KYMACH Application Laboratory: Turning Your Formulation into a Product

At the KYMACH Application Laboratory, we help customers move from material formulation to practical product development through small-scale extrusion trials, process validation, and technical support.

With twin screw extrusion equipment and practical polymer processing experience, our laboratory is designed to help customers evaluate new formulations and address real processing challenges before moving to larger-scale production.

Core Services: Formulation Validation and Process Development

KYMACH provides two main types of laboratory and application services.

1. Formulation Validation

Customers can provide their own material formulation for practical extrusion testing.

We use twin screw extrusion equipment to evaluate whether the formulation can be processed under suitable operating conditions and to assess the resulting material and pellet quality.

Laboratory trials can help customers:

Verify the feasibility of a new formulation
Evaluate processing behavior
Identify suitable extrusion conditions
Obtain trial samples for further testing

Reduce the uncertainty before scale-up

2. Process Development and Implementation

A formulation that works on paper may behave differently during actual extrusion.

Our engineers work with customers to develop suitable equipment and process conditions for their specific materials, with particular attention to key compounding factors such as:

Dispersion
Homogenization
Plasticization
Material conveying
Temperature control
Screw configuration
Feeding stability

The objective is to connect formulation design with a practical and repeatable twin screw extrusion process.

Case Study: PP + PEG Modified Material Trial Production

Recently, KYMACH completed a small-batch trial production project for a PP + PEG + special powder formulation.

Customer Requirement

The customer wanted to develop a modified polypropylene material through twin screw extrusion and pelletizing, with the formulation designed to:

Improve material adhesion
Improve processing flowability
Enhance compatibility between the polymer matrix and filler phase

Extrusion Process

The trial was conducted using a KYMACH HK36 twin screw extruder with a 48:1 length-to-diameter ratio (L/D 48).

The main processing conditions included:

Extruder: HK36 twin screw extruder
L/D ratio: 48:1
Screw speed: 550 rpm
Processing temperature: 160–175°C
Pelletizing: Strand cooling followed by strand cutting
Trial quantity: 300 kg

The temperature profile and screw speed were adjusted according to the material's processing behavior during the trial.

Trial Production Result

The trial successfully achieved a stable production rate of approximately 35 kg/h, and a total of 300 kg of material was produced during the small-batch trial.

The resulting pellets were subsequently intended for desiccant applications in the pharmaceutical industry.

The trial provided the customer with practical material samples and process data for further evaluation.

From Laboratory Testing to Production

For new materials, the transition from formulation development to commercial production can involve significant uncertainty.

A laboratory or small-scale extrusion trial provides an opportunity to verify the formulation under actual processing conditions before committing to larger-scale equipment and production.

At KYMACH, our application laboratory can support customers through several stages of this process:

Formulation → Extrusion Trial → Process Optimization → Sample Production → Scale-Up

By testing the formulation on twin screw extrusion equipment, adjusting process parameters, and producing actual samples, customers can obtain practical information for the next stage of development.

This can help reduce the risks associated with moving directly from laboratory formulation development to full-scale production.

A Practical Partner for New Material Development

KYMACH's application laboratory is designed to be more than a place for equipment demonstrations.

It provides a practical environment where materials, formulations, equipment, and process conditions can be evaluated together.

Whether you are developing a new polymer formulation, evaluating fillers and additives, or preparing a material for scale-up, our engineers can work with you to explore suitable twin screw extrusion and compounding processes.

Bring us your formulation. We will work with you to turn it into a processable product.

Allen

allen.chen@kymach.com

With over two decades of experience in the foreign trade industry, I possess deep expertise in plastic processing and compounding technologies. Leveraging extensive professional knowledge and market insights, I am dedicated to providing global clients with precise and efficient products and tailored solutions.