From Analysis to Assurance: How Thermal, Raman, and Film Extrusion Techniques Validate Crystallinity and Ensure Polymer Product Quality

Crystallinity strongly affects the mechanical, thermal, and barrier properties of polymer films, yet monitoring it during extrusion is difficult. This work presents an integrated workflow using thermal analysis, Raman spectroscopy, lab‑scale film extrusion, and optical film‑quality inspection to predict and confirm crystallinity and overall product quality in LDPE/PEEK. Thermal analysis provides precise enthalpy of fusion values and baseline crystallinity (typically 35–45%), establishing robust reference data. These values inform calibration of Raman regression models built from C‑H and skeletal vibration bands, enabling rapid, non‑destructive crystallinity forecasting.

Using Anton Paar Brabender extrusion equipment, the Raman model is validated in real time during LDPE/PEEK film production, capturing crystallinity changes such as shear‑induced reductions after extrusion. Complementing this, the Film Quality Analyzer identifies defects including black specks, gels, fisheyes, and holes (ASTM D7310). Together, these tools help polymer scientists enhance film uniformity, prevent defects, and accelerate process optimization.

Key Learning Objectives:

1. Understand how crystallinity governs polymer film performance

• Viewers will learn why crystallinity is critical for mechanical, thermal, and barrier properties of LDPE/PEEK films and why real‑time monitoring during extrusion is challenging but essential for product quality.

2. Learn how to quantify crystallinity using thermal and spectroscopic tools

• They will see how thermal analysis establishes accurate baseline crystallinity values and how Raman spectroscopy—calibrated with those values—can rapidly and non‑destructively predict crystallinity in real time.

3. Discover how to validate crystallinity models during extrusion

• The audience will understand how lab‑scale single‑screw extrusion combined with in‑line Raman analysis tracks crystallinity changes under real processing conditions, including shear‑induced disorder.

4. Recognize how optical film‑quality analysis ensures defect‑free products

• They will learn how an optical Film Quality Analyzer detects defects such as black specks, gels, fisheyes, and holes, enabling consistent, standards‑based quality control (ASTM D7310).

Speaker: Christoph Pielen

After earning his degree from RWTH Aachen University in Germany, Christoph Pielen joined Brabender GmbH in 2012 as an Application Specialist. He later becoming Laboratory Manager and then President of Brabender CWB in the U.S., where he supported ASTM standard development and customer applications. Following Brabender's 2023 acquisition by Anton Paar, Christoph now serves as Lead Scientist for Texture and Extrusion at Anton Paar USA.

Outside work, Christoph enjoys traveling, skiing, and spending time with his two children, Alexander and Victoria, while pursuing his passion for aviation and space exploration.