Custom Chemical Formulation
Built Around Your Performance Targets
SantoTolling® develops new specialty chemical formulations and reformulates existing ones for cost, supply, regulatory or performance reasons. Because the same campus in Spartanburg, South Carolina also synthesizes, blends and packages, every formula is developed with commercial production in mind.
Up to 1.2 Billion Pounds
Annually Produced & Supplied worldwide1
66-Acre Facility
Over a Dozen Specialized Buildings
19 Reactors, 33 Vessels,
67 Tanks & More
Certified Quality
ISO 9001:2015 · ChemStewards · EPA & FIFRA registered · Kosher · Halal
WHAT IS CUSTOM FORMULATION DEVELOPMENT?
A Formula That Works in the Lab and in the Plant
Custom formulation development is the work of designing a chemical product's recipe, including its raw materials, ratios and processing steps, so it meets defined performance, cost and regulatory targets and can be made consistently at commercial scale.
A formula that performs well in a beaker can still fail in production. Raw materials may be hard to source at volume, the order of addition may not hold up in a large tank, or the cost may not work at scale. Developing with the manufacturing team at the table avoids those surprises. At SantoTolling, development connects directly to pilot plant & scale-up, chemical synthesis and chemical blending on the same campus, so a finished formula can move into production without changing partners.
WHY DEVELOP OR REFORMULATE
The Problems Formulation Work Solves
Most formulation projects start with one of these. If yours does, we’ve likely worked through something similar.
A New Product Launch
You know what the product needs to do but don’t have a formula yet, or have a lab version that isn’t ready for production.
A Raw Material Is Gone
A supplier discontinued an ingredient or supply has become unreliable, and the product has to keep shipping.
Costs Need to Come Down
Raw material prices have moved and margins are thin. The formula needs to hit the same spec at a lower cost.
A Regulation Changed
An ingredient is now restricted, or a customer requires a lower-VOC or substance-free version of your product.
Performance Falls Short
Customers need better stability, wetting, corrosion protection or temperature range than the current formula delivers.
A Market Needs Certification
New customers require Kosher or Halal certification, or product made at an EPA and FIFRA registered site.
WHAT WE FORMULATE
Specialty Fluids and Formulations
Additives
Corrosion inhibitors, dispersants, defoamers
Surfactants
Emulsifiers, wetting agents, specialty surfactants
Polymers
Thickeners, flocculants, functional polymers
Lubricants
Industrial lubricants, metalworking fluids, greases
Pesticides
Formulated products and adjuvants
Custom Blends
Application-specific, proprietary formulations
TWO PROGRAMS. ONE CAMPUS.
New Formulation or Reformulation
The difference is whether you’re starting from a target or from a product you already sell. Both programs use the same lab, team and production path.
OPTION 1
New Formulation Development
Your Target. Our Lab. A Formula Ready to Scale.
You define what the product must do, where it will be used and what it should cost. We develop and test formulas against those targets until one is ready for pilot and production.
- Performance, cost and regulatory targets set up front
- Raw material selection with supply at volume in mind
- Rounds of lab samples tested against your targets
- Custom ingredients synthesized in our reactors if needed
- Direct path to pilot batches and commercial production
Best for: companies launching a new product or turning a lab concept into something they can sell.
OPTION 2
Reformulation
Your Product. A Better Formula. No Gap in Supply.
You already sell the product, but something has to change. We rework the formula to solve the problem and test it against the original so your customers see the same or better results.
- Replacement of discontinued or restricted ingredients
- Cost reduction while holding the spec
- Performance improvements for new customer needs
- Side-by-side testing against the current product
- Production of the new formula on the same campus
Best for: companies facing a supply, cost, regulatory or performance problem with a product already on the market.
Already have a final formula? See contract chemical manufacturing.
WHY SANTOTOLLING
What You Gain When We Develop With You
A formulation partner that also manufactures brings a different set of priorities to the bench. Here’s what comes with a SantoTolling program.
Developed With Production in Mind
The team that develops your formula works alongside the team that will make it, so it’s built for real tanks and reactors.
Custom Ingredients In-House
When no off-the-shelf raw material fits, we can synthesize one in our own reactors instead of settling for a compromise.
Analytical Depth
A 24/7 lab with NMR, GC-MS, LC-MS, FTIR, viscosity, surface tension and particle size testing measures every sample.
Decades of Specialty Experience
Formulation work draws on decades of specialty chemical manufacturing, including SantoLubes®’ own product lines.
Lab to Commercial on One Campus
Lab samples, pilot batches and production runs happen in one place, with no tech transfer between sites.
Quality & Compliance
ISO 9001:2015, ChemStewards, EPA and FIFRA registration, and Kosher and Halal certified products.
Side by Side
New Formulation vs. Reformulation
Use this to decide which program fits your project.
| Option 1New Formulation | Option 2Reformulation | |
|---|---|---|
| Starting point | Performance targets or a lab concept | A product already on the market |
| Main goal | A formula ready for scale-up | Fix a supply, cost, regulatory or performance problem |
| What you provide | End use, targets, cost goals, requirements | Current formula or product, plus what must change |
| Testing | Against your performance targets | Side by side with the current product |
| Ownership | Set in writing before work begins | Set in writing before work begins |
| Next step | Pilot batches, then production | Production of the new formula |
HOW IT WORKS
From Performance Target to Production Formula
Every formulation program follows the same five steps, so you know what happens next and who owns it.
Consultation & NDA
We sign a confidentiality agreement and agree on ownership terms before any technical details are shared.
Define the Targets
Performance, end use, cost, regulatory needs and packaging, written down and agreed.
Develop & Test
Rounds of lab samples, tested by our 24/7 lab and reviewed with you.
Pilot & Approve
Pilot batches confirm the formula at scale and give you material for customer approval.
Commercial Production
Full-scale production, packaging and delivery from the same campus.
Capabilities Behind Every Formula
Lab, Chemistry and Production in One Place
Formulation programs draw on the same lab and equipment that support SantoLubes® Manufacturing’s own product lines.
- GC, GC-MS, LC-MS, NMR, FTIR/IR and UV-Vis spectroscopy
- Viscosity, surface tension and particle size analysis
- Karl Fischer water analysis and potentiometric and wet titration
- Synthesis: esterification, alkoxylation, amidation, quaternization and more
- Blending, dispersion, homogenizing and aqueous spray drying
- Pilot reactors from 300 gal and commercial reactors to 12,000 gal
24/7
Analytical lab
19 Reactors
Custom ingredients
-15° to 300°C
Temperature range
SantoTolling provides other useful features:
Formulation Lab
Samples developed and tested on site.
Advanced Analytics
NMR, GC-MS, LC-MS, FTIR and more.
Production Ready
Scale into reactors and tanks on the same campus.
Industries We Serve
Formulations for Demanding Markets
Agriculture
Custom synthesis and blending of crop protection formulations and specialty agrochemical intermediates.
Aviation
Contract manufacturing for aerospace-grade fluids and specialty chemical intermediates under strict quality control.
Automotive
Scaled production of specialty fluids, additives, and coatings for OEM and aftermarket supply chains.
Electronics
Precision synthesis and blending for electronics-grade cleaning agents, coatings, and connector treatments.
Lubricants
Full-scale toll manufacturing of synthetic lubricants and base oils, including SantoLubes’ own PPE product line.
Marine
Custom formulation and blending of corrosion-resistant coatings and lubricants for marine and offshore equipment.
Paint & Coatings
Spray drying, blending, and packaging for pigment concentrates, resins, and specialty coating formulations.
Oil & Gas
Contract synthesis and blending of specialty additives and fluids for upstream and midstream operations.
FAQ
Straight answers to what buyers ask us most before a formulation project.
What is custom formulation development?
Custom formulation development is the work of designing a chemical product's recipe, including its raw materials, ratios and processing steps, so it meets defined performance, cost and regulatory targets and can be made consistently at commercial scale. SantoTolling develops formulations for specialty fluids, additives, surfactants, polymers, lubricants and agricultural products at its campus in Spartanburg, South Carolina.
Why do companies reformulate an existing product?
Companies reformulate when a raw material is discontinued or hard to source, when costs need to come down, when a regulation restricts an ingredient, when performance falls short of customer needs, or when a market requires certifications such as Kosher or Halal. Reformulation keeps the product on the market while fixing the underlying problem.
Who owns a formulation SantoTolling develops?
Ownership of any formulation SantoTolling develops is set in writing in your agreement before development begins. Every project starts under a confidentiality agreement, and existing formulas you bring to SantoTolling remain yours.
What information should I provide to start a formulation project?
The most useful starting points are the performance targets the product must meet, the end use and operating conditions, target cost, regulatory or certification requirements, and, for reformulation, the current formula or a product you want to match. Safety data sheets and any test methods your customers use also help.
How does SantoTolling test formulation samples?
SantoTolling's 24/7 analytical lab tests development samples with GC, GC-MS, LC-MS, NMR, FTIR and UV-Vis, along with viscosity, surface tension, particle size, Karl Fischer water analysis and titration. Results are compared against your targets at each round of development.
Can SantoTolling replace a discontinued or restricted ingredient?
Yes. Replacing an ingredient that is discontinued, short in supply or restricted by regulation is one of the most common reformulation projects. SantoTolling can source alternative raw materials or synthesize a custom ingredient in its own reactors, then test the new formula against the original.
Can SantoTolling manufacture the formulation after development?
Yes. Formulations developed at SantoTolling can move directly into pilot batches and commercial production on the same campus, using 19 reactors, 33 vessels and 67 tanks, with blending, spray drying and packaging available on site.
How do I start a formulation development project with SantoTolling?
Start with a free consultation by calling (864) 585-3661 or emailing sales@santolubes.com. Share your performance targets, end use, current formula if reformulating, target volume and timeline, and an engineer will follow up to scope the project.
