The Overview
Philip Tyler Polymers (PTP) has enjoyed a strong, 20-year relationship with an extrusion profile producer. We have supplied them consistently with high-quality recycled polymer content, which they blend with prime polymers. This blend delivers the benefits of prime polymer consistency alongside recycled materials’ cost savings and sustainability credentials. The partnership has allowed our customer to enhance their margins while presenting a positive environmental story to their clients.
The Challenge
Despite the long-standing success of our materials in their applications, the customer encountered an unexpected issue in production. Defects began to appear in their moulded products. While the functionality of the products remained unaffected, the aesthetic quality fell below their usual standards. The cause of the issue was unclear, and production disruptions were a growing concern.
The Solution
As soon as the issue was reported, our team visited the customer’s site to assess the problem firsthand. Observing the defects as they appeared during production, we used our batch traceability system to identify the specific batches of recycled polypropylene copolymer (PPCO) that were potentially problematic. Samples from all remaining stock were collected, and the affected batch references were quarantined.
While conducting a root cause analysis, we recommended the customer test unaffected batches under controlled conditions to minimize potential production losses. Our in-house testing identified a non-melting fraction in the material, which we traced to ABS contamination in the recycled PP copolymer. By tracking the issue back through our traceability system, we pinpointed the feedstock source and identified the root cause: a new operative at the feedstock supplier had failed to distinguish between material types, allowing ABS to enter the PPCO recycling stream.
The contamination issue was swiftly addressed by working with the feedstock supplier to implement corrective measures. To support our customer during this time, we supplied fresh, rigorously tested material to ensure it was free from contamination and suitable for their application. This material was phased into production carefully, with ongoing feedback from the customer to ensure the problem was fully resolved.
The Outcome
The issue was resolved promptly and professionally, minimizing disruption to the customer’s production schedule. The new material met the required standards, restoring the aesthetic quality of their products. Our transparency and responsiveness strengthened the customer’s confidence in PTP as a trusted partner.
Additionally, the root cause investigation reinforced the importance of stringent quality controls throughout the supply chain. By enhancing monitoring processes with our feedstock supplier, we ensured that the quality of incoming materials met our high standards moving forward. This case highlights the value of batch traceability, hands-on support, and robust customer relationships in maintaining trust and delivering exceptional service.
