Custom unsaturated polyester resin grades used to take our team six to eight weeks to move from formulation to first dispatch. Over the last year, we’ve brought that down to under four weeks without compromising the batch-to-batch consistency our customers rely on.
Where the time was going1
Most of the delay wasn’t in the chemistry — it was in how formulations moved between our lab and the production floor. Every custom grade needed to be re-validated at production scale before a customer could receive their first shipment, and that validation step was happening in isolation from the rest of the schedule.
The fix wasn’t a new process. It was running two processes we already had, in parallel instead of in sequence.
What we changed
We restructured the handoff between R&D and production so that scale-up trials begin as soon as a lab formulation is stable, rather than after it’s finalised on paper. This required closer coordination between our technical team and shift supervisors, but it meant we could catch scale-related issues two to three weeks earlier than before.
- Lab-to-floor formulation handoff moved from a single sign-off to a shared checklist reviewed at each stage
- Scale-up trials now run in parallel with final lab validation, not after it
- Raw material sourcing for new grades is confirmed before formulation is finalised, not after
What this means for customers
For composite manufacturers working with us on bespoke grades, this mostly shows up as a shorter gap between a technical conversation and a usable first batch — which matters most for customers replacing an imported material on a deadline.
Custom unsaturated polyester resin grades used to take our team six to eight weeks to move from formulation to first dispatch. Over the last year, we’ve brought that down to under four weeks without compromising the batch-to-batch consistency our customers rely on.
Where the time was going
Most of the delay wasn’t in the chemistry — it was in how formulations moved between our lab and the production floor. Every custom grade needed to be re-validated at production scale before a customer could receive their first shipment, and that validation step was happening in isolation from the rest of the schedule.
The fix wasn’t a new process. It was running two processes we already had, in parallel instead of in sequence.
What we changed
We restructured the handoff between R&D and production so that scale-up trials begin as soon as a lab formulation is stable, rather than after it’s finalised on paper. This required closer coordination between our technical team and shift supervisors, but it meant we could catch scale-related issues two to three weeks earlier than before.
- Lab-to-floor formulation handoff moved from a single sign-off to a shared checklist reviewed at each stage
- Scale-up trials now run in parallel with final lab validation, not after it
- Raw material sourcing for new grades is confirmed before formulation is finalised, not after
What this means for customers
For composite manufacturers working with us on bespoke grades, this mostly shows up as a shorter gap between a technical conversation and a usable first batch — which matters most for customers replacing an imported material on a deadline.