KBSU and SIBUR: A Joint Step Toward Creating the Polymers of the Future

High-Strength Superstructural Polymers (PFA) Will Soon Replace Metals

SIBUR and the Kabardino-Balkarian State University (KBSU) named after Kh.M. Berbekov are jointly leveraging their scientific potential for laboratory research and the subsequent transition to industrial-scale production of superstructural polymers.

What stage is the introduction of superstructural polymers into production at?

Currently, there are no large-scale production facilities for superstructural plastics in Russia. However, as reported by the press service of PJSC SIBUR, specialists from the SIBUR Innovations Research Center and the university have begun work on scaling up the method for producing polyphthalamide (PFA).

This high-strength polymer demonstrates resistance to extreme temperatures, chemically aggressive environments, and severe mechanical stress, which in many situations makes it possible to eliminate the need for metal parts. This joint initiative opens the door to improving everyday products used by millions of consumers, from food and medical packaging to various devices and vehicles.

Currently, the project is in the laboratory phase: synthesis conditions are being optimized and the consistency of the resulting material’s properties is being verified. The next task will be to develop a pilot plant for scaling up. This will allow the method to be tested under conditions simulating actual production and lay the foundation for future pilot production.

The unique properties of PFA are in demand in various industrial sectors.

Polyphthalamide’s uniqueness lies in its combination of several key qualities: increased mechanical reliability, geometric stability, chemical inertness, and the ability to withstand long-term heating at temperatures up to 210°C (or short-term heating up to 280°C). These properties have attracted interest in the material from the automotive, electronics, and mechanical engineering industries, and also expand its potential for use in flexible packaging production.

In the automotive industry, polyphthalamide is essential for the manufacture of underhood components such as thermostat housings, cooling circuit components, and fuel system components. Lighter, heat-resistant materials enhance vehicle reliability while reducing overall weight, which positively impacts energy efficiency.

Products made from super-engineered plastics are 40-50% lighter than aluminum and titanium, are durable, and resistant to high temperatures and mechanical stress. In many industries, including transportation, choosing polymers over metals can mean greater fuel economy, reduced carbon dioxide emissions, and increased load-bearing capacity. Furthermore, these materials are highly flame- and smoke-resistant and non-toxic, which is important for the aerospace and shipbuilding industries.

Their high biocompatibility and radiolucency make some types of these plastics popular in the medical industry, including for the creation of high-tech implants and prosthetics.

In electronics, this polymer is used to manufacture connectors, inductors, and insulating components, ensuring the stable operation of devices and gadgets.

Furthermore, the plastic is used in flexible packaging, where it improves oxygen and water barrier properties, optical properties, and strength, while also reducing fragility and increasing elasticity. Films made from it are highly resistant to moisture, fats, and temperature fluctuations, which helps extend the shelf life of food products and pharmaceuticals.

Thus, advances in superstructural polymers impact not only manufacturing sectors but also everyday life.

PFA debuted at Innoprom 2025

At the Innoprom exhibition in 2025, SIBUR first demonstrated polyphthalamide, produced using its own patented technology. The material has expanded the range of superstructural plastics being developed at the company’s research centers to strengthen technological sovereignty and increase the potential of the domestic industry.

Svetlana Khashirova, Vice-Rector for Research at KBSU: «For the university, involvement in the project to develop a polyphthalamide synthesis technology signifies the development of the long-standing work of our scientific school, which specializes in special polymers. In laboratory conditions, the main goal is to achieve controllability of the synthesis, a consistent polymer structure, and the required physical and mechanical properties.»

Ivan Menshikov, Senior Project Manager for Special Polymers at the SIBUR Innovations Research Center: «Improving the polyphthalamide production technology is a significant step in the development of SIBUR’s portfolio of superstructural plastics. Such materials offer new advantages to industry, enabling the production of lighter, more heat-resistant, and wear-resistant products. Collaboration with KBSU allows us to synthesize fundamental scientific research and practical engineering experience, which is critical when translating laboratory developments into a fully-fledged industrial technology.»

In 2026, the project will move from scaling to the pilot phase.

This year, the pilot plant is planned to test the synthesis parameters under conditions as close as possible to factory conditions. The results of the scaling and a detailed analysis of the data obtained jointly with the partner will form the basis for a decision on moving the project to the pilot phase.

The development of polyphthalamide production technology will significantly contribute to the development of Russian expertise in the field of superstructural plastics and to the expansion of opportunities for the creation of innovative materials that improve the reliability and safety of equipment, vehicles, and consumer goods.