Acrylic Processing Aids

Acrylic processing aids (ACRs) are critical for supporting smooth melt processing of PVC. They promote faster fusion, improve melt homogeneity, and help control rheological properties ensuring consistent quality and appearance in finished products. Without processing aids, PVC would require higher temperatures and longer processing times, increasing the risk of thermal degradation. ACRs make it possible to manufacture rigid and flexible PVC products efficiently and reliably.

Choosing the right processing aid depends on your application’s specific needs, whether it’s fusion speed, melt strength, surface finish, or foam structure. Dow’s PARALOID™ and SURECEL™ product lines offer tailored options for everything from rigid profiles to foamed PVC decking and siding. Consider factors like molecular weight, compatibility with other additives, and processing conditions to select the appropriate processing aid for your formulation objectives. 

Yes, modern processing aids can significantly support circularity in PVC applications. By improving melt flow and fusion at lower temperatures, they help reduce energy consumption and support or help enable better incorporation of recycled content. Some hybrid additives also enhance compatibility between virgin and recycled materials, making them a good choice for formulations that incorporate recycled content in building and construction products.

While general-purpose ACRs can offer baseline performance, foamed PVC applications often require specialized processing aids with higher molecular weight to ensure optimal cell structure and surface quality. Dow’s SURECEL™ and PARALOID™ K-series ACRs are engineered for foam density control, melt strength, and smooth finishes, making them a good choice for applications like foam core pipes, decking, and decorative trim.

Start by defining your end-use requirements – fusion time, surface aesthetics, mechanical strength, or recyclability. Then, consult Dow’s technical data sheets or collaborate with our technical service team to match the right additive to your formulation. Tools like rheological analysis and fusion torque curves can also help validate performance during development.

Acrylic processing aids are not limited to PVC. They also offer significant performance benefits in other polymer systems such as polyvinyl butyral (PVB) and select engineering resins. In recycled PVB, for example, Dow’s acrylic processing aids improve processability, reduce stickiness, and enhance mechanical properties like rigidity, indentation resistance, and tensile strength. These aids are highly miscible with PVB and increase its glass transition temperature (Tg), enabling new applications in flooring, coatings, and synthetic leather.

Acrylic processing aids are typically added during the dry blending or compounding stage of PVC manufacturing, before the material is shaped or formed. They are compatible with a wide range of processing techniques, including extrusion, calendaring, injection molding, blow molding, and thermoforming. These aids help reduce fusion time, improve melt flow, and enhance surface finish making them essential for both rigid and flexible PVC applications. Their role is especially critical in high-output processes where thermal stability and consistent quality are key.