The short answer
Flexible PVC is usually the lower-cost choice per pound and remains the default for clear tubing, many power cords and refrigerator gaskets. TPV wins when plasticizer migration, phthalate rules, halogen content, cold flexibility, compression set or weight matter: it uses no PVC-type plasticizer, standard grades contain no chlorine, stays flexible far colder, and is about a quarter lighter. Compare cost per part, not per pound, because the density gap closes much of the price gap.
Buyers look at this switch for gaskets, boots, grommets, extruded profiles and cord jackets. For the wider field, see TPV vs. other elastomers, and for PVC grades, our PVC page.
TPV vs. flexible PVC side by side
| Property | TPV (EPDM/PP) | Flexible PVC |
|---|---|---|
| Hardness range | About 35A to 50D | About 40A to 95A |
| Service temperature | About −40 to 125°C / −40 to 257°F | About −10 to 60°C / 14 to 140°F for general grades; low-temperature and wire grades extend this |
| Compression set | Good | Fair to poor; creeps under load |
| Oil and fluid resistance | Fair; swells noticeably in hot oil | Fair; oils and solvents can extract plasticizer |
| UV and ozone | Very good | Good with stabilizers or carbon black |
| Density, g/cm³ | About 0.9–1.0 unfilled | About 1.2–1.4; filled grades higher |
| Plasticizer | No PVC-type plasticizer; the rubber phase is extended with paraffinic oil | Typically 20–50% or more of the compound by weight, depending on hardness |
| Processing | Injection, extrusion, blow molding. Melt about 175–230°C / 347–446°F | Extrusion, injection, calendering. Melt about 163–200°C / 325–392°F; corrosion-resistant steel |
| Drying | About 80°C / 176°F, 3 h (4 h with regrind), to 0.08% or less | Usually not needed |
| Scrap | Same-grade regrind goes back in | Regrind works, but each pass uses up heat stabilizer |
| Typical parts | Weatherseals, gaskets, grommets, boots, appliance seals | Tubing, cord and cable jacket, refrigerator gaskets, boots, dip-molded parts |
Typical ranges. Flexible PVC properties depend heavily on the plasticizer type and level, filler and stabilizer; TPV properties on hardness and grade. Processing values agree with our processing parameters and drying guide.
Plasticizer migration
Flexible PVC gets its softness from plasticizer, a liquid mixed into the compound. Over time some of it can move out of the part. It can soften or stain plastics and adhesives the part touches, be extracted by oils and solvents, fog nearby glass in hot cars, and leave the PVC stiffer and shrunken as it ages. Plasticizer type matters: higher-molecular-weight and polymeric plasticizers migrate less, at higher cost.
TPV contains no PVC-type plasticizer. Its rubber phase is extended with paraffinic oil, and some soft grades can show a slight oily or tacky surface, especially when warm; see sticky TPE surfaces. But it does not attack neighboring plastics the way PVC plasticizer can.
Phthalate rules
Several common PVC plasticizers are phthalates, and their use is restricted in some products and markets. In the U.S., 16 CFR 1307 under the CPSIA bars more than 0.1% of eight specified phthalates in accessible plasticized parts of children’s toys and child-care articles. The EU restricts several phthalates in many articles under REACH, and California lists several under Proposition 65, which can require warnings. Many retail and automotive programs go further and ask for non-phthalate plasticizers outright.
Non-phthalate flexible PVC is widely available, so phthalate rules alone do not force a switch. If your customer wants phthalate-free or halogen-free material, ask for the grade’s regulatory statement either way. These rules change, so check the current text for your market rather than relying on this summary.
Low-temperature flexibility
General-purpose flexible PVC stiffens noticeably below about −10 to −20°C / 14 to −4°F, and can crack if flexed or struck when cold. Low-temperature plasticizers extend that, at some cost. Many TPV grades stay flexible to about −40°C / −40°F or lower, which is why TPV is common in outdoor and automotive seals. TPV also runs hotter, to about 125°C / 257°F, against about 60°C / 140°F for general flexible PVC.
Weight, density and cost per part
TPV is much lighter. At 0.97 vs. 1.30 g/cm³, the same part weighs about 25% less in TPV (0.97 ÷ 1.30 = 0.75), and a pound of TPV makes about 34% more parts (1.30 ÷ 0.97 = 1.34). Flexible PVC is usually lower in price per pound, so multiply each price by its density to compare cost per unit volume. Use the densities on your grades’ data sheets; filled PVC can be heavier still.
Recyclability and scrap
Both can be reground in-house. PVC regrind uses up heat stabilizer with each pass, so burned or purged PVC should never go back in; see regrind limits by resin. TPV regrind goes back in with virgin at a tested ratio, dried like virgin. Keep the two apart: PVC contamination in a polyolefin-based material, or the reverse, causes defects, and PVC must never meet acetal at processing temperature. Standard TPV grades contain no chlorine, so they do not release hydrogen chloride and does not need corrosion-resistant tooling.
Extrusion profiles and cords
Flexible PVC extrudes at low temperature, co-extrudes with rigid PVC for window and door profiles, and is the long-standing material for refrigerator door gaskets, garden hose and many power cords. TPV is used for automotive and building glazing seals, weatherstrip, expansion-joint seals and some outdoor and appliance cords where cold flexibility or halogen-free material is wanted. A switch needs a new or re-cut die, because TPV swells and draws down differently, and drying. Wire and cord compounds are UL-recognized by grade and color; ask for the recognition that covers the exact grade.
When to choose TPV, and when to choose flexible PVC
When to choose TPV
- Plasticizer migration or fogging has caused problems
- Customer wants phthalate-free or halogen-free material
- Parts flex outdoors in winter or sit near heat
- Seals that must keep their squeeze
- Weight reduction
When to choose flexible PVC
- Lowest cost per pound for tubing, cord or non-critical gaskets
- Clear flexible tubing or parts
- Rigid-flexible co-extruded profiles
- Existing UL-listed cord or wire constructions
- Parts that run near room temperature with no sealing demand
What to send us
- The PVC compound you run now, its hardness and the plasticizer type if known
- Service temperature range, especially the coldest
- Regulatory needs: phthalate-free, halogen-free, food contact, UL
- Whether it is extruded or molded, with a profile drawing if you have one
- Quantity and ship-to city
A polymer chemist reviews every request and checks the grade against your part, process and documents before we quote. Every lot ships with a COA, and orders start at one gaylord. Samples of about 50 lb are available upon credit approval. We aim to send your quote within one to three business days.
Common questions
Is TPV a replacement for flexible PVC?
Often, where the reason to switch is plasticizer migration, halogen content, weight, cold flexibility or compression set. Flexible PVC usually stays lower in cost per pound and remains the default for clear tubing and many cords.
Does TPV contain phthalates?
TPV is not made with PVC-type plasticizers; its softness comes from the rubber phase and paraffinic oil. Do not assume, though: ask for the grade’s regulatory statement if your customer requires phthalate-free material.
What are the phthalate rules for flexible PVC?
In the U.S., 16 CFR 1307 under the CPSIA bars more than 0.1% of eight specified phthalates in accessible plasticized parts of children’s toys and child-care articles. The EU restricts several phthalates under REACH, and California lists several under Proposition 65. Many buyers now specify non-phthalate plasticizers. Rules change, so check the current text for your market.
Is TPV lighter than PVC?
Yes. Unfilled TPV is about 0.9–1.0 g/cm³ and flexible PVC about 1.2–1.4. At 0.97 vs. 1.30, the same part weighs about 25% less in TPV, and a pound of TPV makes about a third more parts.
Which stays flexible in the cold?
TPV. Many TPV grades stay flexible down to about −40°C / −40°F or lower, while general-purpose flexible PVC stiffens noticeably below about −10 to −20°C / 14 to −4°F unless it uses a low-temperature plasticizer.
Can I run TPV on my PVC extrusion line?
Often on the same extruder after a thorough purge, but the die usually needs to be re-cut, because TPV swells and draws down differently. TPV also needs drying. Never let PVC meet acetal in the barrel.
Tell us the flexible PVC part you want to compare
A polymer chemist reviews every request, then matches your grade or finds a qualified equivalent and prices it.
What to send for an accurate quote
- The grade name, from any supplier, or a data sheet
- Color (natural, black or a custom match)
- Fill type and percentage, if any
- Melt flow, if you know it
- Quantity for this order and what you use in a year
- Ship-to city and state or province