Research & Development at Green Petro™
Driving Innovation in Mold Release Agent Technology
Mold Release Agent Research & Development
At Green Petro™, our Research & Development (R&D) division is the engine behind every formulation we produce. From concept to commercialization, our goal is clear: to develop advanced, eco-friendly, and high-performance mold release agents that meet the evolving needs of rubber, PU, plastic, and composite molding industries.
Our Faridabad-based R&D lab is equipped with the latest instrumentation and staffed by a team of chemists, process engineers, and application specialists. Whether you’re seeking a standard water-based mold release agent or a fully custom, silicone-free formulation, we use science-backed methodology to create stable, scalable, and industry-ready solutions.
Our Core R&D Capabilities
Green Petro™’s R&D operations are focused on solving real-world problems that manufacturers face every day. These include:
- Sticking or tearing during demolding
- Carbon build-up in high-temperature molds
- Incompatibility with coatings, adhesives, or paints
- Excessive overspray and waste
- Lack of regulatory compliance for export
- Cycle time inefficiencies
Our team develops mold release agent R&D solutions based on rigorous testing, feedback from production facilities, and continuous benchmarking with international standards.
🧪 Facilities & Instrumentation
Our R&D lab includes:
- High-shear mixers for emulsion development
- Brookfield viscometers for shear-thinning profile testing
- pH meters, centrifuges, and homogenizers
- IR heating plates and lab-scale molding dies
- Anti-stick performance test rigs
- Slip angle test setup (ASTM D1894)
- Microbial resistance testing station
- Stability chambers for accelerated aging studies
All formulations undergo stability, thermal, slip, residue, and VOC testing before they’re scaled for production.
🔧 Formulation Science: The Green Petro™ Process
1. Requirement Mapping
We start by understanding your process:
- Material molded (EPDM, NBR, PU, TPE, etc.)
- Mold temperature range
- Surface finish expectations (matte, gloss, semi-gloss)
- Application method (spray, brush, dip, automated)
- Regulatory requirements (REACH, RoHS, CLP, BIS)
2. Formulation Design
Our chemists design a base formula using:
- Water-based or solvent-based carrier
- Silicone, wax, or fluorine-free systems
- Rheology modifiers, defoamers, and stabilizers
- Preservative systems: BIT/MIT, phenoxyethanol, potassium sorbate
- Additives to adjust slip angle, gloss, or residue profile
3. Prototype & Testing
A prototype is developed and tested on:
- Compatibility with mold substrate (metal/composite)
- Resistance to buildup at 150°C–300°C
- Ease of cleanup and spray pattern
- VOC levels and odor profile
- Cycle testing (10–50 demold cycles)
4. Customer Trials
We dispatch pilot batches (20L or 50L) with full TDS/SDS. Our application engineers guide on:
- Dilution ratios
- Nozzle selection for spray
- Mold conditioning steps
- In-line performance monitoring
5. Approval & Commercialization
Once performance is validated:
- Final specs are locked
- Product is scaled to 200L/1000L batches
- Shelf life validation (6–12 months)
- Export-compliant labeling and documentation
🧪 Custom Mold Release Agent R&D
No off-the-shelf solution will suit every mold. That’s why custom formulation is a core offering of our R&D unit.
✅ We customize:
- Base type (silicone-based, non-silicone, solvent-free)
- Viscosity and sprayability
- Gloss level and residue minimization
- Thermal and pH range
- Regulatory and export compliance
📦 MOQ for Custom Formulation: 1000 kg (1 ton)
Sustainability Through Research
Green Petro™ is a pioneer in sustainable mold release agent R&D. We’ve invested significantly in:
- PFAS-free and PTFE-free formulations
- Biodegradable, plant-based release agents
- Low-VOC and non-flammable chemistries
- Zero-silicone agents for post-molding processes
- Closed-loop spray and recovery systems
All products are REACH, CLP, BIS, and RoHS compliant, and we stay updated with EU and Indian environmental norms.
🧪 Example Innovations from Our Lab
✅ GP-MRA300 (Silicone-Based | Water Carrier)
Used in high-temp EPDM hose manufacturing, stable up to 300°C, non-staining, 1000–1300 cP, 12-month shelf life.
✅ GP-MRA110B (Biodegradable | PFAS-Free)
Silicone-free agent for PU soles and rubber gaskets. Clean release, low VOC (<50 g/L), REACH-compliant.
✅ GP-MRA720 (Solvent-Based)
Designed for fast-evaporation in PU rotational molding. Ultra-thin film, no post-cleaning needed.
📈 R&D Success Stories
🏭 Rubber Gasket Manufacturer – Pune
Challenge: Carbon buildup and post-processing residue
Solution: Water-based GP-MRA310 with adjusted pH and slip angle
Result: 28% reduction in mold cleaning frequency
🏭 PU Footwear Exporter – Agra
Challenge: Silicone transfer affecting bonding
Solution: GP-MRA110B, non-silicone, eco-friendly solution
Result: 0% bonding failure, improved paint adhesion
🏭 Cable Manufacturer – Gujarat
Challenge: Frequent overspray and VOC concerns
Solution: PFAS-free water-based agent with optimized viscosity
Result: VOC compliance passed, 18% reduction in product rejects
🧪 Certifications & Documentation
Each Green Petro™ R&D output comes with:
- TDS (Technical Data Sheet)
- MSDS / SDS (Globally Harmonized System)
- REACH / CLP documentation for exports
- VOC and heavy metal test reports
- Third-party test reports (SGS / Intertek)
Let’s Innovate Together
Green Petro™’s R&D team works directly with production teams, QA departments, and OEMs to co-develop new-generation mold release agents.
Whether you’re optimizing for cleaner release, faster cycles, or regulatory compliance, our lab is ready to partner with you.
📞 Contact Our R&D Team
📧 Email: info@greenpetro.in
📞 Phone: +91-9899-009-726
🌐 Website: www.greenpetro.in
📍 Location: Faridabad, Haryana, India