An automotive carpet manufacturer struggled with costly and time-consuming external testing to meet OEM UV stability requirements. Without in-house testing capabilities, they faced long delays and increased expenses while optimising their formulations. The reliance on third-party labs made it difficult to fine-tune UV stabiliser levels efficiently, leading to higher production costs and extended development timelines.
A prominent manufacturer of automotive interior carpets faced a significant challenge in optimising the use of expensive UV stabilisers within their product lines. These stabilisers, which are critical for ensuring the long-term durability and colour retention of the carpet fibres under the harsh conditions of automotive interiors, represented one of the most costly raw materials in their production process. However, the manufacturer lacked in-house testing capabilities to efficiently fine-tune the amount of UV stabilisers used in each formulation, and they found themselves relying heavily on third-party testing laboratories for all qualification and development testing.
The process was very time-consuming. Whenever the manufacturer developed a new carpet formulation, they would need to send multiple sample batches to an external testing lab to assess their performance under accelerated weathering conditions.
Once the samples were at the testing lab, the manufacturer would face a long waiting period for results. If the initial tests showed any issues with the product's colour retention, they would need to make adjustments to the formulation, re-send the revised samples to the lab, and wait for further evaluation. This iterative process could take weeks or even months, making it difficult for the manufacturer to streamline the development cycle or respond quickly to any issues that arose. Moreover, each round of testing came with substantial costs, including setup fees, hourly rates for test runtime, and additional charges for evaluations and reports. These repeated expenditures placed a significant strain on the manufacturer's budget, especially considering the ongoing development of multiple formulations at once.
Aside from the financial burden, the lengthy testing and evaluation process also hampered the manufacturer’s ability to optimise the concentration of UV stabilisers and other additives. Without the ability to conduct rapid, real-time testing, the manufacturer was unable to make small adjustments in response to the performance of their formulations, resulting in suboptimal use of expensive raw materials. The time and money spent on each round of testing compounded these inefficiencies, further escalating costs and prolonging the overall development timeline.
After assessing the challenges they were facing, the manufacturer decided to make a strategic investment in a Q-SUN XE-3-H Xenon Arc Weathering Tester, an advanced system capable of simulating the effects of UV exposure and other environmental stressors on materials in a controlled laboratory setting. By bringing this testing capability in-house, the manufacturer gained the ability to perform both initial development testing and qualification testing without relying on external labs.
The Q-SUN XE-3-H was a game changer for the manufacturer. With this new capability, they were able to test new carpet formulations in a matter of days rather than weeks or months, enabling faster iterations and more efficient product development. The system allowed for precise control over the testing parameters, including the intensity and duration of the UV exposure, which meant that the manufacturer could more accurately replicate the real-world conditions that their products would face once installed in vehicles. This level of control empowered the manufacturer to fine-tune their formulations with a much higher degree of precision.
One of the primary benefits of using the Q-SUN XE-3-H was the ability to optimise the amount of UV stabilisers used in each formulation. As stabilisers are one of the most expensive components in the carpet production process, this optimisation directly translated into cost savings. The manufacturer was now able to experiment with different stabiliser concentrations and quickly assess their impact on the carpet’s colour retention, without the need for lengthy delays or costly external lab tests.
This in-house testing approach provided the manufacturer with a significant advantage in terms of both time and money. By reducing the number of external tests required, they were able to significantly lower testing-related expenses, including setup fees, runtime costs, and evaluation charges. Furthermore, the faster development cycle allowed the manufacturer to bring products to market more quickly, responding more nimbly to changes in customer demands or industry trends.
The financial savings from reducing external testing costs were substantial. For just one of the formulations tested, the manufacturer was able to save over $10,000 per month in raw material costs by optimising the use of UV stabilisers. This was just the beginning—savings from other formulations were even greater. The cost of purchasing and operating the Q-SUN XE-3-H was quickly offset by the ongoing reduction in raw material expenses. In fact, the investment in the weathering tester paid for itself in under four months, with every month thereafter delivering a strong return on investment.
Beyond the immediate cost savings, the manufacturer also gained significant competitive advantages. With the ability to optimise UV stabiliser use, they could produce high-quality products at lower costs, allowing them to improve profit margins. The reduction in development time also enabled faster time-to-market for new products, providing a competitive edge in the fast-paced automotive industry.
Moreover, the ability to conduct in-house testing gave the manufacturer greater control over product quality. They no longer had to rely on external labs to provide feedback or report on product performance; instead, they could assess the results in real time and make adjustments as needed, ensuring that their products met or exceeded OEM standards with minimal delays.
By investing in a Q-SUN XE-3-H Xenon Arc Weathering Tester, the manufacturer was able to drastically improve their testing efficiency, reduce their reliance on third-party labs, and optimise their use of expensive UV stabilisers. These improvements led to significant cost savings, a faster development timeline, and higher-quality products. The overall impact was a more efficient production process, stronger profit margins, and a notable return on investment. The decision to bring testing in-house not only solved a critical problem but also transformed the manufacturer's approach to product development, making them more agile and competitive in the marketplace.
Ready to optimise your formulations and reduce testing costs? Contact us today to learn how a Q-SUN weathering tester can accelerate your product development and drive significant savings.