The developmental process to create new products is critical to the future of companies in the polymer industry. New ideas can be a slow and expensive process if traditional scale production facilities are used. Traditional size facilities often waste expensive materials and are forced to deal with the headache of commercial production down time during the R&D process.
The average toll compounder will not let you participate directly in your R&D project. Traditionally, a person is only allowed to supply the compounder with ingredients and a formula and hope for the best. Unfortunately, if you’re not promising truckloads of material in business, the project will often fail to get the true attention it deserves. This leaves a customer with zero ability to modify control methods as needed. This process can too easily result in wasted time and most importantly, lots of wasted money!
Pilot scale up research and development services
Birch Plastics is taking a refreshing new approach to help you develop your products. We have an open-door policy that encourages our customers to be on site and an active part of the development of their materials. This hands-on approach allows our clients to make real time modifications to the process and material characteristics directly on the line. This allows us to reduce the developmental cost and your time to market.
How to get started
First and foremost, we start with a nondisclosure agreement and move forward from there. Our laboratory scale facilities can produce multiple short runs of material that your business needs to research and develop its products. You can schedule our facility by the day, week, or month. This will include staff support and full access to all of our equipment and full access to our laboratory.
We regularly work with material suppliers, product manufacturers, and designers. A lot of time our clients have had opportunities to grow new segments of their business but were held back due to the size of the orders in the initial stages of growing the business. At Birch Plastics we strongly believe in innovation which is why we’re here to help you with those very orders.
Another common issue we hear from our customers is how often they are forced to pass on seasonal business which they would be happy to take if it wasn’t so expensive to break into large production runs of existing products. Naturally, it’s not cost effective to break into large production runs of existing products to make a few thousand pounds or even a truckload of a custom product. That’s where Birch Plastics comes in. Our team is here to help you fill that gap and be your one-stop-shop for less than truckload (LTL) toll manufacturing. Call us today to see how we can help you!
Pilot Plant and scale up equipment:
Our lab and equipment are housed in a 67,000 SQFT building in Houston, Texas.
- Comac co- rotating twin screw extruder 43 mm, 32 to 1 L/D
- 8 zones, vented with vacuum, DSM dose feeder, and strand cut pelletizer.
- 2 High intensity powder mixers
- Post blender up to 4000 pound batches
- Multiple certified scales
- Small Injection molding machine
Laboratory Testing Capabilities:
- Perkin Elmer FT-IR Spectrometer Two with multiple software packages including Bio Rad
- Melt Flow Index Testing using ASTM D1238
- Ash Content Testing – ASTM D 5630
- Bulk Density Testing
- Izod Impact Testing – ASTM D256, D4812
- Durometer Shore A