In our second behind-the-scenes look at KRYSTALFLEX® TPU, Zarif Farhana Mohd Aris, Technical Manager at Huntsman, talks us through the work undertaken at the corporation’s Elastomers’ technical center in Derry, New Hampshire. She explains why the site is pivotal to the continued success of the technology in safety glazing applications and how the team supports customers worldwide using interlayer films based on its TPU (thermoplastic polyurethane) chemistry.
When did the Derry site become involved in the development of KRYSTALFLEX® TPU?
Our Derry technical center was established 25 years ago and has been core to KRYSTALFLEX® TPU innovation ever since. Today, the site is a technical hub for TPU development, housing both our Technology & Innovation (T&I) and Technical Service functions. Derry is the center of excellence for KRYSTALFLEX® TPU with the team also providing comprehensive technical support to customers across a range of application areas.
How has the focus of work at Derry evolved as applications for KRYSTALFLEX® TPU have expanded?
In the early days, the Derry team focused on foundational chemistries – building on the excellent work that preceded them. Over the years, that has expanded into application-focused innovation, reflecting the growth of KRYSTALFLEX® TPU into more demanding end uses across architecture, transportation, security and defense. In parallel, there has been an increased emphasis on improving the durability, optical clarity, and adhesion performance of resulting films in line with customer requirements, including meeting stringent industry specifications.
When it comes to R&D, what are the key steps involved in developing a new KRYSTALFLEX® TPU grade or formulation?
The development of new KRYSTALFLEX® TPU grades typically follows the same process. We begin by defining precise application requirements; pinpointing target end-use performance parameters spanning durability, optical clarity, adhesion and regulatory needs. Once we’ve agreed the scope, we start formulation design - selecting the base polymer chemistry and deciding which additives we’ll use to achieve the desired results. When we are happy with the formulation, we move into lab pilot scale development – producing and screening candidate resins and films on a small scale.
Once resins and films are available for testing, we evaluate their performance in laminate constructions. Here we set our sights on adhesion, optics, and durability – looking at characteristics including peel strength and accelerated aging. When we are confident we have created a product that satisfies all the right parameters, we move on to process validation, defining how to take production from pilot scale to full manufacturability to ensure reproducibility. In parallel, customer validation kicks off to qualify the product. At this point, we continue to work closely with our customers, taking on any feedback they give us and refining the formulation as required. The final step is to begin the transition to full-scale manufacturing.
What testing capabilities do you have at Derry?
On site we have fully integrated testing and application labs that support the end-to-end development of interlayer films. That work begins with equipment and processes that help us create initial resins and culminates in tests that explore the performance of full laminate systems under simulated real-world conditions. Specific capabilities include:
How closely do lab-scale processes simulate real-world lamination and end-use conditions?
Our processes are designed to replicate real-world lamination and end-use conditions as closely as possible. The mix of equipment we have in-house and the approach our team has adopted ensures a high correlation between lab results and full-scale production performance, which enables reliable scale-up and customer validation.
How does the team ensure new developments meet global regulatory requirements?
Early alignment is key. Our R&D, quality, regulatory, and manufacturing teams work closely together with customers, from the outset, to identify requirements and potential risks. The team follows an integrated, validation-driven approach throughout development and scale-up, supported by stage-gate reviews that assess compliance, quality, technical feasibility, and documentation before projects progress. This structured approach helps ensure products meet relevant regulatory standards, ultimately supporting the move to mass manufacture and market introduction.
How is sustainability incorporated into KRYSTALFLEX® TPU and your R&D and innovation work?
Sustainability is embedded throughout the KRYSTALFLEX® R&D process, with a strong emphasis on improving efficiency, reducing waste, and enhancing long-term product performance. We are continually looking for ways to optimize manufacturing processes and refine our formulations to reduce the unnecessary consumption of raw materials and energy while maintaining high quality and safety standards. The other great thing about KRYSTALFLEX® TPU is that the resulting films are designed to extend the service life, structural integrity and appearance of safety glazing. In doing so, KRYSTALFLEX® TPU is actively helping to reduce the frequency of glass replacement and the associated environmental impact that comes with that. By enabling the creation of longer-lasting glazing systems, this innovative product range is supporting lower lifecycle resource consumption and customers' own sustainability objectives through improved product longevity.
How does the Derry R&D team collaborate with the teams at Huntsman’s KRYSTALFLEX® TPU manufacturing site in Ringwood?
Obviously, there is a very close working relationship. Again, early alignment and continual communication is vital. At the beginning of a project, our T&I associates work with manufacturing to ensure new formulations are designed with processability in mind. At the pilot-scale validation stage, we cooperate to ensure materials are developed and tested in line with real-world production conditions. When it comes to scale up – there is a careful transfer of knowledge with teams sharing detailed process parameters, learnings and troubleshooting advice. This is underpinned by an ongoing technical feedback loop that enables the refinement of formulations and processes based on manufacturing performance. Add in an integrated approach to customer support and it’s a winning combination that ensures consistent product quality and qualification.
For more information or to discuss a project with the KRYSTALFLEX® TPU team, please contact: Elastomers_Americas@huntsman.com
Disclaimer
While all the information in this publication is to the best of our knowledge and belief accurate at the date of publication, NOTHING HEREIN IS TO BE CONSTRUCTED AS A WARRANTY, EXPRESS OR OTHERWISE. Huntsman warrants only that its products meet the agreed specifications. Typical properties, where stated, are to be considered as representative of current production and should not be treated as specifications. In all cases, it is the responsibility of the user to determine the applicability of such information and the suitability of any product for its own particular purpose. The sale of products referred to in this publication is subject to the general terms and conditions of sale of Huntsman International LLC or of its affiliated companies.
KRYSTALFLEX® is a registered trademark of Huntsman International LLC or an affiliate thereof in one or more, but not all, countries. © 2026. Huntsman Corporation or an affiliate thereof. All rights reserved.
