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We provide practical examples to demonstrate the various process parameters that can be evaluated and analyzed by a torque rheometer prior to the initial transfer to production. In the lab, a new material has been developed specifically to improve or adjust its properties to make" /> <meta property="og:url" content="https://www.thermofisher.com/blog/materials/elastomers-easing-the-transition-from-lab-to-production-using-torque-rheometry/" /> <meta property="og:site_name" content="Advancing Materials" /> <meta property="article:publisher" content="https://www.facebook.com/thermofisher" /> <meta property="article:published_time" content="2023-09-21T13:00:37+00:00" /> <meta property="article:modified_time" content="2023-10-03T18:25:07+00:00" /> <meta property="og:image" content="https://www.thermofisher.com/blog/materials/wp-content/uploads/sites/7/2019/02/iStock-1278374987_orings.jpg" /> <meta property="og:image:width" content="2121" /> <meta property="og:image:height" content="1414" /> <meta property="og:image:type" content="image/jpeg" /> <meta name="author" content="Jordan Seefeldt" /> <meta name="twitter:card" content="summary_large_image" /> <meta 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></span> <span aria-label="breadcrumb separator">/</span> <span class="breadcrumb-current-title">Elastomers: Easing the Transition from Lab to Production using Torque Rheometry</span></div></div></header> <section class="hero-banner" style="background-image:url(https://www.thermofisher.com/blog/materials/wp-content/uploads/sites/7/2019/02/iStock-1278374987_orings.jpg)"> </section> <div class="site-inner"><div class="content-sidebar-wrap"><main class="content"><article class="post-10084 post type-post status-publish format-standard has-post-thumbnail category-manufacturing-processing category-process-control category-rheology tag-elastomers tag-polymer-plastics tag-polymers tag-torquerheometer entry" aria-label="Elastomers: Easing the Transition from Lab to Production using Torque Rheometry"><header class="entry-header"><h1 class="entry-title">Elastomers: Easing the Transition from Lab to Production using Torque Rheometry</h1> <span class="post-info-author"> By <a href="https://www.thermofisher.com/blog/author/jordanseefeldt/" title="Posts by Jordan Seefeldt" rel="author">Jordan Seefeldt</a> </span> <span class="post-info-date"> 09.21.2023 </span> </header><div class="entry-content"><div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Implementing new elastomer compounds into a production process is </span><span class="ContextualSpellingAndGrammarError SCXW142066984 BCX0">complicated</span></span><span class="TextRun SCXW142066984 BCX0"><span class="ContextualSpellingAndGrammarError SCXW142066984 BCX0">, but</span><span class="NormalTextRun SCXW142066984 BCX0"> using <a href="https://www.thermofisher.com/us/en/home/industrial/manufacturing-processing/extrusion-compounding-equipment/instruments/polylab.html?icid=CAD_blog_materials_2023Sept">torque rheometry</a> </span><span class="NormalTextRun SCXW142066984 BCX0">can ease that transition</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">.</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">We provide</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">practical</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> examples to demonstrate the various process parameters that can be evaluated and analyzed by a torque rheometer prior to the initial transfer to production.</span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">In the lab, </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">a</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> new material has been developed specifically to improve or adjust its properties to make better products</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> for your company</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">. However, hundreds of process parameters will change when the process is scaled up; larger volumes, different environments, and heavily used production equipment are all inherently different than the lab environment. </span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Is there a way to anticipate process changes prior to production, so that when similar results are seen in production, the process en</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">gin</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">eer knows </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">exactly</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> the </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">parameters</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> to adjust to achieve the </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">correct</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> result?</span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Torque rheometers, equipped with <a href="https://www.thermofisher.com/us/en/home/industrial/manufacturing-processing/extrusion-compounding-equipment/instruments/polylab.html?icid=CAD_blog_materials_2023Septr#measuring-mixers">laboratory-scaled internal mixers</a>, have been used </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">in the </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">rubber industry for decades</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">. These instruments process small rubber samples in conditions </span><span class="AdvancedProofingIssue SCXW142066984 BCX0">similar to</span><span class="NormalTextRun SCXW142066984 BCX0"> those encountered in production. Using this type of torque rheometer</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">, many process parameters can be evaluated at laboratory scale, resulting in clearer understanding of the material properties long before the new material hits production.</span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> (See <a href="https://players.brightcove.net/3663210762001/08UsfMRkC_default/index.html?videoId=6160187547001">video</a>.)</span></p> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <h2 class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Curing</span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></h2> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Using a <a href="https://www.thermofisher.com/us/en/home/industrial/manufacturing-processing/extrusion-compounding-equipment/instruments/polylab.html?cid=fl-torquerheometer?icid=CAD_blog_materials_2023Sept#torque-rheometer">torque rheometer</a> allows testing for minimum viscosity, the onset of scorching and the rate of cure for various additives. The small volume size allows multiple polymer/additive combinations to be </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">graded and</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> determine which compound ingredients affect material properties. </span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <h2 class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Mastication</span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></h2> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Rubber polymers require the mastication process to reduce their viscosity and even out </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">variations</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> between lots. </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Using a torque rheometer, the initial flow properties of the sample can be evaluated, by using the torque peak caused by the high resistance of shear while cold. </span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <h2 class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Viscosity</span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></h2> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Strongly dependent on the shear rate, different non-Newtonian liquid elastomers of equal molecular weight may exhibit the same viscosity at high shear rates. However, by varying the shear rate to extremely slow rates, by reducing </span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">rotor</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> speeds perhaps, differences between polymers is often detected. </span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> <h2 class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Flow-Curing Behavior</span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></h2> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0"><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0">Vulcanization occurs at a higher temperature in elastomers when curing agents such as </span></span><span class="TextRun SCXW142066984 BCX0"><span class="SpellingError SCXW142066984 BCX0">sulphur</span></span><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> are added. The vulcanization process is best monitored at its onset; important process parameters include the ways in which mixing, extrusion or injection molding affect the onset of vulcanization, which in turn, affects viscosity. </span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0">When a<a class="Hyperlink SCXW142066984 BCX0" href="https://www.thermofisher.com/order/catalog/product/567-0021?cid=7010z000001DAtV" target="_blank" rel="noopener noreferrer"><span class="TextRun Underlined SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> torque rheometer</span></span></a><span class="TextRun SCXW142066984 BCX0"><span class="NormalTextRun SCXW142066984 BCX0"> has automated extrusion-capillary, die swell behavior, and qualitative testing of extreme shapes — which all provide valuable information when solving problems in the production processing of un-vulcanized rubber — there is insight into such parameters as viscosity, elasticity, and extrudability. </span></span><span class="EOP SCXW142066984 BCX0" data-ccp-props="{}"> </span></p> </div> <div class="OutlineElement Ltr BCX0 SCXW142066984"> <p class="Paragraph SCXW142066984 BCX0">Using rheology to identify which process parameters affect which properties while the material is still in the lab setting will enable process engineers to quickly evaluate and adjust production parameters. Read this application note to see how a <a href="https://www.thermofisher.com/document-connect/document-connect.html?url=https://assets.thermofisher.com/TFS-Assets/CAD/Application-Notes/LR29-e%20How%20to%20Relate%20Test%20Results%20of%20a%20TorqueRheometer%20to%20Problems%20in%20Elastomer%20Processing.pdf" target="_blank" rel="noopener">Torque Rheometer can speed the process of scaling up to production scale.</a></p> <h2>Additional Resources</h2> <ul> <li>Video: <a href="https://players.brightcove.net/3663210762001/08UsfMRkC_default/index.html?videoId=6160187547001">Thermo Scientific™ HAAKE™ PolyLab™ Torque Rheometer</a></li> <li><a href="https://assets.thermofisher.com/TFS-Assets%2FCAD%2Fbrochures%2FBrochure-PolyLab-OS-EN-digital.pdf?icid=CAD_blog_materials_2023Sept">Brochure: Thermo Scientific™ HAAKE™ PolyLab Torque Rheometer </a></li> <li>Application note: <a href="https://www.thermofisher.com/document-connect/document-connect.html?url=https://assets.thermofisher.com/TFS-Assets/CAD/Application-Notes/LR29-e%20How%20to%20Relate%20Test%20Results%20of%20a%20TorqueRheometer%20to%20Problems%20in%20Elastomer%20Processing.pdf" target="_blank" rel="noopener">Torque Rheometer can speed the process of scaling up to production scale.</a></li> </ul> <p><em>Editor’s Note: This article was previously published in February 2019 but has been updated and refreshed.</em></p> </div> <aside class="mashsb-container mashsb-main "><div class="mashsb_above_buttons">Share this article </div><div class="mashsb-box"><div class="mashsb-count mash-large" style="float:left"><div class="counts mashsbcount">49</div><span class="mashsb-sharetext">SHARES</span></div><div class="mashsb-buttons"><a class="mashicon-facebook mash-large mashsb-noshadow" 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