January 2026

Advanced Melt Flow Indexing Creates Better Work Environment; Easier Testing

As a cornerstone of quality control for polymers and plastics, melt flow indexers (MFIs) play a key role in understanding the processing behavior of these types of materials.

Traditional melt flow systems are grounded in the physical interaction between the machine and operator to set up and perform melt flow tests, from loading and unloading the deadweights to properly cleaning the equipment once a test is complete. Repeatability relies heavily on the consistency and stamina of the operator to replicate test conditions across multiple testing scenarios.

A deadweight system is still the mainstay of the industry, but as automation and digitization continue to permeate materials testing environments, loadcell-based technology is starting to gain influence across various melt flow testing applications throughout laboratories, research and development facilities and plastics manufacturers alike.

This advanced melt flow technology offers a clear, practical shift to better efficiency, accuracy, and operator safety in test environments, especially those with variable testing requirements, such materials with different viscosities or compositions as well as facilities with high testing frequencies and fluctuating loads. (Figure 1)

Considerations When Using Traditional MFIs

The manual nature of traditional melt flow indexers puts operator ergonomics at the forefront of workplace safety. Even with an automated deadweight loader, a person still needs to physically manipulate several steps of the load set up, such as making manual judgements and verifications. This can equate to operator strain and fatigue as well as increased risk of injury.

Repetitive, manual tasks are also a part of the traditional MFI testing process. One example is cleaning the system, which takes time and effort and must be done proficiently to ensure batch consistency and avoid cross contamination among different samples.

The industry is looking towards loadcell-based melt flow testing, not only for operator safety and production efficiency, but also to incorporate better data analysis and reporting, as the world of materials testing continues to become digitized. (Figure 2)

Loadcell-based Melt Flow Testing For Improved Production

Digital melt flow indexing becomes even more significant as material compositions change, due to new additives and fillers being incorporated into today’s polymers and plastics in addition to the plastics industry’s move towards sustainability. Commonly referred to as the circular economy, plastics sustainability focuses on materials that are reused, recycled and kept in circulation for as long as possible.

The melt flow index helps determine material performance and quality in a given application. Determining how variations in the MFI correlate to material properties, like density and mechanical behavior, means you have a deeper understanding of how the MFI value affects the material being tested. (Figure 3)

Ensuring new variations and recycled or reused plastics still adhere to the required standards outlined by ASTM D1238-23a and ISO 1133-1:2022, for example, ensures accurate and repeatable results. These standards provide a reliable benchmark that drives quality, enables material selection and supports advancements in material science.

As ASTM points out, “The flow rate obtained with the extrusion plastometer [melt flow indexer] is…an empirically defined parameter critically influenced by the physical properties and molecular structure of the polymer and the conditions of measurement.”

But beyond its uses in materials evaluation, a digital melt flow tester can improve operator safety and production efficiency, giving those on the floor a better work environment as well as insights into evaluating test results. It also empowers them to make real-time changes as needed and perform a different set of process and procedural tasks that can improve overall quality and production efficiency.

When Does A Digital MFI Make Sense

As materials testing becomes more digitized, integration across testing systems and platforms will continue to increase. The timing of adding a loadcell-based MFI to your current test set up comes down to assessing its integration from a holistic viewpoint, so ask yourself these questions:

What are the current digital capabilities of my materials testing system?
Is there a timeline for bringing my whole system into a digital environment?
Am I handling several different polymer types that require many load variations?
Will this help meet ASTM & ISO requirements for new materials development?
Am I happy with the accuracy and repeatability of my current MFI?
Could a digital MFI improve my time between tests?
Do I need to better integrate my MFI results into my overall reporting and analysis?
What will these improvements do for overall efficiency and analysis?
What opportunities will this open for my operators?

What’s Next for Melt Flow Testing

The move to a digitally-enhanced MFI allows those involved with materials testing the ability to focus less on the mechanics of testing and more on the quality of results. The added benefits of operator efficiency and a safer working environment only enhance the implementation of a loadcell-based MFI within a testing environment.

This is especially useful in applications where multiple loads are being manipulated on a regular schedule as well as in environments where new additives and composites need evaluation, so testing personnel can take a more active role in evaluation and analysis to ensure quality results in today’s plastics and polymer melt flow testing.

Ways to Use Exported Data for Better QA Manufacturing

Data has become extremely important in manufacturing. It serves as a collection of information and statistics used for reference or analysis. When gathered from a variety of sources along the production environment, this data gives manufacturers valuable insights to help optimize the supply chain, reduce costs, and improve the quality of their products.

Data analytics takes this a step forward, helping manufacturers predict maintenance needs, prevent downtime, and create a safer work environment. By effectively using data in manufacturing, businesses become more sustainable and more profitable. (Figure 1)

Automation for Improved Testing Efficiency

By running tests continuously or in parallel, often 24/7, automated materials testing is far more reliable than manual testing. It improves testing efficiency by ensuring consistent, repeatable test parameters and reducing errors. The larger datasets generated by an automated materials testing system provide better, more reliable insights, while offering traceability and reproducibility. (Figure 2)

In its Digital Maturity Index 2023, Deloitte “found that 98% of 800 surveyed manufacturers in four major global economic regions have started their digital transformation journey, compared with 78% in 2019, and respondents reported cost optimization, operational efficiency, product innovation, and improving customer experience as key drivers for the shift.”

But how do these systems collecting and exporting data provide better quality assurance manufacturing? And how has the availability of that data improved manufacturing environments?

Data Access Made Easy

As the digital infrastructure continues to grow, working with the data gathered during test, whether for the demanding rigors of R&D or the charting and analysis functions of QC testing, is critical to modern materials testing. Horizon software from Tinius Olsen, for example, offers an intuitive interface, providing quick access to a number of usability and access points, such as:

Test method library
Test editor
Tabbed test and recall area
Multiple machine control
Output editor
Method editor
Result editor
Multifaceted security
Data importing
Report consolidation
Webcam functionality

This ease of gathering and analyzing data improves the manufacturing environment by enabling the collection, processing and analysis of statistically meaningful information that can help direct quality control and production efficiency.

The advanced, data-centric environment provided by the Horizon software delivers a powerful, adaptable interface that supports both research-intensive development and standardized quality assurance work to meet the evolving needs of materials testing. The platform can be used integrated into virtually any materials testing environment.

Putting Unprecedented Data Insights into Action

A typical data collection program will offer a variety of different graphs that can be produced per test, once all data has been gathered. But today’s data collecting and analysis methods can go much, much further relying on data across the continuum, from live data on a currently uploaded specimen to historical data obtained through several previous test iterations. (Figure 3)

In addition to accessing live data during testing, acceptable limits of the results can be selected as well. The results can be viewed graphically in multiple formats and customized for user-specific reporting. Unique results can be calculated from parameters and from other tests and equipment. Information can be exported to a variety of different formats, making data gathering and reporting seamless.

Following International Test Standards

If your testing regimen follows a quality control analysis to a variety of international standards, make sure you enlist a software program with a test method library that has been written in accordance with different international test standards, including ASTM, ISO, EN, BS DIN and more.

It should also allow for customized test setup, using a standard as a template, and be offered in multiple languages and dialects as well as with an option for users to create test method, giving them complete control over how the test machine performs throughout the course of the test. This will also help give you a wide variety of data to match your materials testing needs.

For example, the Horizon platform can convert hardness values into five different hardness (and tensile) scales simultaneously according to international standards (ISO/ASTM). For a global company where materials are tested at various locations, each follows different testing standards. If the same material is to be used across all sites, but the required validation varies according to local standards, different hardness scales may be needed.

For instance, the QA facility might follow ASTM standards requiring Rockwell hardness, while another location adhering to BS standards may specify Brinell hardness for the same material. In such cases, repeating the test in every scale is redundant — instead, the material can be tested once and the results converted using conversion function in Horizon, allowing the report to include equivalent hardness values across all relevant standards.

Conclusion: How is Data Used in Manufacturing?

The innovative use of data in manufacturing appears to be a stabilizing force for the global manufacturing industry. Data helps to predict future outcomes using both current analytics and historical data. This advanced methodology helps to decode complex manufacturing processes and improve materials testing outcomes.

Collecting data on the quality of a specific part can be helpful for auditing production processes and ensuring that work is standardized, as well as helping to reduce waste.

Materials testing analytics improve product quality by capturing machine-level information, boosting production yield and throughput. Data that shows the cost and effort involved in developing products helps quickly identify problems and predict issues. This aids in quality production, while significantly reducing costs. The use of data in manufacturing environments, especially in materials testing, has become a pinnacle of operational improvement.

For a deeper dive into using data in your materials testing environment, check out our white paper on Integrated Data Analysis Improves Efficiency in Materials Testing

Building Trust Through Innovation in Materials Testing: LTI and Tinius Olsen’s Collaborative Journey

Introduction

In the world of materials testing, precision and reliability are paramount. Companies in high-stakes industries such as aerospace, nuclear, and additive manufacturing depend on advanced technology to meet rigorous standards.

Based outside of Philadelphia, PA, Laboratory Testing Inc. (LTI) has been at the forefront of materials testing for over 40 years, ensuring that its clients receive the highest level of accuracy and efficiency. Its long-standing relationship with Tinius Olsen has played a crucial role in fostering innovation, streamlining testing processes, and enhancing overall efficiency.

A Relationship Built on Collaboration

LTI’s partnership with Tinius Olsen is more than just a customer-supplier relationship — it is a dynamic collaboration. Over the years, LTI has provided valuable feedback to Tinius Olsen, influencing the development of new and improved testing systems.

As Mechanical Testing Manager Paul Szczepaniak from LTI shares, “Being part of the actual product development is an interesting experience. There’s a good back and forth between the companies, because we see what we need, and Tinius Olsen is always willing to accommodate.” (Figure 1)

This direct engagement has resulted in tailored materials testing solutions that address real-world challenges, allowing LTI to optimize its operations, while contributing to the continuous evolution of Tinius Olsen’s technology.

Supporting Industries Through Innovative Solutions

To maintain an industry leadership position in the diverse range of industries it serves, LTI relies on sophisticated test systems that seamlessly integrate into its workflows. Tinius Olsen’s Horizon test system has been a game-changer for LTI, providing a streamlined and customizable platform that enhances data acquisition and usability.

“The ability to use that system and have it constantly updated has been invaluable,” says LTI’s Mechanical Testing Coordinator, Nathan Moyer. “Even if we request a specific feature, unless it’s an extremely complex demand, they generally implement it within a day or two.” This level of responsiveness and agility sets Tinius Olsen apart from its competitors, ensuring that partners like LTI can maintain its competitive edge.

Efficiency and Innovation with Non-Contact Extensometry

In high-volume materials testing environments, efficiency is key. LTI has significantly enhanced its operations with Tinius Olsen’s Vector Extensometer, which eliminates the limitations of traditional contact extensometers. The digital extensometer integrates adaptive AI capabilities with optical hardware to reduce test throughput times and complexity, automating the process of capturing strain and improving measurement accuracy, data consistency and operator safety. (Figure 2)

“Since it is non-contact, we could continuously run sample after sample and never have to re-verify the calibration of the extensometer,” Nathan explains. “And because it gives us digital, data-driven materials test processing, we have access to synchronized data in real-time, with virtually no lag.”

These advancements have minimized downtime, reduced costs, and improved throughput. The combination of Tinius Olsen’s precision hardware and sophisticated software has enabled LTI to optimize its testing processes like never before.

Reliability: The Backbone of Testing Operations

In a fast-paced and demanding industry, equipment reliability is non-negotiable. At LTI, almost every mechanical testing process involves a Tinius Olsen test system, from universal testing systems (UTMs) and hardness testers to impact test systems and melt flow indexers. Tinius Olsen systems form the backbone of LTI’s daily operations. This level of reliability ensures that LTI can meet the high standards required by its clients, while maintaining operational efficiency.

Driving Industry Innovation Together

Beyond advanced and innovative system offerings, Tinius Olsen’s active participation in ASTM standardization efforts further underscores its commitment to industry advancement. Paul shares, “If I receive a request from a customer that falls outside normal scopes, I can reach out to them and say, ‘Here’s what I’m trying to do. What can we do?’” This open collaboration has led to the development of custom instruments and unique testing setups that cater to LTI’s specific needs.

Moreover, Tinius Olsen’s commitment to swift customer support ensures that LTI experiences minimal downtime. “We just had a long-standing system go down, and Tinius Olsen had us back up in three days, whereas with another company, it could have taken weeks,” Paul highlights.

Conclusion

LTI’s decades-long relationship with Tinius Olsen exemplifies what true collaboration in materials testing looks like. Through constant innovation, responsive customer support, and advanced technology, Tinius Olsen has not only helped LTI optimize its processes, but has also played a pivotal role in advancing the materials testing industry as a whole.

For companies looking for a trusted partner in materials testing, the success story of LTI and Tinius Olsen speaks volumes. When precision, efficiency, and reliability matter most, Tinius Olsen delivers solutions that stand the test of time.

Hear it direct. Check out this video from Nathan and Paul at LTI about their experience working with Tinius Olsen.

Sustainable Alternatives Gain Validation Through Materials Testing

The past few years have shown us that the world around us is finite and fragile. And we all play a part in its sustainability. There has been a push across several industries to develop inventive, forward-looking products and technologies, while maintaining a better balance with the environment for long-term global health.

With innovation comes the unknown. Will a newly developed material stand up to the defined ASTM or ISO standards or will the use of a different material in an existing application meet the required industry standard benchmarks? Standards exist to ensure product safety and quality, which is all for the benefit and protection of the end user.

Confidence in Material Innovations

As an industry, we are tasked with maintaining a level of confidence in the products and solutions being delivered, and standards are an important aspect of that. There are many promising examples of sustainable products that incorporate recyclable or biodegradable materials and also support an eco-friendly environment. But to be able to confidently put these innovations into the mainstream, companies still rely on materials testing to known industry standards and specifications.

Material testing provides the insight to gauge the useability of certain materials and products in specific environments. And in the world of eco-friendly material innovation, it has helped lay the groundwork to develop solutions beyond just delivery of a product, but also to help combat climate change, to increase types and quantities of materials that can be recycled, and ultimately open doors to innovations that are solving some real-world challenges.

Recycled Glass Aggregate

The collapse of I-95 in Philadelphia, PA seemed, at first, catastrophic. Initial calculations framed the road closure in years, then possibly over several months. So who would have thought that in a mere few weeks, this massive roadway connecting a large swath of the eastern United States would be up and running after such an epic event, using a sustainable material made from glass.

Recycled glass aggregate is not new. Formed by crushing glass into a powder, blending it with a foamy slurry, heating it and then breaking it into briquettes, the crushed aggregate is used in a number of construction applications, including as backfill or in roller applications. The size, shape, density and strength of the aggregate all affect its long-term performance in pavement and structures.

Testing of the ultra-lightweight foamed aggregate is critical to prove its efficacy and ensure it has the strength needed to bear the weight and force of heavy-duty construction. It also confirms that the aggregate is composed of a good mix of chemicals and materials that can compact to and withstand a certain force. Thanks to testing performed using Tinius Olsen equipment, the company developing the aggregate already had the results and data to know this aggregate could serve as the backfill for the temporary lanes constructed along the highway corridor.

Figure 1: Testing of the aggregate is carried out with Tinius Olsen equipment.

Sustainable Wool Rope

Seaweed farming itself is not only a sustainable source for fertilizer, bio-ethanol and livestock feed, but it helps negate carbon and nitrogen levels in the ocean as well as provides a healthy ecosystem for marine life. So the fact that non-recyclable, everlasting polypropylene rope is laid on the sea floor to grow the harvested seaweed counterbalances the environmentally-friendly aspects of growing a renewable resource. And this plastic rope is washing up on coastlines across the globe, rubbing against rocks, resulting in a hard plastic crust coating the coastlines.

But what if the rope was made of biodegradable wool that itself is sustainable and renewable. Would its physical properties still hold up as needed in the corrosive saltwater environment? Tinius Olsen is helping to answer this question.

Manufactured in a range of diameters, from small lengths to full coils, all of the wool rope currently produced is from local farms and craftspeople in the United Kingdom. But this paradigm shift for seaweed farming needs validation and is being accomplished through materials testing. By relying on proven equipment Tinius Olsen is helping to identify the proper breaking strain as well as design the special grips needed to hold the rope for proper testing.

Figure 2: The sustainable rope is used to farm seaweed and shellfish

Testing of Eco-friendly Innovations

In the world of materials testing, manufacturers turn to industry standards to enable them to validate, qualify and prove the viability of their products and raw materials. For materials pushing the envelope of what is known and acceptable, testing to a defined set of compliance levels becomes even more critically important.

Developing sustainable material alternatives and bringing them to market is no small feat. Testing validation is just one aspect of this process. Also of importance is a partner invested in the success of innovative product development and who has the technical knowledge and pedigree to deliver quality testing equipment to validate your product innovations.