Micro-processing has the unique functionality that it enables you to produce test-samples from only a few grams of material, typically 2-15 ml. The advantage of micro-processing over normal processing is its small scale, resulting in the consumption of less material (base + additive), reduced processing time and more and faster data. Therefore micro-processing gives you the opportunity to generate more data in less time at minimum costs.

Functionally processing consists of 2 steps: 1) compounding or mixing (in the case of polymers also melting) and 2) shaping. Because only a few grams of material is consumed in the first step, a fundamental change in the compounding step was necessary. Normally compounders are operated in continuous mode, but micro-compounders typically operate in batch-mode. Residence time is controlled by a 3-way valve and not by screw geometry like conventional machines. Its position determines whether compounded material is recirculated, or guided to the outlet of the compounder. Next to batch-mode, all micro-compounder are able to process materials in continuous mode for film and fiber applications The compounders are equipped with two conical fully intermeshing co rotating screws to ensure maximum dispersion (exfoliation) or counter rotating screws for processing shear sensitive materials. 

The compounding step means that a base material is mixed with additives to form a homogeneous mixture. Alternatively, newly synthesized base material (without additives) can also be compounded in order to obtain its nascent material properties.

Compounded material is further shaped for testing purposes. There are many ways to shape. Below you find the most common:

• The simplest way of shaping occurs when compounded material exits the compounder via a round die. This yields a strand, which can be further analyzed (e.g. TEM or SEM).
• Another way of shaping your compounded material is to further process it into a molded certified test-sample by a micro injection molding machine. The micro injection molding machine can be fed by our micro compounder – via a preheated transfer cylinder – in order to obtain standard test bars or any other desired shape, such as pills, rings, etc without changing their thermal history.
• A 3rd example of shaping takes place when instead of the standard round die, a slit-die is mounted onto the compounder barrel. This gives a cast film with typical dimensions between a few hundred microns down to <5 micron and a typical width of 35 mm. The micro-cast film device is a logical step in our ambition to broaden the portfolio, the desire to satisfy customers needs hence a direct consequence of our customer intimacy policy.
• A last example of shaping given here is the production of a fiber. Typically a mono filament is produced from a few ml of compounded material. Depending on the diameter of the dye and the draw-ratio a certain filament thickness is obtained. This filament can gain even higher draw-ratios in a next step via thermal stretching, in which the filament is guided through an oven.