Fast, affordable solutions for polymers and plastics analysis

Significance of the topic

FTIR-based polymer analysis is a rapid, cost-effective approach for routine quality control, formulation verification and failure investigation across polymer manufacturing and processing. Reliable identification of polymer types, co‑polymer ratios and quantification of additives (release agents, UV stabilizers, plasticizers, etc.) are critical to product performance, regulatory compliance and process optimization. Combining attenuated total reflectance (ATR) sampling with transmission analysis of reproducible thin films extends FTIR utility from simple material ID to quantitative measurement of bulk and low‑level constituents.

Objectives and overview of the kit suite

The Thermo Scientific FTIR Polymer Analysis Kits are designed to equip FTIR laboratories with complete workflows for polymer identification and quantification. Primary goals are:

• Rapid identification of unknown polymers and verification of masterbatch or compounded materials.
• Quantitative determination of co‑polymer blend ratios and additive concentrations over a range of concentrations.
• Provision of standardized sample preparation and software tools to produce reproducible, archiveable transmission spectra and robust mixture analyses.

The product family combines either a single‑bounce ATR accessory or a Heated Mini‑Film Maker with OMNIC Specta software and a large spectral database to cover common industrial tasks from incoming material checks to finished product validation and reverse engineering.

Methodology and analytical approach

The kits implement two complementary sampling strategies:

• ATR sampling: single‑bounce ATR enables direct analysis of solid polymer samples without extensive preparation. It is well suited for rapid identification, blend verification and quantifying high‑to‑moderate concentration components. Choice of ATR crystal (ZnSe, diamond, or optional germanium) tailors the technique to soft, hard or carbon‑black filled materials.
• Transmission of pressed films: the Heated Mini‑Film Maker produces reproducible melt‑pressed films at defined thicknesses (50, 100, 250 and 500 µm). Transmission measurements of constant‑thickness films improve quantitative accuracy and are preferred for low‑level additives, crystallinity assessment and precise copolymer ratio determinations.

Spectral data are processed using OMNIC Specta which includes a polymer‑focused knowledge base and a patented multi‑component search algorithm for mixture deconvolution. Typical workflow elements include spectrum acquisition (ATR or transmission), baseline correction and normalization, library search / multi‑component fitting and development of quantitative calibrations (for example PLS or univariate methods) using pressed film standards or spiked matrices.

Key practical parameters: Mini‑Film Maker heats up to 250 °C to process common thermoplastics; films are mounted in 10 mm aperture cards for archival; ATR crystal selection affects penetration depth and sensitivity to surface vs bulk composition.

Instrumentation used

• Thermo Scientific Nicolet series FTIR spectrometers (e.g., Nicolet iS5, iS20, iS50) configured to accept Thermo Smart Accessories.
• Single‑bounce ATR accessories: ZnSe crystal (recommended for soft polymers such as PE and EVA), diamond crystal (for harder polymers including nylons and glass‑filled polyesters), optional germanium ATR plate (recommended for carbon‑black filled materials due to shallower penetration depth).
• Heated Mini‑Film Maker: compact press with heated platens capable of reproducible films at 50–500 µm thickness and temperatures up to 250 °C; includes press, platens, and 10 mm aperture sampling cards.
• OMNIC Specta software with polymer package: library of >13,000 spectra (polymers, additives, plasticizers and common ingredients) and the Infrared Spectroscopy of Polymers knowledge base; includes patented multi‑component search (patent 7,698,098).

Main results and discussion

The kits offer configurable performance tiers matching material types and analytical tasks. Summary of relative capabilities:

• Basic ATR Polymer Kit: well suited for rapid identification of unknown soft materials and basic verification tasks; fast, minimal preparation, good for bulk ingredient quantification at higher concentrations.
• Advanced ATR Polymer Kit: optimized for more challenging tasks including quantification of lower level additives and improved performance across both soft and hard materials.
• Combo Kits (Basic and Advanced): combine ATR and Mini‑Film Maker capability for the broadest application range—direct ATR screening plus transmission‑based quantitative analysis for low concentration components.
• Mini‑Film Maker Polymer Kit: best choice when transmission quantitation, reproducible film archiving and assessment of crystallinity or precise copolymer ratios are required; particularly valuable for low‑level additive analysis and filled systems.
• Germanium ATR add‑on: recommended for carbon‑black filled polymers where reduced penetration depth minimizes scattering and absorption artifacts and improves spectral quality.

Performance highlights include very fast identification using ATR, reproducible quantitative transmission data from pressed films, and improved mixture resolution via the OMNIC Specta multi‑component search. The combination of hardware and software reduces time‑to‑result and helps standardize methods across incoming, in‑process and finished product testing.

Benefits and practical applications

• Quality assurance: rapid pass/fail screening of raw materials and finished goods, verification of co‑polymer ratios and detection of incorrect formulations.
• Process control: monitor additive levels and compositional drift during production to avoid off‑spec product.
• R&D and reverse engineering: library‑assisted identification of unknown materials and ingredient profiling to support reformulation and troubleshooting.
• Regulatory and compliance testing: archiveable transmission spectra and standardized sample prep support traceable documentation of material composition.
• Operational advantages: compact footprint (Mini‑Film Maker fits on bench), low cost per analysis, and flexibility to scale from basic ATR screening to quantitative transmission analyses.

Future trends and potential uses

• Integration with chemometric calibration toolsets (PLS, PCR, advanced pre‑processing) and automated calibration transfer to improve quantitation across instrument fleets.
• Higher throughput workflows combining rapid ATR screening with automated film pressing and batch processing of spectra to support larger QA labs.
• Application of machine learning and advanced deconvolution algorithms to improve identification of complex mixtures and trace‑level additives in filled or highly scattering matrices.
• Coupling FTIR fingerprinting with complementary techniques (Raman, DSC, TGA) to provide orthogonal confirmation of composition, crystallinity and thermal properties for robust materials characterization.
• Potential development of at‑line or near‑line sampling stations using robust ATR probes or automated film preparation for real‑time process monitoring.

Conclusion

The Thermo Scientific FTIR Polymer Analysis Kits provide a pragmatic suite of hardware and software tools that extend routine FTIR spectroscopy from simple material ID to robust quantitative analyses of copolymers and additives. By combining single‑bounce ATR for fast screening with a reproducible heated film‑press workflow for transmission quantitation, and supporting both with a large polymer spectral library and mixture‑analysis algorithms, the kits address common analytical needs in QC, R&D and reverse engineering. Selection of the appropriate kit and ATR crystal enables analysts to tailor sensitivity and sampling depth to specific materials, including filled systems.

Reference

• Thermo Scientific FTIR Polymer Analysis Kits product information and brochure (Thermo Fisher Scientific, 2018).
• OMNIC Specta polymer package and Infrared Spectroscopy of Polymers knowledge base; patented multi‑component search (U.S. Patent 7,698,098).
• Thermo Fisher Scientific trademarks and product family (Nicolet series FTIR spectrometers, iS5/iS20/iS50).