Formulation

A formulation consists of various components, each of which fulfils a specific function:

1. Base polymer

• Function: main constituent, which determines the basic structure and mechanical properties.

• Examples: EPDM, NBR, FKM, silicone.

2. Fillers

• Function: reinforce mechanical properties, influence hardness and often reduce costs.

• Examples: carbon black, silica, chalk.

3. Plasticisers

• Function: improve the flexibility and processing of the material.

• Examples: phthalates, oils, paraffins.

4. Vulcanising agents

• Function: crosslink the polymer to increase elasticity and resistance.

• Examples: sulphur, peroxides.

5. Additives

• Function: optimise specific properties such as ageing resistance, colour stability or chemical resistance.

• Examples: antioxidants, UV stabilisers, flame retardants.

6. Accelerators and activators

• Function: accelerate and optimise the vulcanisation reaction.

• Examples: zinc oxide, stearic acid.

7. Colour pigments

• Function: give the material the desired colour.

• Examples: titanium dioxide, iron oxide pigments.

Formulations are essential to meet the specific requirements of a product:

• Quality assurance: a precisely balanced formulation ensures consistent material properties.

• Adaptability: formulations can be adapted to different applications and operating conditions.

• Cost-effectiveness: optimising the ingredients can reduce costs without compromising quality.

• Regulatory requirements: formulations must comply with legal requirements such as food contact or environmental standards.

Developing a formulation is a complex process that requires expertise and precise testing:

Steps in creating a formulation

• Analysis of requirements: definition of the desired material properties such as hardness, elasticity, temperature resistance or chemical resistance.

• Selection of components: polymers, fillers and additives are selected on the basis of the requirements.

• Mixing: the selected components are mixed in an exact ratio.

• Testing: prototypes are tested for their properties, e.g. by hardness, tensile or ageing tests.

• Optimisation: the formulation is adjusted on the basis of the test results until the desired properties are achieved.

Developing an optimum formulation involves several challenges:

• Complexity: interactions between different components can cause unexpected effects.

• Costs: high-quality materials can increase production costs.

• Regulatory requirements: formulations must comply with legal requirements such as REACH or FDA guidelines.

• Long-term stability: materials must retain their properties throughout the entire product life.

Formulations are indispensable in all areas of the rubber and plastics industry:

Automotive industry

• Rubber parts: seals, hoses and tyres with special formulations for oil, heat and weather resistance.

• Plastic components: interior trim and bumpers with formulations tailored for stability and appearance.

Medical technology

• Sterile materials: formulations with antibacterial additives and chemical resistance.

• Implants: biocompatible, durable materials.

Construction industry

• Sealants: formulations that ensure UV and weather resistance.

• Insulating materials: thermally insulating and flame-retardant plastic formulations.

• How is the quality of a formulation ensured? Through precise documentation, standardised test procedures and strict process controls.

• Can formulations be changed? Yes, formulations can be adapted to new requirements, but this requires extensive testing.

• What is the difference between a formulation and a compound? The formulation describes the exact composition, while mixing describes the physical production process.

• Which standards affect formulations? Standards and regulations such as ISO, FDA, REACH and RoHS set requirements for ingredients and their properties.

The formulation is a decisive factor for the quality and performance of products in the rubber and plastics industry. A carefully developed formulation makes it possible to meet specific requirements, optimise costs and comply with regulations. Thanks to modern technology and comprehensive material knowledge, formulations can now be tailored individually to achieve the best results for every application.