Product Manufacturing

Flexible Batch Sizes

Not every product requires the same manufacturing scale. New products may initially require relatively small quantities, while established systems can require significantly larger and more frequent production runs.

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Our manufacturing capabilities allow us to produce batch sizes ranging from approximately:

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1 kg → 1,500 kg

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This flexibility can be particularly valuable when taking a product through its complete commercial journey. Initial development and pilot batches can progress into larger production quantities without the need to transfer the product to an entirely different manufacturing operation.

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Specialist Mixing & Processing Equipment

Different chemistries and formulations require very different manufacturing techniques.

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StarToll operates a selection of specialist mixing and processing equipment, including high-speed dispersion equipment, conventional mixing systems and low-torque blending equipment.

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The appropriate manufacturing method can be selected according to the chemistry, viscosity, raw materials and processing requirements of each individual product.

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Our equipment allows us to manufacture everything from relatively low-viscosity liquids through to high-viscosity products of approximately 50,000 cP, providing considerable flexibility across adhesives, coatings and other formulated systems.

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A Vast Range of Product Types

The combination of our equipment, chemical expertise and skilled manufacturing team enables StarToll to manufacture a broad range of systems, including:

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• Polyurethane adhesives and coatings

• Single-component and two-component systems

• Polyurea and polyaspartic products

• Water-based systems

• Primers and sealers

• Flooring and protective coatings

• Membranes and waterproofing products

• Low and high-viscosity adhesives

• Filled and pigmented systems

• Specialist industrial formulations

• Bespoke and customer-specific products

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Our manufacturing team understands that producing specialist chemicals involves considerably more than simply combining ingredients. Addition sequence, mixing speed, temperature, dispersion, processing time and raw-material handling can all influence the consistency and performance of the finished product.

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Packaging From Bottles to IBCs

StarToll can manufacture and pack products into a wide variety of formats depending on the product and its intended market.

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Packaging options range from small plastic bottles and containers through to pails, drums and Intermediate Bulk Containers (IBCs).

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For multi-component products, individual components can also be manufactured and packed in the appropriate ratios to create complete, ready-to-use systems.

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This flexibility allows the packaging format to be designed around how the customer ultimately wants to store, distribute, sell and use the product.

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Skilled People, Specialist Equipment

Equipment is only part of successful chemical manufacturing.

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Our experienced production team works alongside our technical and quality personnel to ensure that products are manufactured using established processes and appropriate controls.

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This combination of skilled manufacturing personnel, specialist equipment, formulation expertise and quality control enables us to reliably manufacture products across a wide range of chemistries, viscosities and batch sizes.

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More Than Contract Mixing

StarToll can provide manufacturing as an individual toll manufacturing service, but it can also form part of a much wider product development programme.

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We can support a product through formulation, laboratory development, pilot plant scaling, product testing and quality control, before progressing into routine commercial manufacture, packaging, branding, stockholding and distribution.

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This provides customers with a straightforward route from a laboratory formulation or existing product specification to a professionally manufactured, packaged and commercially ready finished system.

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Whether you require a 1 kg specialist batch or 1,500 kg commercial production run, StarToll has the people, equipment and manufacturing flexibility to help bring your product to market.