Process transfer and extrusion
The step that most materials projects fail at. A formulation that works at gram scale has to survive a real screw, a real die and a real line speed — and then be handed over in a form your operators can run.
Scale-up is
where materials
projects fail
Not usually on chemistry. They fail on residence time, on shear history, on a die that will not hold gauge at the speed the plant needs. We treat the transfer as part of the engagement rather than as something that happens after it.
01
Process window definition
Melt temperature, screw speed, die gap and cooling mapped as a window rather than a set point, so the line has somewhere to move.
02
Pilot extrusion trials
Runs at a scale that exercises the same shear and residence time as production, so what is learned transfers.
03
Line trials with your operators
On your equipment, at your speed, with the people who will run it — which is when the real constraints surface.
04
Hand-over documentation
Process sheets, start-up and shut-down procedures and the records your auditors will ask for.
Where it is applied
The hand-over is part of the engagement, not an afterthought.
This capability sits within Polymer Engineering. If it is the one your problem turns on, tell us the constraint and we will tell you whether it is worth starting.