601 

3,229 

1,468 

1.915 

300 

7,513 

1.701 

138 

11,117 

12.600 

7.578 

5.022 

943 

9.539 

5.848 

11.712 

3.196 

56.794 

64,307 

11.664 

75.971 

S&CU 

606 

3,230 

1,493 

i no 

283 

7.522 

1,583 

162 

11,910 

14,239 

7.904 

6,335 

942 

9,946 

6.000 

11.761 

3.154 

59.697 

67.219 

11.525 

78.744 

1995 

P 

632 

3.204 

1.577 

1,816 

290 

7.519 

1.458 

130 

11.211 

12.886 

7.643 

5.243 

1.020 

10,890 

5.656 

12.295 

3.785 

59.331 

66.85^ 

11.834 

78.684 

S&CU 

620 

3,201 

1,569 

1.810 

286 

7.486 

1.463 

150 

11.837 

13.730 

7,524 

6.206 

1,031 

10,710 

5.799 

12.033 

3.425 

60.178 

67,664 

11.576 

79,240 

1996 

P 

662 

3.476 

1.557 

2.147 

287 

8,129 

1,477 

121 

12.373 

14.145 

7.784 

6.361 

1.103 

11,991 

6.065 

13.220 

4.031 

64.526 

72.655 

11.640 

84.295 

S&CU 

' 643 

3,496 

1,565 

2,139 

293 

8.136 

1.433 

124 

13.211 

15,673 

7.8/4 

7.799 

1.105 

12,121 

6.071 

13.299 

3.962 

66.999 

75.135 

11.291 

86.426 

1997 

P 

654 

3,734 

1,621 

2,335 

303 

8.647 

1,374 

96 

12.557 

14,579 

7,691 

6,888 

1.222 

13.320 

6.380 

14,084 

4,260 

67.872 

76.519 

12.287 

88.806 

S&CU 

650 

3,729 

1.657 

2,334 

326 

8.696 

1,337 

109 

13,482 

16 284 

7.911 

8.373 

1.231 

13.125 

6,489 

14.049 

4,063 

70.169 

78.865 

11,851 

90.716 

Compound Growth Rates 1988-1997 (%) 

S&CU S&CU S&CU 

Epoxy 

Phenolic 

Polyester (Urtsat.) 

Urea 

Melamine 

Total Selected 

Thermosets 

3.4 

2 2 

1.5 

5.6 

4.3 

3.1 

3.S 

2.1 

1.9 

6.3 

5.4 

3.3 

ABS 

SAN 

HDPE 

LDPE 

LLDPE 

Nylon 

Polypropylene 

Polystvrene 

PVC 

Thermoplastic Polyester 

Total Selected 

Thermoplastics 

1.0 

neg 

4.5 

N/A 

N/A 

9.0 

7.0 

2.3 

6.0 

11.1 

5.1 

0.5 

neg 

5.9 

N/A 

N/A 

8.8 

7.1 

2.9 

6.1 

10.6 

5.8 

Total Selected Pla 

All Olher Plastics 

Grand Total 

'. 1.4 2.1 

4.5 5.0 

Source: SPI Committee on Resin Statistics. Monthly Statistical Repon, as compiled by Association Sen-ices Group VLC 
A

pparent consumption is calculated by adding 

imports to production, then subtracting 

exports. It is a measure oj the quantity oj 

material actually consumed in the United States. 

LUI t/U ' t/U_C~_ XJf U1 L LXJUJXXa UXa.XJ. 

jigures were taken jrom SPl's Monthly Statistical 

Report, as compiled by .Association Services Group 

LLC. Both the import and export jigures were 

taken jrom Bureau oj the Census reports. 

P.9 

I 

1997 (millions of pounds) 

«: 

it 

Resin Production 

Low Density Polyethylene 7,691 

Linear Low Density Polyethylene . 6,888 

High Density Polyethylene 12,557 

PVC 14,084 

Polypropylene* 13.320 

Polystyrene 6,380 

Phenolic' 3,734 

ABS" 1,374 

Thermoplastic Polyester15' 2,205' 

Urea' 2,335 

Unsaturated Polyester 1,621 

Nylon' 1,222" 

Epoxy 654 

Melamine' 303 

1997 Total.. 74,368 

1996 . ... ..70,797 

1995 66,720 

1994 62.107 

1993 56,942 

1992 .54,995 

1991 52,061 

1990 49,071 

Imports 

324 

1,373 

1,228 

94 

97 

269 

30 

188 

68 

7 

65 

150 

3,902 

4,043 

3,509 

3,972 

3,236 

2,453 

1,950 

2,112 

Exports 

1,763 

921 

1,715 

1,292 

1,552 

669 

72 

177 

597 

13 

151 

459 

144._> 

30 

Apparent 

Consumption 

6,252 

7,340 

12,070 

12,886 

11,865 

5,980 

3,692 

1,385 

1,676 

2,329 

1,535 

913 

560 

282 

9,555 

8,688 

7,624 

7,526 

7,496 

7,539 

8,167 

6,260 

Import % 

Of Apparent 

Consumption 

68,715 

66,152 

62,605 

58,553 

52,682 

49,909 

45,844 

46,923 

5.2 

18.7 

10.2 

0.7 

0.8 

4.5 

0.8 

13.6 

4.1 

0.3 

4.2 

16.4 

8.9 

3.2 

5.7 

6.1 

5.6 

6.8 

6.1 

4.9 

4.3 

4.5 

* Production, Trade & Apparent consumption are based on U.S. and Canadian data in 1997. 

Data for those and other resins in prior years reflect U.S. only. 

** Represents Bottle Grade PET resin sa'ics; no production data available. 

"' Bottle Grade only. 

(1>

 Represents SPI prtmary data. Epoxide e.xpons as reponed in U.S. Census repon EM 545 conform to a different specification and are not 

comparable. 

°

!

 Included with Production. 

Sources: Production—SPI Monthly Statistical Repon, as compiled by Association Services Group LLC 

Import—Bureau of the Census. IM 145 

Exports—Bureau of the Census. EM 545 
P.10 

lAJIlieSUL V>UIIbUllipUUll Uy CilU-UbC (milliouofprands) 

End-Use 1993 1994 1995 

Domestic Reinforced Plastics, Total 911 1,021 1,087 

Marine and Marine Accessories 267 306 298 

Transporuuion, Total 98 119 143 

Auto, trucks, buses, etc. 87 105 118 

Other transportation 11 14 25 

Construction, Total 444 472 513 

General construction 71 74 70 

Bathroom components & fixtures . 145 150 158 

Pipes, tankr and fittings 141 157 165 

Panel 88 91 120 

Electrical/Electronic, Total 32 41 45 

Consumer Goods, Total 34 55 65 

Recreational goods, toys, etc 18 24 35 

Other consumer goods 16 31 30 

Other Reinforced 36 28 23 

Domestic Non-reinforced Plastics, Total 326 410 409 

Transportation/Body Putty 48 55 46 

Construction, Total 154 209 232 

Marble/Onyx: 120 162 187 

Polymer concrete 12 19 22 

Other construction 22 28 23 

Consumer Goods, Toial 35 36 39 

Furniture 3 2 5 

Other consumer goods 32 34 34 

Gel CoaLs/Surfacc.Rcsins/Protcaivc Coatings D{1) DO) D(l) 

Gel coats 62 79 68 

Surface resins and protective coatings D D D 

Other Non-reinforced 89 110 92 

1996 1997 

1,045 

280 

134 

110 

25 

494 

75 

156 

145 

118 

51 

52 

28 

24 

34 

430 

44 

252 

205 

20 

27 

38 

3 

35 

80 

75 

5 

16 

1,116 

262 

156 

132 

24 

553 

88 

191 

140 

134 

59 

62 

32 

30 

24 

430 

43 

250 

200 

22 

28 

40 

4 

36 

83 

78 

5 

14 

Distribution by Major Market (millions of pounds) 

Major Market 1993 1994 

Transponation 463 543 

Packaging — — 

Building/Construction 623 711 

Electrical/Electronic 32 41 

Furniture/Furnishings — — 

Consumer & Institutional 111 127 

Industrial/Machinery — — 

Adhesives, Inks &r Coatings * 

All Other 8 9 

Exports1 42 62 

Total 1,279 1,493 

' Sales to Canada included in Exports. 

D = Disclosure 

D( 1) = Included in Other Non-reinforced 

• Included in All Other. 

1995 1996 1997 

540 

770 

45 

13 

8 

73 

495 

786 

51 

142 

1 

90 

499 

843' 

59 

144 

1 

111 

1,569 1,565 1,657 

Source: SPI Committee on Resin Statistics. Monthly Suiistical Report, as compiled by Assodation Services Group LLC 
P.11 

C

omposites are a special jamily oj materials in 

which the polymer matrix is reinforced by fibers or 

other jorms oj reinforcement. The most common 

reinforcement jibers are glass, carbon, aramid, boron, 

as well as thermoplastic jibers. The most popular 

composite resins are thermosets (unsaturated polyester, 

vinyl ester, epoxy and phenolic). Reinjorced 

thermoplastics (nylon, polyokjins, ABS, PVC, etc.) are a 

rapidly growing segment oj the mdustry. 

The primary benefits of composites include high 

strength, oriented strength, light weight, high 

strength-to-weight ratio, high dielectric strength 

corrosion resistance, and long term durability. 

These benefits allow manufacturers and designers 

to select just the right combination of materials to 

fit the needs of specific applications in a wide range 

of end-use products: The U.S. composites industr)' 

is very advanced in technical activities due largely 

to the engineered lypes~bf products which are 

manufactured from composites and the relatively 

high value-added nature ofthe ultimate 

applications. 

Since 1990, the Composites Institute has been 

involved in industry market and apphcation 

development activities, coordinated through its 

Market Development Alliance. For example, the 

Marine/Waterfront Task Group (MWTG) is 

developing new forms of composite bearing piles, 

fender piles and sheets piles (bulkheading) for pon 

and harbor installations. MWTG is also 

investigating techniques for repair and upgrading 

of pier facilities. The Composites Infrastructure 

Task Group (CITG) has programs to develop a new 

generation of products for reinforcing concrete 

(dowel rods, reinforcing bars, tendons, cable_tays, 

etc.) as well as primary and secondary structural 

applications. It is expected that structural 

applications for composites in civil engineering and 

the nation's infrastructure will continue to-be the 

focus of this exciting industry development 

initiative. 

Needs for lightweight structural materials also 

continue to support increased demands for 

composites in die aircraft/aerospace/defense, 

appliance/business equipment, construction, 

consumer/recreational products, electrical/ 

electronics, marine and surface transportation 

markets. Typical composite applications in these 

industries include tubs/showers, pipes and tanks, 

grating, railings and ladders, window lineals, 

paneling, housings for appliances, utility poles and 

lighting standards, and nearly 500 composite 

automotive and truck applications. 

•-I 

K 

Composites Shipments by Market (thermoset 6~ thermoplastic resins) (millions of pounds)1 

Markets 19S7 1988 1989 1990 1991 1992 1993 1994 _ 1995 1996 1997 

Aircrafl/Aerospace/Miliiary 

Appliances/Business Equipment 

Construction 

Consumer Products 

Corrosion-Resistant Equipment 

Electrical/Electronic 

Marine 

Land Transportation 

Miscellaneous 

36 

HI 

506 

167 

329 

214 

413 

656 

75 

39 

150 

495 

169 

34.9 

230 

452 

695 

80 

41 

151 

470 

158 

335 

229 

405 

677 

76 

39 

153 

468 

165 

350 

241 

375 

705 

79 

39 

135 

420 

149 

355 

231 

275 

682 

74 

32 

143 

483 

162 

332 

260 

304 

750 

83 

25 

148 

530 

166 

352 

275 

319 

822 

89 

24 

161 

597 

175 

376 

299 

363 

946 

102 

24 

167 

629 

184 

394 

315 

372 

982 

107 

24 

177 

655 

194 

381 

319 

368 

989 

107 

24 

185 

700 

210 

396 

348 

353 

1,095 

111 

Total 2,537 2,659 2.542 2,575 2,360 2,549 2,726 3.043 3,174 3,214 3,422 

1

 Includes reinforced thermoset and thermoplastic resin composites, reinforcements, and fillers. 

i_j_i»________»_«.M_in^^i-M_uTM-llM^^ 

Source: SPI Composites Institute.