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Processing R&D in 2 weeks
Injection moulding defects, extrusion instability, blow moulding inconsistency, thermoforming issues — we run DOE on your real equipment, find the root cause, and deliver validated processing windows.
What We Solve
Three core engagements
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Compound development in 4 weeks
We formulate polymer compounds from scratch — base resin, additive package, filler loading — precisely tuned to your processing route: screw geometry, melt temperature, line speed, cycle time.
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Defect & failure analysis in 48 h
Warp, sink, delamination, melt fracture, die drool, brittle fracture — we diagnose root cause using FTIR, DSC, SEM, and rheological testing, and give you a corrective action plan, not just a report.
Discover
What We Do
We're polymer technologists who specialise in plastic processing R&D — injection moulding, extrusion, blow moulding, thermoforming, and more. We solve process instability, reformulate compounds for better processability, and scale validated parameters to industrial lines.
Where other labs hand you a test report, we hand you a set-point sheet your operators can use tomorrow. From rheology to running production — that's our track.
Start a Project →Case Study
Extrusion instability eliminated — line running at 110% output.
A pipe extrusion plant was losing 18% of output to melt fracture and gauge variation on a HDPE compound. Three previous suppliers had changed the formulation without solving it. Timeline to fix: "as fast as possible."
POLY·R&D ran a full rheological characterisation, identified a processing-aid imbalance, and reformulated the compound. After two extrusion trials, the line ran clean at 110% of target output with zero melt fracture.
11 days
Root cause to solution
+110%
Extrusion output
0 scrap
After trials
Our Capabilities
Every processing route.
One R&D partner.
Injection moulding, extrusion, blow moulding, thermoforming, rotomoulding — we R&D across all major plastic processing technologies, and we formulate materials tuned to your specific process.
Get a Quote →
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Injection Moulding Optimisation
DOE on melt temp, pack pressure, cooling, and cycle time. Warp, sink, and flash elimination.
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Extrusion Process R&D
Die design, screw profile analysis, melt stability, draw ratio and haul-off optimisation.
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Blow Moulding & Film
ISBM, EXBM, blown film — gauge uniformity, parison programming, bubble stability.
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Thermoforming & Rotomoulding
Sheet forming, oven profiling, rotational moulding powder optimisation and cycle development.
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Polymer Compounding
Custom formulation: base resin + additives, stabilisers, fillers — tuned to your processing route.
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Testing & Compliance
Rheology, thermal, mechanical, FTIR, XRF. ISO & ASTM reports. REACH, RoHS, food-contact.
Who We Work With
We solve material problems
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⚡ Packaging ⚡
Blown film, cast film, ISBM bottles, thermoformed trays — barrier formulation, food-contact compliance, seal integrity.
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⚡ Automotive ⚡
Injection-moulded structural parts, extruded seals and tubing — heat resistance, dimensional stability, under-bonnet performance.
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⚡ Medical & Pharma ⚡
ISO-class moulded components, extruded tubing — biocompatible grades, sterilisation-stable formulations, ISO 10993.
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⚡ Construction ⚡
Extruded window profiles, pipe systems, thermoformed panels — UV-stable, flame-retardant, long-term weathering performance.
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⚡ Electronics ⚡
Injection-moulded housings, connector bodies — ESD-safe compounds, UL94 V-0 flame retardancy, dimensional precision.
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⚡ Recycling & Circular Economy ⚡
Recyclate upgrading for extrusion and moulding lines — compatibilisers, restabilisation, mechanical property recovery.
Portfolio
Formulated. Tested. In Production.
PP · Blown Film · Food Packaging
PP Blown Film — Barrier Optimisation
PA66 · Injection · Automotive
PA66-GF30 for Injection Moulding
PVC · Extrusion · Construction
PVC Window Profile Extrusion R&D
PET · Blow Moulding · Packaging
ISBM Bottle — Cycle Time Reduction
TPE · Extrusion · Medical
Medical TPE — Extrusion Tubing
rPP · Thermoforming · Circular
rPP Compound for Thermoforming
Materials
R&D Across Every Processing Route
Injection Moulding
Extrusion
Blow Moulding
Thermoforming
Rotomoulding
Blown Film
Cast Film
Foam Extrusion
Pipe & Profile
Overmoulding
Co-Extrusion
ISBM / EXBM
Injection Moulding
Process R&D· DOE on temp / pressure / cooling
· Warp, sink & flash elimination
· Multi-cavity & thin-wall work
Extrusion
Process R&D· Screw & die design support
· Melt stability & output rate
· Profile, pipe & sheet lines
Blow Moulding
Process R&D· ISBM, EXBM, RSBM
· Parison programming
· Gauge uniformity & top-load
Thermoforming
Process R&D· Sheet formulation & pre-drying
· Oven profile & forming force
· Draw ratio optimisation
Blown & Cast Film
Process R&D· Bubble stability & gauge
· Barrier layer formulation
· Seal & print compatibility
Rotomoulding
Process R&D· Powder formulation & grind
· Cycle time & oven profiling
· Wall thickness uniformity
How We Work
Our process is science-driven end to end.
We start with the performance requirement, not a polymer catalogue. Every step is designed to get you a production-ready material — not a lab report.
Process & Application Brief
Tell us your processing route (injection moulding, extrusion, blow moulding, thermoforming…), your equipment, the defects or limitations you face, and your target properties. A call, email, or spec sheet.
Lab Formulation & Processing Trials
We compound candidate formulations and run small-scale processing trials — extruder, lab press, or blow unit — iterating until the compound processes cleanly and hits your property spec.
DOE & Parameter Optimisation
Designed experiments on real or pilot-scale equipment: melt temperature, screw speed, back pressure, cooling, cycle time, die geometry. We define and validate the processing window.
Production-Line Scale-Up
We transfer to your industrial line — injection press, extruder, blow moulder, thermoformer — running trials with your operators, documenting set-points, and handling any scale-up surprises.
Ongoing Process Support
We stay involved through raw material changes, machine upgrades, seasonal variation, and quality incidents — available on retainer for continued technical support on the production floor.
Let's Chat!
Send a spec,
a failed sample,
or just describe the problem.
We start with your process — not a polymer catalogue. Tell us your processing route, your equipment, and the problem. Our engineers respond within one business day with an approach and a cost estimate.