TECHNOLOGY | POLYMER TESTING
questions about processability, stability, and end-use behaviour, which means testing has to become more targeted, more frequent, and more application-specific.”
Right: The new ZwickRoell extrusion
plastometer is available in three versions: basic, with pneumatic weightlifting, and with weight pegging function
Another issue is the gap between material modeling and real-world behaviour. “Simulation and predictive tools are valuable for narrowing down design space and avoiding obvious dead ends, but they can only approximate how complex, highly formulated materials will actually behave in processing and in use,” said Haake. “As more variations of materials are developed and then further compounded into specialty solutions, small formulation changes can lead to disproportionately large changes in flow, stability, or perfor- mance. Modeling helps you under- stand where you might land; actual testing is what tells you where you really are.” Haake said the demand for tight
tolerances and reliable performance in end-uses, combined with short production runs, is driving increasing use of continuous, online measure- ment that provides immediate feedback. Continuous measurement catches deviations in real time, which reduces scrap. In-line systems for rheological and flow-related measurements, for example, allow operators to quickly identify drift and correct it. Goettfert’s newest instrument is the Rotational Online-Rheometer, an inline oscillatory rheometer that provides continuous, detailed characterisation of the viscoelastic properties of polymer melts. “Traditionally, oscillatory
answer both sides of the rheology question directly in the process: capillary-type measurements for high-shear, process-relevant flow behaviour, and oscillatory measurements for viscoelastic and structural insight. This means users no longer have to choose between lab-based structure analysis and inline flow monitoring. Depending on whether the question is ‘How does it flow in my process?’ or ‘What is happening to the polymer structure?’, we can now provide the best measurement method – capillary or oscillatory – directly where the material is being made or processed.”
Melt flow New from Hydramotion, which manufactures process viscosity sensors, is ViscoMelt, a next- generation melt flow analyser that is purpose- built for polymer compounding, masterbatch, and extrusion processes. The instrument uses a new sensor technology called Scorpion, which delivers real-time data on melt flow, viscosity, and viscoelastic properties, directly relating to MFI, IV, and molecular weight, directly from the melt stream, said John Rowe, Chief Marketing Officer at Hydramotion. New from ZwickRoell is the Mflow extrusion plastometer for plastics testing in accordance with ASTM D1238 and ISO 1133-1/-2. The Mflow per- forms tests according to method A for melt mass flow rate (MFR) and method B for melt volume flow rate (MVR). A modular design provides expandable
features such as a cleaning function and a pneumatic weight-
IMAGE: ZWICKROELL
measurement using rotational rheometers has been the reference method for understanding polymer structure and viscoelastic behaviour,” noted Haake. “By applying oscillating deformation over a range of frequencies, these systems reveal subtle changes in molecular architecture, such as branching, networking, or changes in molecular weight distribution. Because they operate at relatively low deformation rates, they are highly sensitive to structural differences, making them ideal for answering ‘structure’ questions – how a polymer is built and how that structure affects its elastic and viscous response. With the introduction of an inline oscillatory rheometer, this capability is no longer limited to the laboratory. We can now
30 COMPOUNDING WORLD | March 2026
lifting unit with pegging function that eliminates the need to move weights manually. “One of the most significant
changes is a major improvement in cleaning efficiency, with cleaning times reduced by up to 30% between tests. This was achieved through better access to all material contact surfaces, optimised smooth stainless steel finishes, and a redesigned outlet area below the die to prevent extrudate buildup,” said Bob Donohue, Industry Manager for Plastics/Composites at ZwickRoell. “When combined with the pneumatic weightlift-
ing unit, the system can also automatically eject residual material, further reducing manual effort. Ergonomics were another major focus of the redesign. The new Mflow offers an optimised working height and specimen filling position, improved visibility of the test area and controls,
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