Why can colors vary lot to lot

dye lot is a record taken during manufacturing ensuring the products received  coloration in the same vat at the same time. Paint and dye manufacturers assign each lot a unique identification number and stamp it on the label before shipping. Slight differences in temperature, dyeing time, and other factors can result in different shades of the same color between different dye lots of otherwise identical production. Although elements of a dye lot number kept by internal business record keeping, retail yarn and paint consumers have an interest in ensuring that they purchase a given color from identical dye lots.

PRL Resins has expertise of over 40 years perfecting their products, service and processes. They hold the go-to authority reputation regarding the sensitive nature of products made of resins, solvents and other industrial surfaces .

Resin

  • Resin holds together the pigment in suspension, provides surface adhesion and determines the quality and durability.

Pigment

  • The pigment is in a powder form  much like concrete, and the average aftermarket automobile paint system includes about 100 colors or toners to mix formulas, including metallic and pearl colors.

Solvent

  • The solvent provides transferability, as without solvent the paint would be too thick to transfer between containers.

Theory vs Chemical Reactions

The paint is mixed to exact specifications and all painting performed from that lot of paint will be exactly the same even after sunlight, drying and ultraviolet exposure. However, if the same formula is followed at another temperature or humidity on another day, that lot of paint can be a different shade and sometimes in some of the related colors such as blue-green, it can be another color altogether.  Therefore, lots are important and paint compound from one is not going to match perfectly when application is finished.

The same is true in fabrics, and yarn or fabric from the same dye lot is desirable in sufficient amount to complete an article of clothing.

Modern Technical Controls of PRL Resins

PRL Resins has conquered most inconsistency problems with expert handling of their resin that goes beyond that found in any other manufacturing company, and with their high UL certification. The industrial compound ingredients that permit

PRL Resins to manufacture products with truer color matches include:

  • Additives-
    • UV stability
    • Colorants
    • easy release by mold releases
    • other stability additives
  • Modifiers-
    • Impact Modifiers
    • Flame Retardants
    • Flow Enhancers
  • Reinforcing Agents-
    • Glass fibers
    • Mineral fillers

Revolutionary Data Color Spectrophotometer

Merging SPC with their integrated statistical process control ensures PRL Resins of precise color matching with their custom color control.

Precision color matching:

The continued reinvestment by PRL Resins back into their plastic resin technology, together with their staff of experienced color lab specialists, ensure precise color matching. A Data Color Spectrophotometer with integrated statistical process control SPC gives exact color matching capabilities and ensures lot-to-lot color consistency.This SPC control makes PRL a go-to authority in color and lot consistency.  It provides them with expertise to warranty their products fully and offer complete service support to their clients.

Why the light source effects color

Color provides an emotional impact and is sometimes synonymous with a brand. Having the precise color match for your product is a quality that consumers will rely on and expect. However, different light sources can adjust the perceived color of polymers and resins, which you need to take into consideration when manufacturing and displaying your products.

Molecular Structure

The polymer’s molecular structure dictates how it processes light emissions. For example, crystalline resins have a semi-opaque look because of the mixture of their ordered and disordered domains. These characteristics cause the crystalline resins like PP to bend light differently. In comparison, non-crystalline resins are usually comprised of disordered domains, so this causes the light to pass straight through them, causing their transparency.

Melting Points

Another characteristic that has a significant impact on how much light influences a particular resin is its melting points. For example, crystalline resins have a high melting point, requiring much more heat before they alter in appearance. To maintain their appearance, inorganic pigments or other materials may be used that provide stability even at higher temperatures.  Not using heat-stable materials can cause there to be light and dark streaks in the resin.

Chemical Makeup

When polymers contain cross-linked rubber particles, their appearance may be whiter in appearance.  This is the case with such polymers as acrylic, HIPS and ABS. Rubber alters the way that light passes through the resin once it is toughened. If two different color coatings have the same chemical composition, they will match under any light source.
Refractive Index

Another component that affects the color of the resin based on the light source is the angle at which the light bends as it passes through the polymer. Resins that have a combination of different refractive indices can be mixed together, which causes the light to not have a single path to go through. This causes the resin to have a more opaque quality to it.

Energy Distribution

Color changes as it is observed under two different light sources when they have different energy distributions. Even if the resin appears to be the same color due to the same refractive index, the color will be observed differently if the energy distribution is different between the two samples due to a different light source.

Color Matching Tips

Because each light source can affect the color of a polymer, it is important for you to specify the light source in which you plan the resin to be viewed. This will help ensure precise color matching. Here are a few tips to ensure your color will match and that you are satisfied with your experience:

  • Specify if you need a color match with more than one light source.
  • Ask about any additional costs associated with manufacturing a polymer with different colorants due to varying light sources
  • Consider the color match’s tolerance under different light sources
  • Specify the type of spectrophotometer that you wish to use as this tool will help provide the basis for the color match.

The advantages to the customer of multiple warehouses

There are many techniques and theories when it comes to warehousing. Companies can choose between operating between single centrally located warehouses and operating multiple warehouses throughout a region or a country. In multiple warehousing systems, companies spread out to cover territories and be easily accessible to customers. It offers many benefits as compared to single centrally located warehouse systems. There is plenty of debate regarding which is the most efficient and effective. Ultimately, it all comes down to the satisfaction of customers. Depending on the customer satisfaction, it is more appropriate to have multiple warehouses.

Imagine a customer trying to get a product to the middle of Texas when there is only one single located warehouse in New York. While the product would eventually get there, would you lose anything by having it take long? When you have multiple warehouses, there are clear advantages that make you reliable to customers in the long run. From saving on transportation costs to making clients happy, the use of multiple warehouse system just makes sense.

Here are the advantages of having multiple warehouses:

  • Quick delivery: with multiple warehouses, delivery time can be cut down pretty dramatically, meaning that you can move more products at a quicker pace. Instead of customers waiting for products to arrive from one single centrally located warehouse, their orders will be shipped quickly from various warehouses, meaning their purchased products arrive quickly.
  • Low transportation costs: because products will spread out over a larger area when you have multiple warehouses, the cost of delivering purchased products significantly decreases as warehouses are in the vicinity of customers.
  • Easy accessibility: instead of having your products in one place, they will be in multiple places, meaning that if a customer needs a product, the entire process becomes much easier. Having your products spread out means having easy access to multiple warehouses rather than one centrally located warehouse.

Other advantages of multiple warehouses are:

  • Elimination of middlemen in between manufacturers and ultimate consumers.
  • They avail the advantages of bulk purchasing.
  •  Uniformity of prices and quality of products sold is maintained at all warehouses.
  • If one warehouse has short supplies, then it can be immediately replenished from another warehouse so that customers can easily access products.
  •  There are low operating costs hence prices are not increased to cater for operations.
  • There are flexibilities of operation in such warehouse systems.
  • If one warehouse is closed, customers can still access products in other warehouses as compared to single centrally located warehouses where if closed, there are no more operations.

What is a Data color Spectophotometer and why do I care

Serious investment in a Data Color Spectrophotometer is required to be a major force in the plastic and resin technology field. By equipping our production facilities with the latest Data Color Spectrophotometer technology, Polymer Resources’s color lab specialists are able to engineer precise consistency between lots. Accurate color matching is essential for establishing brands, creating consistent products and taking precise samplings of existing materials. No matter the scope of the project, our specialists are capable of dealing with all types of color matching – even gloss and fluorescent material!

Dye mills and colorant manufacturers agree that Data Color Spectrophotometer products are superior in their accuracy and consistency. By deploying this technology, Polymer Resources is able to work with highly precise and close-tolerant specifications. Our use of high resolution color management allows us to produce both short and long-term reliability while our highly experienced staff guides the plastic and resin manufacturing process.

Spectrophotometry is a vital aspect of skilled plastic work. By analyzing the reflective capacity of a material as well as its diffusivity, we can accurately reproduce any sample or mockup in a sizable scale. Our cutting edge use of Data Color Spectrophotometer technology lets us know exactly what materials are present in a lot and accurately reproduce it with production-level quality. Our double beam Data Color Spectrophotometer technology is highly accurate, using both a reference sample as well as your sample to guarantee precision engineering.

Regular diagnostic testing is essential when producing large amounts of product, and our Data Color Spectrophotometer technology is able to periodically check samplings of a lot to ensure consistency throughout. Integrated with Datacolor TOOLS, we are able to analyze and convey quality control results for our clients. Quality control information can be easily shared between members of our supply chain, making sure only perfect results pass through our gates.

Our exclusive use of industry leading and stable technology requires us to make use of very little calibration, causing our turn times to be significantly faster than less adept companies. Our lead times, among the lowest in the industry, result in shipping custom colors within 4 weeks and standard colors within 2 weeks. With regional warehouses throughout the nation, stock colors can be quickly delivered to you with little delay.

When you want a quality product, Polymer Resources employs only the best people and Data Color Spectrophotometer technology to get the job done. Celebrating over 40 years of success, we have the track record to inspire confidence and proudly guarantee accurate custom color matching for our all our cherished clients.

Polyetherimide sheet – Performance Characteristics and Applications

Polyetherimide sheets (PEI) guarantees exceptional fire resistance along with excellent mechanical and thermal properties. The amorphous Polyetherimide sheets are suitable for high temperature applications. With properties like low levels of smoke evolution during combustion and very low flammability, they are widely used in electrical and electronic insulators. It can also resist a wide range of chemicals and offers good resistance to UV and gamma radiation.

There are several companies which utilizes the finest Polyetherimide sheets to custom fabricate components which needs long term mechanical strength and rigidity at elevated temperatures. Available either in transparent or opaque colors along with glass filled grades depending on the requirements, PEI exhibits higher levels of heat resistance, dielectric strength, chemical resistance and many more properties.

Custom sizes and colors of PEI sheets are available on request. So, what are the major performance characteristics of Polyetherimide sheets?

  • High mechanical strength and stiffness
  • Higher levels of dielectric strength
  • Excellent thermoforming properties
  • Resistance to hydrolysis during exposure to steam and hot water
  • Able to withstand repeated sterilization cycles
  • Excellent resistance to high energy radiation like UV and gamma
  • Excellent for food industry as it is physiologically inert

Because of the above mechanical, thermal and electrical properties, Polyetherimide sheets are widely used in the following applications

  • Electrical insulation parts
  • Manifolds
  • Chip test sockets
  • Medical instruments
  • Scientific equipments
  • Electrical connectors
  • Semiconductor components

Sheets and rods of Polyetherimide (PEI) are usually available in dark and glass filled formulations. It can easily maintain its strength at elevated temperatures in the range of 200 degree centigrade. For medical applications which require repeated sterilization cycles, Polyetherimide sheets are most suitable as this uniquely balanced thermoplastic can exhibit excellent mechanical properties and heat resistance. The easy to process thermoplastic material allows industries the flexibility in plastic injection molding and manufacturing.

Low moisture absorption and excellent creep resistance allows Polyetherimide sheets to possess amazing dimensional stability. When compared to other amorphous thermoplastics, the Polyetherimide resins show better resistance to stress and cracking in extremely demanding and challenging conditions. One of the key features of PEI sheets is to retain its properties even at high temperatures. Its resistance to mineral acids is simply outstanding, however it can be attacked by use of strong bases and partially halogenated solvents such as methylene chloride and trichloroethane.

Polyetherimide (PEI) is extruded to produce film, sheets, coated wire and profiles. Using solvent casting techniques, the thickness of PEI film can be around 0.25 mil. Major competitors of PEI sheets include polysulfones, polyketones, and polyphenylene sulfides.