diff --git a/docs/quality-automation.md b/docs/quality-automation.md index 2b3e7e4..e3cfe58 100644 --- a/docs/quality-automation.md +++ b/docs/quality-automation.md @@ -138,6 +138,57 @@ the lot ID follows every record pressed from it: and verification of the virgin/regrind ratio at the extruder; regrind batch IDs are logged like any other lot +### The PVC lab, in tiers + +**Per lot, in-house from day one** (benchtop instruments, all with data +export for the traceability gate): + +- Moisture content: halogen moisture analyzer or Karl Fischer titration; + minutes per sample, and the most common cause of noisy surfaces +- Heat stability: oven strips at pressing-relevant temperatures watching + discoloration over time; the formal methods are ISO 182 (Congo red / + conductivity), tracking HCl evolution +- Density: checked against the compound spec; feeds record weight + consistency +- Color: spectrophotometer L\*a\*b\* against the reference, plus gloss for + black compound +- Granulate physicals: sieve analysis for particle size distribution, bulk + density, dust/fines content +- Ash content: muffle furnace burn-off as a filler-loading drift check +- Pressed-plaque inspection for specks, gels, and contamination (shareable + with the optical inspection investment) + +**In-house as the lab matures** (the PVC-specific workhorses): + +- Torque rheometry (Brabender class): fusion/gelation time and torque, + the standard predictor of how a PVC compound behaves in the extruder; + plain melt-flow index is less informative for PVC than for other + thermoplastics because the material is shear- and heat-sensitive +- DSC: glass transition, additive signatures, and the record-relevant + application of measuring the degree of gelation of a pressed record, + which correlates with surface noise and durability, turning DSC into a + process-tuning tool as well as an incoming check +- FTIR: identity fingerprint; record compound is classically a vinyl + chloride/vinyl acetate copolymer rather than pure PVC, and FTIR verifies + the copolymer and catches unannounced formulation changes + +**External lab, per supplier qualification** (not per lot): + +- K-value / dilute solution viscosity (ISO 1628-2): molecular weight, the + headline spec for record-grade resin since it governs flow into the + groove +- XRF elemental analysis: stabilizer system identification (Ca-Zn or tin + acceptable, legacy lead rejected) and heavy-metals compliance for export +- TGA: full compositional breakdown (plasticizer, filler, carbon black) +- Volume/surface resistivity: static behavior, which becomes dust + attraction on finished records + +The tiers define the protocol: the per-lot gate runs moisture, heat +stability, color, density, and granulate physicals plus the release test +pressing; a new supplier additionally gets the full external panel and +pressing trials. This is the working method for qualifying Thai and +regional compounds against the European references. + ## Packaging QC Packaging comes from local carton partners, so QC splits into an incoming