The plastic products do not have color from the beginning, and additives or pigments are needed in the production process to obtain the desired color. Masterbatch is an additive.
Masterbatch, a solid product (usually plastic, rubber, or elastomer) in which pigments or additives are optimally dispersed in a carrier material at high concentrations. The carrier material is compatible with the main plastic that will be mixed during the molding process so that the final plastic product obtains color or performance from the masterbatch.
Types of Masterbatch
White masterbatch can be used in many different manufacturing processes, such as lamination, coatings, pipes, thermoforming, protective films, fibers and nonwovens, blow molding, and injection molding. The white masterbatch is used to provide transparency and brightness in the final synthetic product and can be composed of 75% titanium dioxide. In the final product, this masterbatch provides the best opacity and maximum whiteness.
Good thermal stability and changeable colors are the two main factors for the masterbatch to become the perfect solution for plastic products. A variety of basic polymer colors (such as ABS, PS, PP, PE, and EVA) are offered. Color masterbatche made of high-grade pigments can be used in various processes, such as insulated cables, injection molding, and blow molding of bottles.
The black masterbatch is a typical monochromatic masterbatch, which is mixed by the batch feeding process. Compared with the above two types of masterbatch, black masterbatch has a higher injection rate and dispersion rate. Chuangbo can provide many raw material manufacturers with professional mixing systems in the black masterbatch compounding process. Black masterbatch is mainly used for film, thick film and sheet extrusion, pipes and irrigation branches, injection molding/blow molding, polyester staple fiber, PET sheet, etc.
The application of additive masterbatch is very wide, as wide as the various additives used and their functions. The masterbatch can achieve specific product attributes or properties. The requirements for raw materials and final products from high loads or aggregation conditions of various additives to shear and temperature-sensitive materials vary widely, so a universal batching system is needed. The system design of Chuangbo extruder can realize the constantly changing requirements in the mixing process through targeted configuration.
The standard additive properties canbeincorporated into plastics include luminescence, anti-skid, anti-blocking, nucleation, whitening agents, flame retardant, UV protection, anti-static, UV protection, anti-blocking, lubricants, etc.
Special Effect Masterbatch
For the consumer market, the differentiation of product design and packaging design has become the industry's highest importance. The rapid development of technology and the accumulation of new exclusive pigments enable us to help the plastics industry market. Special effect masterbatch is not only used in the field of plastic decoration, but also the field of functionality, and has become an important part of modern product design. Special effect masterbatches change the appearance of plastics, usually including glitter, metal, pearlescent, marble, granite.
Filler MB compounding is a special field in the production of masterbatch. If the content in MB is high (sometimes> 80%), the filler is usually in powder form. Filling masterbatch (masterbatch) is calcium carbonate (Caco3)-based filler used in the plastics industry. It is mainly composed of a concentrate of CaCO3 or talc or BaSO4 in a polymer matrix. Filling masterbatch is used to change various properties of basic plastics or plastic polymers, and is widely used in injection molding, blow molding, film (one or more layers), sheet and tape and other fields. Plastic-filled masterbatches are a solution for plastic enterprises to save production costs, and play a role in the anti-burning of the molded lip under higher loads.
Masterbatch processing is very demanding because a high proportion of pigments, additives, or filler materials must be incorporated into the base polymer. Chuangbo can tailor all the process steps from raw material feeding, conveying, melting, dispersion, homogenization, devolatilization, pressure accumulation to filtration, and granulation according to the requirements of the raw material formula. This will give you exact expectations: a compounding extrusion system tailored to your application.
In the pre-mixing process, first of all, all the raw material components of the masterbatch are uniformly mixed in the mixer. Then, usually through a volume feeder, the mixture is fed into a twin-screw extruder for processing.
The quality of the masterbatch depends largely on the previous mixing process. This is why this process step is extremely important: if the premix is not good, for example, if lumps are formed, the failure cannot be corrected during the extrusion process.
The batch feeding process is especially used to produce single pigment and additive masterbatch. In this method, the polymer is fed into the extruder's feed barrel in the form of pellets. The pigment is then slowly fed into the extruder through a twin screw side feeder downstream of the melting zone.
In this masterbatch production method, polymers and possibly small amounts of additives are introduced into the process through the main feed port and then plasticized. The polymer must be 100% melted before the pigment is fed through one or two side fillers.
Advantages of Chuangbo Extruders
• Excellent dispersion
• Large-capacity pigments and additives can be added