In the R&D lab, a new polymer is created by synthesizing polymeric chains in small amounts or by blending existing raw materials until a final product with the desired high performance is obtained. A wide range of test methods and tools is required to classify a new polymer and to enable one to make accurate predictions of its behavior during compounding and production. Precise tests done in the laboratory reduce costs at later stages. In fact, during polymer formulation, rheometry (dynamic mechanical analysis) and methods that combine rheometry and spectroscopy are often used to test the properties of the anticipated final product extensively.
One of the most difficult tasks is mixing and extruding several polymers that are immiscible by nature. Special additives have to be tested and evaluated to reduce the interfacial barriers between the different blends. Modular small scale extruders can be used to mimic and test a full-scale production. They’re used in producing polymers and polymeric compounds as well as testing processability of such materials.
Lab scale processing is the second stage in the scale-up process. Kilograms vs. grams of the new polymer are produced. Material tests are performed to obtain detailed information on the processability and material strength of the new polymer.
During pilot plant and small-scale production, the developed and tested polymeric material is transformed into the end product. To meet high-end user requirements, a thorough and precise quality control process is mandatory.