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Jamal Al Sadi¹

¹Faculty of Engineering, Jadara University, Irbid 21110, Jordan.

Materials (Basel, Switzerland)

|January 28, 2026

Summary

Optimizing polymer extrusion involves controlling processing parameters to maintain color consistency. This study found that reduced pigment particle size at increased screw speeds significantly improves color quality in opaque polycarbonate grades.

Keywords:

Anova DOM SEM characterization data mining models dispersion opaque PC grades particle size analyzer rheology speed parameters

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Area of Science:

Polymer Science and Engineering
Materials Science
Color Science

Background:

Color constancy in polymer extrusion is challenging due to processing parameter fluctuations affecting pigment dispersion.
Preliminary historical data mining was conducted in 2009.
This study focuses on Opaque PC Grade 5 with specific resin compositions and Melt Flow Index (MFI).

Purpose of the Study:

To identify significant processing parameters (PPs) that minimize color deviation in polymer extrusion.
To analyze interactions between processing parameters under various conditions.
To quantify the impact of particle size on color quality.

Main Methods:

A General Trends (GT) diagnostic procedure was applied, varying parameters individually.
Particle Size Distribution (PSD) and colorimetric data (CIE Lab*) were systematically measured.
Viscosity, Digital Optical Microscopy (DOM), and PSD were characterized at different temperatures and speeds.

Main Results:

Increased screw speed (700-775 rpm) reduced mean pigment particle size and increased particle count proportion.
A positive correlation exists between mean particle size and particle count, influencing color response.
Reduced pigment size at increased speed positively impacts color quality, with a quantified color value of 1.36.

Conclusions:

Screw speed and pigment size distribution are critical for achieving consistent color in polymer extrusion.
Optimizing these parameters leads to improved pigment dispersion and enhanced color matching.
Further research will involve design experiments for multi-parameter interactions and broader application across polymer grades.