Our Reactive Extrusion Services
At Industrial Chemistry, we offer complete, end-to-end reactive extrusion consulting services:
Formulation Development
We help you design functional polymer blends and compatibilizers suited to your specific application. This includes choosing base polymers, selecting reactive additives (such as grafting agents or chain extenders), and defining ratios for optimal performance. Our Reactive Extrusion Consultant ensures the formulation works chemically and mechanically within the extrusion process.
Process Troubleshooting
Many extrusion challenges arise from complex reactions happening under heat and shear. We resolve problems like excessive torque, melt pressure fluctuations, poor dispersion, or degraded product quality. Our consultants diagnose the root cause and implement changes to stabilise the line and improve material output.
Pilot-Scale Testing
Taking a formulation from bench to industrial production requires careful pilot testing. We help plan and execute trials, selecting appropriate feed strategies, screw designs, and process conditions. Whether at your facility or with a trusted partner, we guide the transition step by step.
Equipment Selection
Choosing the right extruder and configuration is crucial for reactive processes. We provide guidance on selecting twin-screw extruders, barrel designs, screw elements, and feeder systems. Our consultants also advise on venting, temperature zoning, and residence time control for optimal reactivity.
Devolatilization Strategy
Volatile by-products can destabilise the process or contaminate final product properties. We design devolatilization strategies that include vacuum venting, vent stuffer setups, and optimal positioning in the extruder. Clean processing means better product purity, odour control, and compliance with safety standards.
Quality Control Protocols
Good output requires good control. We help you establish QC protocols for raw materials, in-process monitoring, and finished product testing. This includes tracking melt flow index, molecular weight, conversion levels, and mechanical properties. These protocols ensure repeatable results and smoother operations.
Our practical, grounded approach ensures every step works in your environment. We work with your team onsite or remotely and provide clear documentation and training where needed.
Discover our broader chemical consulting capabilities here.
