Focusing on Total Cost of Ownership (TCO)

For procurement professionals in the cable and automotive sectors, raw material selection has evolved beyond simple unit price comparisons. Today, a strategic approach must encompass the Total Cost of Ownership (TCO), including parameters such as production efficiency, energy consumption, scrap rates, and downtime.

While the raw material price of Halogen-Free Flame Retardant (HFFR) compounds can be higher and their processing more demanding, it is important to note that conductors (copper/aluminum) dominate the total cost of a cable. Consequently, the price gap between PVC and HFFR often becomes negligible in the final product cost. Therefore, rather than selecting the "cheapest material," professionals should prioritize the compound that maximizes production performance. A correctly formulated HFFR compound does more than just prevent issues; it delivers higher yields, lower energy consumption, and consistent quality.

HFFR Compound Performance in the Extrusion Process

The characteristics of an HFFR compound on the extrusion line are the primary determinants of production speed and continuity. An optimally composed HFFR compound provides the following strategic advantages:

• Lower Pressure and Torque: HFFR formulations optimized with specialized additives improve melt fluidity, thereby reducing pressure and torque within the extruder. This enables significantly higher production speeds.

• Stable Flow: High-quality HFFR compounds with superior dispersion minimize fluctuations in the melt flow. This stability helps maintain diameter and ovality tolerances throughout the extrusion process. Furthermore, it reduces surface irregularities and melt fracture, resulting in a smoother, high-quality cable finish.

• Reduced Energy and Maintenance Needs: Lower pressure and torque reduce the mechanical and thermal load on the machinery. Optimized additives lower the energy consumption of extruder motors and heaters. This not only cuts energy costs but also prevents quality issues such as material degradation or gas release.

These advantages lead to fewer manual interventions, reduced part replacement, and an extended lifespan for the equipment. Conversely, using a poorly formulated or difficult-to-process HFFR compound can result in line breakages, diameter fluctuations, and increased scrap due to surface defects.

Factors Enhancing Production Efficiency

The impact of a high-quality HFFR compound on extrusion efficiency is highlighted across four key areas:

1. Higher Line Speed

An HFFR compound that provides excellent fluidity increases the extruder output. This allows for higher line speeds, directly boosting total production capacity.

2. Smooth and Consistent Surface

HFFR compounds that ensure steady flow help eliminate surface defects and bubble formation. This maintains strict diameter tolerances and reduces the need for rework, leading to lower scrap rates and faster quality control approvals.

3. Low Processing Temperatures and Energy Savings

HFFR formulations with a wide processing window allow for operation at lower melt temperatures. This reduces the energy consumption of heaters and motors while preserving the material’s color and mechanical properties.

4. Reduced Unplanned Downtime – High OEE

Every unplanned stop represents lost production and wasted material. A stable HFFR compound minimizes interruptions, thereby increasing Overall Equipment Effectiveness (OEE). In this context, a slightly higher cost per kilogram becomes a significant advantage by lowering the total production cost.

Procurement Perspective: Looking Beyond the Price

When selecting critical HFFR raw materials, a process-oriented approach is essential. To achieve this, companies should:

• Conduct trials on actual production lines in collaboration with technical teams.

• Meticulously record line speed, energy consumption, scrap amounts, and downtime.

• Compare HFFR compounds based on total production cost and quality contribution rather than just price per kilogram.

Strategic decisions made through this lens ensure long-term profitability. With regulations like the EU Construction Products Regulation (CPR) making HFFR mandatory in many infrastructures, evaluating efficiency and reliability is more important than ever.

HFFR Solutions by Lys Polychem

At Lys Polychem, our goal is not merely to supply HFFR compounds but to be a solution partner that facilitates your production flow. We formulate our HFFR compounds with a focus on wide processing windows, low extrusion pressure, stable torque, high surface quality, and minimal scrap rates.

We continuously optimize our formulations based on real-world production conditions, integrating feedback from field trials directly into our R&D processes. Shifting the focus from price-per-kilogram to a total production cost perspective is the key to sustainable success. With the right HFFR compound, it is possible to increase line efficiency and eliminate hidden costs. The Lys Polychem team is ready to support your process with technical analysis and customized trial studies tailored to your specific lines.