Process for manufacturing olefin polymers and products prepared by the process

A process for producing bimodal olefin homopolymers or copolymers in a polymerization sequence, comprising:

• a) conducting a first polymerization step in a first polymerization reactor to form a unimodal low molecular weight polymer having a weight average molecular weight of from 15,000 to 30,000 and a melt index of from 10-10,000 g/10 min.;
• b) diverting from 5 to 50% of said unimodal polymer to a separate stream and directing the remaining portion of said unimodal polymer to a second polymerization reactor so that said diverted portion bypasses said second polymerization reactor;
• c) conducting a second polymerization step in said second polymerization reactor to form a first bimodal olefin homopolymer or copolymer consisting of:
• i) 30-55% of said unimodal low molecular weight polymer;
• and
• ii) 45-70% of a high molecular weight polymer, having a weight average molecular weight of from 250,000 to 700,000;
• and
• d) melt blending said diverted portion of said unimodal low molecular weight polymer with said first bimodal olefin homopolymer or copolymer to form a second bimodal olefin homopolymer or copolymer having a decreased amount of gels.