Product Development.

Start With the Problem, Not the Product

Many successful products begin with a simple question: “Can we make something that does this better?”

A customer may need an adhesive with greater moisture tolerance, a coating that cures more quickly, a system with improved environmental credentials, or a product specifically designed around an unusual application or manufacturing process.

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Rather than trying to force an existing product to fit the application, StarToll can work backwards from the required performance.

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We consider factors such as:

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• Required mechanical and chemical performance

• Substrate and application conditions

• Cure speed and working time

• Temperature and moisture tolerance

• Application method and equipment

• VOC, odour and environmental requirements

• Packaging and kit sizes

• Relevant testing and industry standards

• Manufacturing cost and commercial viability

• Storage, shelf life and distribution requirements

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This allows us to develop a product around the real-world requirements of the customer and end user.

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Concept → Development → Testing → Manufacture → Supply

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Our involvement can begin at virtually any stage.

For some customers, we may be asked to manufacture an established formulation. For others, StarToll becomes a development partner, helping to take a completely new concept through laboratory development, evaluation, pilot production and ultimately full-scale manufacture.

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The development journey can include:

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Concept & Specification
We establish exactly what the product needs to achieve, how it will be used and the commercial and technical requirements it must satisfy.

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Chemistry & Formulation
Our technical team selects and develops the most appropriate chemistry, balancing performance, application characteristics, safety, environmental considerations and cost.

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Laboratory Development
Initial formulations can be produced and evaluated on a laboratory scale, allowing different technologies, raw materials and formulation approaches to be compared.

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Product Testing
Performance can be assessed against the required properties and, where appropriate, recognised industry standards or independent testing programmes.

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Pilot Plant Scaling
Moving from a laboratory batch to commercial manufacture is a critical stage of development. Pilot production allows us to evaluate mixing, processing and manufacturing characteristics before progressing to larger-scale production.

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Quality Control
Suitable raw-material, in-process and finished-product quality controls can be established to help ensure consistency from one production batch to the next.

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Commercial Manufacture
Once the formulation and manufacturing process have been established, StarToll can manufacture the finished product using our own production equipment and facilities.

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Branding, Packaging & Labelling
Products can be supplied under your own brand, with suitable packaging, labels and supporting documentation to create a complete, market-ready system.

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Stock & Distribution
Our involvement does not have to end when the product leaves the production line. We can also support stockholding, order fulfilment and distribution, helping provide a complete route from manufacture to your customer.

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More Than a Toll Manufacturer

Traditional toll manufacturing often begins with a customer supplying a formulation and asking a manufacturer to make it. StarToll can become involved much earlier.

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By combining product development, chemistry, manufacturing, testing, quality control, documentation, packaging and logistics within a single service, we can help customers bridge the gap between having an idea for a product and actually having a finished product ready to sell.

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This approach can be particularly valuable for businesses that understand their market and know what their customers need but do not have their own chemical laboratory, specialist production equipment or manufacturing infrastructure.

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It can also provide established manufacturers with additional development expertise, specialist chemistry, extra production capacity or access to technologies outside their existing capabilities.

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A Complete Development Partnership

Every project is different, which is why StarToll can provide as much or as little support as required. Customers can use individual elements of our service or work with us throughout the complete development and manufacturing process.

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Our wider StarToll capabilities include Chemistry, Pilot Plant Scaling, Quality Control, Product Manufacture, Equipment, Branding & Labelling, Stock & Distribution, System Types, Product Testing, Safety Data & Documentation and Approved Partners.

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Together, these services allow StarToll to provide a genuinely integrated route from:

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Problem → Idea → Formulation → Testing → Scale-Up → Manufacture → Finished Product → Supply

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Have a Product Idea or a Problem That Needs Solving?

You don't necessarily need a formulation or even know which chemistry you require.

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Tell us what you need the product to do.

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Our team can work with you to understand the challenge, investigate the available technologies and develop a practical route towards a finished commercial product. From the first laboratory sample to repeat commercial production, StarToll can help turn an idea into a product.