Case Studies &
Success Stories

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Scaling EPDM Crosslinking Efficiency with High-Purity DCP

How Do Sender Chemicals helped SIBUR optimize their EPDM rubber production line, achieving 15% higher throughput and industry-leading scorch safety.

The Challenge

SIBUR, Russia's largest integrated petrochemical company and a major global producer of synthetic rubbers, was expanding its EPDM (ethylene propylene diene monomer) production capacity at its Tobolsk facility. The plant needed a reliable, high-purity dicumyl peroxide (DCP) for crosslinking their EPDM compounds used in automotive seals, roofing membranes, and wire & cable insulation.

SIBUR's previous peroxide supplier struggled with batch-to-batch consistency. Variations in DCP purity (ranging from 92% to 97%) led to unpredictable crosslinking density, forcing SIBUR to overcompensate with higher peroxide loading — increasing both material costs and scorch risk. The facility required DCP with assay ≥99% and moisture content below 0.1% for their high-speed extrusion lines.

The Solution

Do Sender Chemicals delivered pharmaceutical-grade Dicumyl Peroxide (CAS 80-43-3) with 99.5% minimum purity, manufactured under ISO 9001:2015 certification at our Zibo, Shandong facility. Our technical team worked closely with SIBUR's process engineers to:

• Optimize the peroxide-to-polymer ratio based on real-time rheometer (MDR) data from SIBUR's compound development laboratory
• Provide pre-blended DCP/masterbatch formulations on silica carriers to improve dispersion in the EPDM matrix
• Establish a dedicated stock and just-in-time delivery program with guaranteed 60-day lot homogeneity testing
• Supply comprehensive documentation including Certificate of Analysis (CoA), Safety Data Sheet (SDS), and REACH compliance declarations

The Results

After six months of production-scale validation, SIBUR reported the following key improvements:

The successful DCP supply partnership has since expanded to include additional peroxide grades for SIBUR's TPE and TPV product lines, making Do Sender Chemicals a preferred crosslinking peroxide supplier for the SIBUR Elastomers division.

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Precision Polymerization with Ultra-Pure AZO Initiators

LyondellBasell adopted Do Sender's high-purity AIBN and ABVN for controlled PP resin production, improving molecular weight distribution consistency by 28%.

The Challenge

LyondellBasell, one of the world's largest plastics, chemicals, and refining companies, operates advanced polypropylene (PP) production facilities across Europe. Their controlled-rheology PP grades — used in automotive components, food packaging, and medical devices — require precise control over molecular weight distribution (MWD) during the reactive extrusion process.

The existing azo initiator supply chain exhibited variability in decomposition kinetics, with AIBN assay fluctuating between 96% and 98.5%. This inconsistency caused MWD drift in 12% of production batches, leading to off-spec material and costly rework. LyondellBasell needed an initiator supplier capable of delivering ≥99% purity AIBN with documented half-life data verified by DSC analysis for each lot.

The Solution

Do Sender Chemicals supplied ultra-pure Azobisisobutyronitrile (AIBN, CAS 78-67-1) and Azobisisovaleronitrile (ABVN) with:

• 99.2% minimum assay (HPLC verified), exceeding industry standard of 98%
• Tightly controlled residual moisture (<0.05%) to prevent premature decomposition
• Crystal morphology optimization for consistent feeding in gravimetric dosing systems
• Custom anti-caking treatment for bulk silo storage and pneumatic conveying
• Full thermal stability documentation per UN Manual of Tests and Criteria, Section 28

The Results

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Accelerating UV-Cure Formulations with Advanced Organic Peroxides

Arkema leveraged Do Sender's BPO and TBPB to develop next-generation UV-curable industrial coatings with 30% faster curing and enhanced scratch resistance.

The Challenge

Arkema's Coating Solutions division was developing a new line of UV-curable industrial coatings for the European furniture and flooring markets. The formulation required a dual-cure system combining UV photoinitiators with thermal peroxide initiators to ensure complete cure in shadow areas — a common challenge in 3D coating applications on molded MDF and engineered wood products.

Arkema's R&D team found that commercially available Benzoyl Peroxide (BPO) and tert-Butyl Peroxybenzoate (TBPB) showed inconsistent decomposition profiles when used alongside UV photoinitiators. The interaction between residual impurities in the peroxide and the UV system caused yellowing and reduced coating transparency, limiting their application in clear-coat formulations.

The Solution

Do Sender Chemicals supplied custom-purified BPO (CAS 94-36-0) and TBPB (CAS 614-45-9) with:

• Ultra-low chloride content (<10 ppm) to prevent photoinitiator poisoning
• Controlled water content (<0.2% for BPO paste; <0.05% for TBPB liquid)
• Particle size distribution D50 = 8–12 μm for BPO to ensure rapid dissolution in acrylate monomers
• Dedicated phlegmatizer options (DIDP, DOP, silicone oil) matched to Arkema's specific resin systems

The Results

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Enhancing Tire Vulcanization with Thiuram Accelerator TMTD

Goodyear's Asia-Pacific plants adopted Do Sender's TMTD, delivering faster cure, improved tensile properties, and superior heat-aging resistance in passenger car tire tread compounds.

The Challenge

The Goodyear Tire & Rubber Company's Pulandian (Dalian) manufacturing facility — one of its largest production bases in Asia-Pacific — was targeting a 10% reduction in vulcanization cycle time for its passenger car radial (PCR) tire production. The facility produces over 5 million tires annually, and even a 30-second reduction per cure cycle translates to substantial throughput gains.

Goodyear's existing TMTD (Tetramethylthiuram Disulfide) supplier was unable to maintain particle size consistency — with D97 values ranging from 150 to 280 μm across lots. This variability led to uneven accelerator dispersion in the rubber matrix, causing localized over-cure and under-cure zones that compromised tire uniformity and high-speed durability.

The Solution

Do Sender Chemicals delivered premium TMTD (CAS 137-26-8) produced via optimized amine-carbon disulfide synthesis followed by controlled oxidation, achieving:

• 99.0% minimum purity (HPLC), melting point 146–148°C (tight range)
• Consistent particle size D97 <100 μm with oil-coated (1.5%) powder form for dust-free handling
• Low free amine content (<0.1%) to eliminate nitrosamine precursor risk
• Compatibility testing with Goodyear's NR/BR/SBR tread formulations completed in our application lab

The Results

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Advancing PU System Performance with Specialty Polymer Agents

Wanhua Chemical integrated Do Sender's TMPTMA and TAIC co-agents into advanced PU formulations, achieving superior crosslink density and chemical resistance.

The Challenge

万华化学 (Wanhua Chemical Group), the world's largest MDI producer and a Fortune Global 500 company headquartered in Yantai, Shandong — just 300 km from Do Sender's Zibo manufacturing base — was developing next-generation high-performance polyurethane elastomers for wind turbine blade coatings and offshore pipeline insulation. These demanding applications required PU systems with exceptional crosslink density, hydrolytic stability, and chemical resistance against salt spray and hydrocarbon exposure.

Wanhua's R&D team found that commercially available acrylate co-agents showed inhibitor levels that interfered with the PU curing kinetics, causing incomplete cure at the elastomer surface (tacky surface defect). The team required co-agents with controlled inhibitor content and documented reactivity profiles for their patent-pending PU-acrylate hybrid system.

The Solution

As a Shandong-based neighbor, Do Sender Chemicals provided rapid-response technical collaboration, supplying:

• Trimethylolpropane Trimethacrylate (TMPTMA, CAS 3290-92-4) with MEHQ inhibitor precisely controlled at 100 ± 15 ppm — low enough for fast cure, high enough for storage stability
• Triallyl Isocyanurate (TAIC, CAS 1025-15-6) with 99.5%+ purity for high-temperature PU applications
• 24-hour sample delivery for formulation screening (enabled by proximity)
• Joint DSC and DMA characterization of cured PU networks at Wanhua's central R&D lab

The Results

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High-Pressure LDPE Reactor Optimization with Organic Peroxide Initiators

Sinopec's 300 kt/a LDPE plant in Maoming achieved record continuous operation cycles using Do Sender's TBPP and TBPEH peroxide initiators.

The Challenge

中国石化 (Sinopec), Asia's largest oil refiner and petrochemical producer, operates a 300,000 metric ton per annum LDPE (low-density polyethylene) unit in Maoming using LyondellBasell's Lupotech T^® high-pressure tubular reactor technology. The process operates at 2,200–3,000 bar and 160–300°C, requiring precisely metered organic peroxide initiator injection at multiple points along the reactor to control the free-radical polymerization of ethylene.

The plant experienced unplanned reactor shutdowns every 35–40 days due to initiator decomposition residue build-up (fouling) in the injection nozzles. Each shutdown cost an estimated $1.2 million in lost production. The peroxide initiator supplier at the time could not provide product with sufficiently low non-volatile residue content.

The Solution

Do Sender Chemicals qualified as an alternative supplier for two critical peroxide grades:

• TBPP (tert-Butyl Peroxypivalate, CAS 927-07-1) — low-temperature initiator for the front reactor zones (decomposition at 55–75°C)
• TBPEH (tert-Butyl Peroxy-2-ethylhexanoate, CAS 3006-82-4) — mid-temperature initiator for the middle zones (decomposition at 75–95°C)
• Non-volatile residue <0.01% (verified by thermogravimetric analysis per lot)
• Isododecane solution at 25–50% active content with precisely controlled viscosity
• Cold-chain logistics (−15°C) for TBPP from Zibo to Maoming with real-time temperature monitoring
• Six-month shelf-life guarantee with monthly active oxygen titration verification

The Results