At Polyclean Technologies, we transform challenging polymer materials into valuable resources through our specialized processing capabilities. Our custom engineered solutions help manufacturers maximize material value, enhance product performance, and strengthen their bottom line.
SPECIALTY POLYMER POWDER MILLING
Converting Materials into Precision Powders
For compression molders using PEEK, PEI, PAI, PPS, and other high performance polymers, we offer cost effective options for your powder needs. Our specialized milling services include:
- Virgin-to-Powder Conversion: Transform virgin pellets or flakes into precisely sized powder for your applications
- Custom Particle Sizing: Tailored to your specific requirements beyond our standard 140 mesh offerings
- Consistent Quality Control: Rigorous sieving and classification for reliable particle distribution
- Small-to-Medium Volume Processing: Responsive service for specialty applications
- Difficult Material Expertise: Specialized equipment for challenging polymers like PEEK, Torlon (PAI), PEI, PAI, and PPS
Our milling capabilities produce fine powders suited for compression molding, 3D printing, powder coating, reinforced composites, non critical aerospace components, non critical medical devices, and other demanding applications that require precise particle sizes.
Applications and Industries We Serve
- Compression molding applications
- 3D printing / Selective Laser Sintering (SLS)
- Powder coating processes
- Composite matrix material for carbon fiber fabrics
- Rotomolding applications
- Non critical aerospace components
- Non critical medical devices
Custom Powder Solutions
Is there a polymer you need in fine powder form but do not have a supplier? We can help you convert a resin that is only available as pellets or flake into the powder you need for filament tape, woven fabric, or highly reinforced prepreg mat.
Rotomolding Powder Services
Do you consume small to moderate volumes of rotomolding powders and need a more responsive milling service provider?
We specialize in milling less common materials and would welcome the opportunity to partner with you.
Contact us with your problems. We can develop a customized powder milling solution to give you what you need.
HIGH-PURITY RECYCLING
Transforming Scrap into Premium Raw Materials
Our proprietary recycling processes convert manufacturing scrap into high quality materials that perform like virgin at significant cost savings:
- Scrap Recovery: Converting rejected parts and manufacturing waste into valuable resources
- Shavings Processing: Transforming machining waste into clean, consistent materials
- Contamination Removal: Eliminating oils, surface residues, debris, and foreign materials
- Material Segregation: Density separation for mixed materials
- Repelletizing: Converting processed materials into easy handling formats
We can process your manufacturing scrap into various forms such as cleaned flake, consistent regrind, or repelletized material to meet your specific needs with up to 60% savings over virgin PEEK resin.
Click Here to learn why typical recycling projects for special materials fail and what we do differently that ensures your satisfaction, achieves measurable results, and can reduce your virgin material purchasing costs by 10%, 20%, or more.
Recycling Success Stories
PEEK 450GL30
PEEK 450GL30 manufacturing scrap with tape, labels, glue, embedded contamination, and cutting oils. Processed to remove surface and internal contamination, yielding a dust free, clean regrind ready to use.
Up to 20% regrind displacing virgin pellets, nearly 15% reduction in raw material costs.High Purity Polycarbonate
Wafer shipper of high purity polycarbonate. Shredded, granulated, and cleaned via high purity process. Regrind used back into the same product.
Up to 75% recycled content, 33% cost savings.
PEEK 450G
PEEK 450G shavings with cutting oils and foreign material contamination. Processed into a clean flake ready for compounding, or repelletized for easier handling and use.
Up to 100% recycled content depending on end use specifications, up to 60% savings over virgin PEEKPFA
PFA wafer carrier, shredded, granulated, and purified for use in high purity semiconductor applications.
MATERIAL PURIFICATION
Enhancing Performance Through Superior Cleanliness
Our specialized purification processes remove contaminants and unwanted residues from both virgin and recycled materials:
- Enhanced Virgin Materials: Improving resin purity beyond supplier standards
- Contamination Recovery: Restoring off spec or contaminated inventory
- Dust and Fines Removal: Eliminating troublesome particles that cause black specks and processing issues
- Decontamination Solutions: Customized processes for specific contaminant challenges
- Product Quality Improvement: Enabling higher performance in demanding applications
By upgrading material purity before manufacturing, your products can achieve lower levels of extractable residues and stronger performance in semiconductor, electronics, non critical medical, non critical aerospace, and other industrial applications.
Material Recovery Examples
If you have quarantined virgin or regrind materials in inventory, we can resolve the problems and enable you to use them safely. Processing can be configured to resolve issues such as:
- Dust from external contamination sources
- Dirt and debris from spill recovery
- Dust and fines from scrap grinding
- Surface oils or residues
- Density separation of materials accidentally mixed in a silo or granulated together
- Visible contamination removal
- Embedded or loose metal flakes
Ultem 1010, Regrind
High loading of dust and fines and occasional foreign material particles were removed. (Move cursor over photo to see before and after difference.)
Ultem 1010, Virgin
Spilled pellets contaminated with debris and other types of pellets. Restored to virgin quality. (Move cursor over photo to see before and after difference.)
PC/Nanotube, Virgin
Pellets recovered after a forklift punctured a gaylord. Processed to remove dust and debris and restore cleanliness. (Move cursor over photo to see before and after difference.)
PP / SAN Pellets
Accidental mixing in a silo. Density separation used to recover materials, since optical sorting would have been very difficult.
Polycarbonate, Regrind
Moderate loading of dust, fines, and foreign material. Processed to enable use as natural PC, not downgraded to black. (Move cursor over photo to see before and after difference.)
ABS with Dust and Metal
Dust causing black specks, metal plugging hot tips. Processed to resolve both issues and maintain static dissipation properties.
High Purity PP with Fines
Fines causing black specks. Deduster was ineffective due to rapid tribocharging. Successful processing to remove fines and maintain purity.
PP / PC Regrind Mix
Careless feed of a PC part into a PP grinder. Density separation successfully removed PC flakes, not possible with optical sorting.
High-Purity Recovery Achievements
Examples below showcase some of our achievements in high purity recovery of virgin and scrap materials. More examples on this page.
5 Railcars of Virgin PP Pellets
Quarantined due to high levels of chloride and sulfate residues. Nearly $1,000,000 of virgin pellets purified to exceed cleanliness specifications and accepted for consumption in a semiconductor market packaging application.
Virgin Conductive Polycarbonate
100,000 lbs of pellets out of spec due to high sulfate ion residues (red bar in graph at left). Purification processing achieved 80 to 90% reduction in sulfate level throughout the entire quantity of material (green bars in graph at left).
Over $250,000 of material was recovered for less than $20,000.Purification of Intrinsically Dissipative Polymer (IDP)
Lab testing results of two different IDP materials that were purified to reduce extractable ionic species. Achieved up to 95% reduction in various anions and cations, with no loss of static dissipation properties.
