| 1. Improved processing stability | Consistent processing can help reduce interruptions and variation between production runs. | Run a controlled comparison using the same resin, equipment, settings, and production duration. | Output rate, pressure or torque trends, temperature settings, downtime, and run-to-run variation. |
| 2. Potential reduction in die or tool buildup | Less buildup may reduce cleaning frequency and help maintain product appearance and dimensional consistency. | Inspect and photograph the die or tool at predefined intervals during comparable production runs. | Time to first visible buildup, cleaning frequency, deposits observed, and production interruptions. |
| 3. More consistent surface quality | Surface consistency can affect appearance, downstream coating, printing, sealing, or assembly. | Compare samples under consistent lighting and use the same agreed visual or instrumental inspection method. | Defect count, surface appearance, gloss or roughness readings where relevant, and inspection conditions. |
| 4. Potential change in coefficient of friction | Friction can influence film handling, feeding, stacking, and part-to-part movement. | Measure the coefficient of friction using a documented method, such as ASTM D1894 for applicable plastic film or sheeting. | Static and kinetic friction results, sample conditioning, test direction, and time after production. |
| 5. Better material dispersion | Uniform distribution of an additive can help limit localized variation in appearance or performance. | Examine representative samples from different positions in the production run using a suitable microscopy or imaging method. | Observed distribution, agglomerate count or size where measurable, sampling location, and preparation method. |
| 6. Potential improvement in output efficiency | A change that supports higher stable output may improve equipment utilization. | Compare output at the same quality requirements and record the operating conditions for each trial. | Mass or parts produced per unit time, reject rate, line speed, and process settings. |
| 7. Compatibility with the existing formulation | Compatibility can affect product appearance, mechanical properties, and process consistency. | Test the intended formulation at the planned addition level and inspect for visible defects or property changes. | Formulation, addition level, appearance, dispersion observations, and relevant product-property results. |
| 8. Retention of required mechanical properties | Processing or surface changes should not compromise the product’s performance requirements. | Compare treated and untreated samples using the relevant product specification and test method, such as ASTM D638 for applicable plastics tensile testing. | Tensile strength, elongation, or other specified properties; specimen preparation and test conditions. |
| 9. Suitability for downstream operations | Printing, coating, bonding, sealing, or assembly requirements may determine whether a formulation is usable. | Run representative downstream trials after a defined conditioning period and assess against the existing acceptance criteria. | Adhesion or seal results where applicable, print quality, rejects, conditioning time, and process settings. |
| 10. Potential reduction in total operating cost | Material price alone does not show the full cost impact; output, waste, cleaning, and downtime also matter. | Calculate cost per accepted unit using production data from comparable trials and include all relevant operating costs. | Additive use, material consumption, accepted output, scrap, cleaning time, downtime, and cost per accepted unit. |