Sample-to-FCL Qualification Process

Switching TiO2 suppliers or qualifying a new grade requires structured validation. Skipping steps risks quality problems at production scale that are difficult to diagnose. The standard 4-stage qualification process minimizes risk.

Stage 1: Sample request and CoA review (Week 1)

Sample size: typically 5–25 kg, sometimes up to 100 kg for free.

What we send: - Sample TiO2 in original 25 kg paper bag (or smaller sealed container) - Full batch CoA - SDS - Technical data sheet (TDS) - Recommended dispersion procedure

Buyer activities: - Review CoA against specification target - Verify regulatory compliance (REACH letter, FDA, food contact as needed) - Compare TiO2 content, tinting strength, color, heavy metals against current reference - Decision: proceed to lab batch or reject

Time: 5–10 working days for sample arrival; review takes 1–3 days.

Stage 2: Laboratory batch trial (Week 2–3)

Lab batch size: typically 100–1000 g of finished product.

Standard test sequence for paint: 1. Disperse TiO2 in formulation per standard procedure 2. Measure Hegman dispersion grade 3. Make drawdown on contrast card 4. Measure contrast ratio (ISO 6504-3) 5. Measure CIE L*a*b* on the drawdown 6. Compare gloss at 60° if relevant 7. Run accelerated weathering (QUV-A 100 hr minimum) if outdoor 8. Compare results against current reference TiO2

Standard test sequence for plastic masterbatch: 1. Compound 50% MB on small twin-screw extruder 2. Extrude 50 μm test film at 50% loading 3. Count fish-eye defects per 100 cm² 4. Measure Δb* before and after 280°C / 5 min 5. Compare against current reference

Standard test sequence for ink: 1. Mill TiO2 in test ink vehicle for 60 min 2. Measure Hegman 3. Drawdown print test 4. Compare opacity, gloss, anilox release against reference

Acceptance criteria: - Critical parameters within ±5% of reference (or tighter for premium applications) - No catastrophic failures (e.g., film defects, color anomalies) - Cost-performance analysis vs incumbent

Time: 1–2 weeks lab work + analysis.

Stage 3: Pilot production batch (Week 4–6)

Pilot batch size: typically 100–500 kg of finished product (1–5 t of TiO2).

Process: - Order sample quantity sufficient for 1 production batch - Receive within 2–4 weeks (FCL or LCL) - Run production-scale batch on real equipment - Compare against historical reference batches - Hold finished product for 30+ day storage stability monitoring - Send finished product samples to key customers for evaluation

Acceptance criteria: - Production-scale parameters match lab batch results - No equipment issues (dispersion, extrusion, application) - Customer feedback positive on finished product - Storage stability acceptable (no settling, no color shift)

Stage 4: First FCL commercial order (Week 7+)

After successful pilot, order a 1 FCL (18–20 t TiO2) commercial volume.

Process: - Place commercial order on new supplier - Receive FCL with full CoA - Use in production parallel with existing supplier (50/50 split typical) - Monitor finished product quality over 1–3 month period - Compare yield, defect rates, customer returns - After successful FCL, transition to 100% new supplier or maintain dual-source

Common pitfalls in qualification:

1. Skipping lab batch: shipping FCL before lab validation often fails — color drift, dispersion issues caught only at production scale 2. Inadequate hold time: 30-day storage stability matters; rushing through and approving immediately misses storage-related issues 3. Comparing CoA only, not application: two TiO2 grades with identical CoA can behave very differently in your specific formulation 4. Single batch validation: validate against 2–3 batches to catch batch-to-batch variation issues 5. Production substitution without lab validation: highest-risk approach; always validate before substituting

Cost of qualification (typical): - Stage 1 sample + CoA review: minimal (sample is free) - Stage 2 lab work: $1000–5000 internal labor + materials - Stage 3 pilot batch: $5000–25000 (TiO2 cost + lab analysis + lost-time on equipment) - Stage 4 first FCL: TiO2 cost + monitoring effort

Total ~$10,000–50,000 for a complete qualification, depending on application complexity. Premium applications (automotive OEM, cosmetic) at the high end.

Payback for cost-down substitution: For a paint plant doing 5000 t/year at 20% TiO2 loading switching from premium-priced TiO2 to SEMITI 996: - TiO2 consumption: 1000 t/year - Cost saving (typical $0.80/kg): $800,000/year - Payback: < 1 month on $50k qualification cost

SEMITI qualification support: - Free samples up to 25 kg - Technical support for lab batch design - On-site visits for premium accounts in Asia - Co-development for complex applications (automotive OEM, premium PVC) - Customer reference program — connect with similar customers who've completed qualification