Though there are virtually thousands of possibilities for performance additive use with formulations, there are six primary manufacturing concerns that account for the majority of performance additive applications. The suggested solutions provided here are addressed in detail in the Power of Performance Additives article.
Scrap too high due to inconsistent weighing:
Consider using oil treated, pre-mixed powders, which are cleaner to handle and easier to weigh, to improve process and product uniformity. They are delivered to the compounding plant surface wetted for faster mixing and multi-ingredient for reduced weighing, as well as the correct critical ratio of powders.
Too many ingredients to weigh for each batch: These are pre-weighed and packaged multi-component powder blends that are heat-sealed in a low-melt batch inclusion bag. They are customized to customer formulation and specialized weight, reducing labor and increasing formulation accuracy.
Health, safety and environmental concerns: Leading compounding services providers supply single- and multiple-component dispersions in clean, easy to handle solid forms – such as slabs, strips, pellets, and cubes – with rapid incorporation during mixing.
Mill cure addition: Consider single- and multiple- component dispersions that are flexible for custom requirements, and/or additives that feature encapsulation technology designed for rapid incorporation.
Undispersed powder in batches: Identify the powder and substitute it with a dispersion of that ingredient. (See the Dispersive and Distributive Mixing Chart.)
Cycle times are too long: Consider single- and multiple- component dispersions to replace powders or additives that feature encapsulation technology designed for rapid incorporation. These dispersions are flexible for custom requirements.
Performance additives properly selected to address manufacturing and process concerns, such as those listed above, help to maintain quality and consistency during compounding. They are often critical to successful, efficient, and pro table compound manufacturing because they:
- Ensure timely and complete dispersion of active ingredients into the compound
- Shorten mixing cycles, increasing machine output and reducing energy use
- Minimize airborne dust in transport, on the factory floor, and on mill mixing lines
- Simplify handling of difficult dry powders and raw materials
- Provide a safer environment and reduced exposure for workers
- Improve and extend compound shelf life Financial considerations and cost reduction opportunities for using performance additives include:
- Reduced labor requirements: Less measuring of materials and clean up
- Reduced mixing time: Rapid incorporation of materials
- Reduced mixing cost through alternative procedures: Pre-manufacturing with premixed ingredients
- Reduced in-process losses: Oil-treated and polymer-based materials are easier to handle and weigh
- improved product and process uniformity: Pre-weighed materials ensure the consistency of every batch