When it comes to powder processing, precision matters. Particle size, consistency, flow, and performance all play a critical role in how a material behaves in real-world applications. That’s why manufacturers across industries turn to Specialty Powders not just as a processor, but as a long-term partner offering reliable tolling services that align with material requirements, production timelines, and performance expectations. Our tolling services help customers transform polymers and specialty materials into high-performance powders ready for coatings, compounding, additive manufacturing, and industrial applications.
From early-stage trials to full-scale production, Specialty Powders delivers custom powder solutions through flexible tolling services designed around exact specifications. Backed by decades of polymer expertise and a full suite of processing capabilities, the team helps customers move materials forward with confidence, consistency, and control.
Decades of Expertise, Built for Scalable Precision
For around 60 years, our strategically located, ISO 9001:2015 certified facilities across the United States have supported manufacturers with reliable powder processing solutions. We work with a wide range of polymers and specialty materials, reducing them into powders of precise sizes, from small laboratory batches to full-scale production volumes reaching millions of pounds each year.
Every project is approached with flexibility and care. Services can be combined or tailored to suit specific material requirements, performance goals, and production timelines, all while maintaining the highest level of confidentiality. This commitment to precision, scalability, and trust forms the foundation of our long-standing partnerships across industries.
A Full-Spectrum Approach to Powder Processing
Specialty Powders supports the complete powder processing lifecycle through flexible tolling services designed to meet precise material and performance requirements. Whether the goal is particle size reduction, blending, classification, or advanced modification, each service is engineered to deliver repeatable results while protecting material integrity. This end-to-end capability allows customers to streamline their supply chain, reduce risk, and scale efficiently without investing in their own processing infrastructure.
Attrition Milling (Ambient Grinding)
Ambient grinding is one of the most widely used methods for producing polymer powders. Operating under standard temperature conditions, this process is suitable for materials that are stable at elevated temperatures.
Attrition milling produces particle sizes ranging from 2000 to 63 microns, with oversized particles automatically recycled until they meet specification. The result is a consistent, high-quality powder with reliable distribution.
This method works well for a broad range of materials, including polyethylene, polypropylene (HPP above 500 microns), polystyrene, nylon 6, ABS, TPEs, PET/PBT, polycarbonate, engineering resins, and recycled materials. It’s a dependable option within Specialty Powders’ tolling services portfolio for applications where efficiency, consistency, and throughput matter.
Cryogenic Grinding
Some materials require a more controlled approach. Cryogenic grinding is designed for heat-sensitive or low-melt polymers that could degrade under ambient conditions.
By freezing the material with liquid nitrogen, polymers become brittle and grind cleanly without thermal damage. Particle sizes typically match ambient grinding ranges, from 2000 to 63 microns, while preserving color, molecular structure, and performance properties.
This process is ideal for materials such as polycaprolactones, coPP (HPP below 500 microns), high-impact polystyrene, non-PA6 nylons, ABS, soft TPEs and TPOs, TPUs, low-melt polyesters, ionomers, and PLA. When material integrity is critical, cryogenic grinding offers peace of mind.
Jet Pulverizing for Ultra-Fine Powders
For applications that demand ultra-fine particles, jet pulverizing delivers results without introducing heat. Using compressed air or gas, particles collide at high velocity, breaking down into powders below 45 microns with tight distribution control.
As particles become airborne, they are either collected or recycled until they reach the desired size. This process is commonly used for powder coatings, specialty additives, waxes, chemicals, reactor granule polymers, and inorganic materials. It is a key capability for customers relying on Specialty Powders’ tolling services for precision-driven applications.
Granulation: Preparing Materials for Success
Granulation is often the first step in effective powder processing. Oversized parts, slabs, purgings, or scrap materials are reduced into manageable granules that can be fed smoothly into downstream equipment.
This step improves feed consistency and milling efficiency while reducing wear on processing equipment. Granulation plays a key role in recycling workflows and in handling challenging materials like rubbers, elastomers, extruder purgings such as polycarbonate, and scrap polyolefins.
Blending and Mixing for Uniform Performance
Consistent performance starts with consistent mixing. Specialty Powders offers a range of blending solutions, from high-intensity batch blenders to tumble mixers, capable of handling 100 lb. to 12,000 lb. batches.
Materials can be blended in powder, pellet, or granule form. Whether combining additives, fillers, colorants, or custom formulations, precise mixing ensures uniform distribution and reliable downstream performance.
Size Classification and Screening
Particle size distribution affects everything from flowability to surface finish. Specialty Powders utilizes the latest classification technologies to separate powders into precise size ranges.
This process removes fines or oversized particles and optimizes powders for compaction, coating performance, and processing efficiency. Classification is a critical step for customers targeting tight tolerances or application-specific performance.
Analytical Services and Quality Control
Quality assurance is built into every step of the process. Specialty Powders offers in-house analytical services, including particle size analysis, bulk density, moisture content, melt flow index, and visual inspection.
Advanced characterization tools are selected based on material type and particle size range. Methods include Rotap for coarse powders, Jet Sieve for finer particles, and laser diffraction using MicroTrac and other systems for precise micro-scale measurement. Bulk density and flowability are evaluated using ASTM D1895, while surface fineness is measured with industry-standard grindometers.
These insights help customers meet performance targets, regulatory requirements, and batch-to-batch consistency.
Bulk-to-Bulk Processing at Scale
Handling large volumes requires both precision and control. Specialty Powders’ bulk-to-bulk processing capabilities support high-throughput operations while maintaining material integrity and traceability.
From incoming bulk containers to final packaging, every step is designed to minimize waste, preserve uniformity, and support efficient production schedules for high-volume customers.
Research and Development Support
Innovation doesn’t always start at full scale. Specialty Powders’ R&D team works closely with customers to develop new powder formulations, refine processing methods, and plan scale-up strategies.
Trial batches, iterative testing, and performance validation allow customers to explore new ideas without committing to upfront capital investment. This collaborative approach shortens development cycles and reduces technical risk.
Powder Modification and Characterization
Beyond size reduction, Specialty Powders offers advanced powder modification services to fine-tune material behavior. By analyzing flowability, density, surface characteristics, and moisture sensitivity, the team helps optimize powders for specific applications and processing environments.
These services ensure materials meet both performance expectations and regulatory standards.
Flexible Packaging Options
Packaging matters more than many realize. Specialty Powders offers flexible packaging solutions ranging from 10 lb. bags to super sacks and gaylord boxes. Each package is labeled, sealed, and prepared to maintain cleanliness, prevent contamination, and integrate smoothly into downstream operations.
From Prototype to Production
Across aerospace, automotive, 3D printing, consumer goods, coatings, and industrial manufacturing, Specialty Powders helps customers turn raw materials into precision-engineered powders that perform as intended. Our scalable tolling services support everything from trial batches to high-volume production, without compromising quality or consistency.
With a full-service tolling facility, deep polymer expertise, and a hands-on, collaborative approach, Specialty Powders delivers more than processing. Through dependable tolling services, they provide confidence, control, and results at every stage of development.
From prototype to production, Specialty Powders is the partner that moves your material forward.