A continuous process for incorporating a thermally sensitive additive into
a polymer melt of virgin polymer at a temperature at least 10.degree. C.
below a temperature at which the virgin polymer is typically processed.
The virgin polymer is first processed in an apparatus which extensively
shear-thins the polymer until its normally entangled molecules are
substantially disentangled. This is preferably done in a TekFlow.RTM.
processor. The additive is then added to the resulting modified melt
which is then processed in a high-shear apparatus, e.g. a co-rotating,
twin-screw extruder, but more preferably in a second TekFlow.RTM.
processor. This novel process allows making concentrates having a level
of additive which could not be made to date and yet have the additive
substantially uniformly dispersed. In particular a concentrate of
polypropylene having a 30% by wt concentration of an organoclay in which
the platelets are substantially uniformly dispersed, at least 10% more
strongly intercalated than prior to treatment, and substantially fully
exfoliated, is made with this process.