Engineering Plastics always gain an edge where metals are not an option. Injection molding makes it easier to make complex parts compared to casting. So, with ease and freedom of design with great performance, Polyphenylene Sulfide can be a material of choice for various applications. The grade and filler material of a particular engineering plastic depends on the area of application. Companies have been developing newer and stronger grades for various end-uses. The majority of the research and development is based on providing materials with ease of processing and more efficient manufacturing.

Polyphenylene Sulfide has already entered the automotive, aerospace, industrial, and filter media industry. Industries such as medical devices/healthcare, food & beverages where there has been increasing use of plastics are the major areas to be explored for Polyphenylene Sulfide. These industries account for a small share of the global market and companies have been investigating the feasibility of the use of Polyphenylene Sulfide in various other untapped areas.

While comparing Polyphenylene Sulfide to its competitors, polyetherimide (PEI) and polyether ether ketone (PEEK) have better physical and chemical properties but are not as economical as Polyphenylene Sulfide. Polyphenylene Sulfide is also said to be the common man’s PEEK. Compared to Polyphenylene Sulfide, PEEK, from the polyether ketone family accounts for a very small market share in high-end-engineering plastics.

Para-dichlorobenzene is the major raw material to produce Polyphenylene Sulfide. Para-dichlorobenzene (p-DCB) is a chlorinated aromatic monomer produced by reacting chlorine with benzene. Chlorinated solvents have various environmental concerns responsible for groundwater and soil contamination. PCBs and dioxin can also cause cancer and other human health hazards. The US-based company’s Standard Chlorine Chemical Company, Inc. Kearny; N.J. site has been listed as a Superfund site for which the EPA expects the spend USD 11 Million for clean-up.

Considering the economic and ecological aspects, companies have been finding economical ways to modify existing plants and shift product slates. Maximum para-dichlorobenzene selectivity can be achieved using the right catalyst, while also finding acceptable commercial outlets for by-products. Shutdowns of various chlorinated solvent plants in the US and Europe have been one of the major reasons for delays in the production of Polyphenylene Sulfide. This has led manufacturers to build integrated plants that produce p-dichlorobenzene, and sodium hydrosulfate which are the raw materials for Polyphenylene Sulfide resin.

The global Polyphenylene Sulfide capacity stood at 163 Kiloton in 2023 and it is further projected to cross 200 Kiloton by the end of the forecast period. Some of the prominent PPS manufacturers in the world include Solvay SA, DIC Corporation, Fortron Industries, Kureha Corporation, Tosoh Corporation, Lion Idemitsu Composites, SK Chemicals (Initz Co. Ltd.) and Toray Industries Inc. Toray stands out as the largest producer of Polyphenylene Sulfide globally, accounting for around 18% of the total capacity, followed closely by DIC Corporation, which holds a 15% share of the market. The Polyphenylene Sulfide market has seen a remarkable expansion in recent times and is anticipated to sustain its upward trajectory in the coming years. This growth can be attributed to the increasing demand from various sectors, including automotive, electrical & electronics, and industrial end-use sectors. Moreover, the market's positive outlook is further bolstered by the expanding manufacturing capabilities in emerging economies.

The main driving factor for the demand for Polyphenylene Sulfide is its widespread use in automotive applications, particularly in under-the-hood applications. In 2023, the automotive sector represented the largest market, accounting for more than 40% of the total Polyphenylene Sulfide market, followed by electrical & electronics applications. Both the automotive and electrical & electronics industries show a similar growth trend in terms of Polyphenylene Sulfide resin demand. Filter media accounted for about 18% of the total Polyphenylene Sulfide market and is expected to grow at a CAGR of 8% during the forecast period. The Aerospace & Defense industry is anticipated to experience robust growth, leading to an increase in the utilization of Polyphenylene Sulfide at a CAGR of 10%. As a result, the market share of Polyphenylene Sulfide in this industry, is expected to reach 13% by 2032. The use of Polyphenylene Sulfide in industrial and other applications is estimated to maintain their respective market shares, which currently stand at approximately less than 10% of the global Polyphenylene Sulfide market.