Applications
Color and filler masterbatches
Color and filler masterbatches compounding is one of the main applications for co-rotating twin screw extruders.
There are 3 main types of color masterbatches:
1. Mono color masterbatches or SPC (single pigment concentrate): polymer compounding with one single pigment and mostly without the wax and additives;
2. Tailor-made masterbatches or custom coloring: mixing different Mono color masterbatch pellets to get the color the customer wants;
3) Customized masterbatches: mix polymer and several pigment and additives.
Applications
Fiber ( Carpet, Textiles, Upholstery, etc . )
Film ( Shopping bags, casting film, multiple layer film, etc . )
Blow Molding ( Medical & Cosmetic container, Lubricant & Paint container, etc . )
Extrusion Molding ( Sheet, Pipe, Wire & Cable, etc . )
Injection Molding ( Automotive, Electronic, Construction, House wares, Furniture, Toys, etc . )
Experience for Special Applications
1. PP Base Mono and Tailor-Made Masterbatch for BCF&CF
There are more than 20,000 color for PP base carpet, BCF&CF yarn. So it is better to make Mono Color Masterbatch first, then produce tailor-made masterbatches for the final product.
For mono color masterbatches:
One extruder for one type of color (such as from light red to dark red).
Most of pigments need premix process for better dispersion. Need separate room and dust collecting system for mixer. And PP in powder form is necessary for one time compounding. You just need PP in pellet form, if you do twice compounding process and the first time compounding with split feeding system.
It is better to use the triple screw extruder for the better dispersion and more output, due to 40% extra free volume and one more screw for mixing.
For tailor-made masterbatches:
It is clean production with high degree of automation.
Just need high torque and high screw speed for more output.
Fast cleaning type strand die plat for change of color, without heater, just need 2 minutes to change the die plate for different color.
two types of processes:
1) Mixer + Twin Screw Extruder + Water Cooling Strand Pelletizing
2) Loss-in-weight Feeding + Twin Screw Extruder + Water Cooling Strand Pelletizing
2. PBT Base Color Masterbatch for POY&FDY
PBT has less viscosity than PP, so it need special screw design
PBT in powder form is necessary for premixing process, and need separate room and dust collecting system for mixer
Strong vacuum system for removing moisture and minimum IV drop
It is better to use the Triple Screw Extruder for the better dispersion and more output
The clearance between twin screws & the clearance between screw and barrel should be minimum. So small extruder is better
3. PET Base Color Masterbatch for PSF
PSF is always made from recycle PET
The dispersion inquiry is less than the Color Masterbatch for POY
The most popular formula: bottle flakes (with the size less than 10mm) compounding with 25-40% carbon black powder by split feeding and water cooling strand pelletizing
Split feeding by two loss-in-weight feeder, with minimum dust pollution
Prefer to use Under Water Strand Pelleting System for more output: the strands go into the pelletizer automatically by the water flow, even the strands break during changing the filter. So there will be almost no waste during the manufacturing process.
4. Special-Effect Masterbatch
Effect pigments are used in the decorative area of plastics as well as in the functional area and have become an essential part of modern product designs. Social developments and associated colour trends are constantly being researched. Selected colours are refined by special effect pigments and make the end product unique and worthy.
The main type of Special Effect Masterbatch:
· Pearlescent effect
· Metallic effect
· Fluorescent effect
· Marble/Granite effect
· Phosphorescent (Glow in Dark)
· Fragrance
The Effect pigments have a layer structure and with particle size up to 170 micron. It is sensitive to shearing, so the best process is thus split-feed — feeding into the fifth barrel of extruder by side force feeder
Need special kneading elements with more effect of distribution than dispersion
Need less shearing force but more mixing
5. Micro Pellets Color Masterbatch
Micro pellets are pellets with a size of ≤ 1mm, made by using underwater pelletizing system
Advantages
Due to their small particle size micro pellets spread much more uniform and distribute finer as the conventional raw polymer. In contrast, conventional master batches with “normal” sized pellets must be used in higher dosages to achieve the desired effect. Therefore, using micro pellets, less colorants are required, which lead to significant cost savings as master batches are extremely expensive compared to crude polymers, Master batches in shape of micro pellets are easier to handle, better to dose and dust free.
The barrel can be opened in minutes. This makes product changeover, maintenance and research fast and easy. Both screws and barrels are designed using the building block principle. The screw configuration, barrel setup, feeding and venting, screen changing, way of pelletizing and process requirements, in consideration of the machine’s versatility in other general applications.
Applications:
Various plastic inorganic filler, polymer blending (plastic alloy), plastic coloring, ect
Various plastic inorganic filler, polymer blending (plastic alloy), plastic coloring, ect
Various engineering plastic reinforcement of glass fiber, flame-retartant pellets
Various antibacterial, insulated, toughening materials for specific uses
Light/biology degradable film materials, amylum degradable plastics and multi-functional anti-fog film materials, etc.
Specific material for automobiles and household appliance and cable materials, etc
Themoplastic elastomers, such as TPR, TPE, and SBS, etc
Regenerate pellets for PVC airproof pieces, thermo-soluble glue, etc
FILLER masterbatches are used in injection, blow-moulding, film(One layer or Multiple layer), sheet and tapes applications. They offer the following advantages:
a) Injection & blow-moulding
Lower raw materials cost, as they are usually more economic than polymer resins
Increased output due to faster mould cooling
Reduction of colour masterbatch requirement
Higher resistance to heat deflection, higher rigidity and stiffness
Improved dimensional stability, weldability and printability
Addition rate of FILLER masterbatches in injection & blow-moulding applications can be up to 50 %, however, most usual levels are between 5-30 %.
b) Film, sheet, sacks, bags, raffia
Lower raw materials cost, as they are usually more economic than polymer resins
Reduction of colour masterbatch requirement
Higher stiffness, paper-like effect
Improved weldability and printability
Improved anti-blocking properties
Better bubble stability
Addition rate of FILLER masterbatches in film applications is 2-20 %.
c) PE & PP tapes
Antifibrillation (also known as anti splitting)
Lower raw materials cost, as they are usually more economic than polymer resins
Reduction of colour masterbatch requirement
Higher stiffness
Improved weldability and printability
Improved anti-blocking properties
Improved weaving ability
Easier processing
Usual addition rate of FILLER masterbatches in tapes is 3-8 %.
d) HDPE & PP Pipe
Replacing expensive white masterbatch with its high white degree
Lower raw materials cost, as they are usually more economic than polymer resins
Higher stiffness
Smooth pipes with lower coefficient of friction to better prevent them from blocking
Being less possible to be brittel in low temperature due to its excellent cold resistance
Usual addition rate of FILLER masterbatches in tapes is 5-30 %.
In the process of compounding , in order to reduce costs, many film, sheet, profile and pipe manufacturers are adding more and more mineral fillers to their material formulations. For compounding processors, increasing filler content is a new challenge. If the screw and the machine are damaged and corroded by the filling products, it will directly affect the normal operation of the equipment, production efficiency and product quality. For such problems, if you only try to increase the grade of the filler in the single-screw extruder, it is not better to disperse the filler. The twin-screw extruder provided by Nanjing Haisi can make the percentage of calcium carbonate up to 85%, therefore, a large proportion of fillers are added to the product, which can save a big amount of resin per year and fully recover the cost of the extruder equipment.
There are 3 main types of color masterbatches:
1. Mono color masterbatches or SPC (single pigment concentrate): polymer compounding with one single pigment and mostly without the wax and additives;
2. Tailor-made masterbatches or custom coloring: mixing different Mono color masterbatch pellets to get the color the customer wants;
3) Customized masterbatches: mix polymer and several pigment and additives.
Applications
Fiber ( Carpet, Textiles, Upholstery, etc . )
Film ( Shopping bags, casting film, multiple layer film, etc . )
Blow Molding ( Medical & Cosmetic container, Lubricant & Paint container, etc . )
Extrusion Molding ( Sheet, Pipe, Wire & Cable, etc . )
Injection Molding ( Automotive, Electronic, Construction, House wares, Furniture, Toys, etc . )
Experience for Special Applications
1. PP Base Mono and Tailor-Made Masterbatch for BCF&CF
There are more than 20,000 color for PP base carpet, BCF&CF yarn. So it is better to make Mono Color Masterbatch first, then produce tailor-made masterbatches for the final product.
For mono color masterbatches:
One extruder for one type of color (such as from light red to dark red).
Most of pigments need premix process for better dispersion. Need separate room and dust collecting system for mixer. And PP in powder form is necessary for one time compounding. You just need PP in pellet form, if you do twice compounding process and the first time compounding with split feeding system.
It is better to use the triple screw extruder for the better dispersion and more output, due to 40% extra free volume and one more screw for mixing.
For tailor-made masterbatches:
It is clean production with high degree of automation.
Just need high torque and high screw speed for more output.
Fast cleaning type strand die plat for change of color, without heater, just need 2 minutes to change the die plate for different color.
two types of processes:
1) Mixer + Twin Screw Extruder + Water Cooling Strand Pelletizing
2) Loss-in-weight Feeding + Twin Screw Extruder + Water Cooling Strand Pelletizing
2. PBT Base Color Masterbatch for POY&FDY
PBT has less viscosity than PP, so it need special screw design
PBT in powder form is necessary for premixing process, and need separate room and dust collecting system for mixer
Strong vacuum system for removing moisture and minimum IV drop
It is better to use the Triple Screw Extruder for the better dispersion and more output
The clearance between twin screws & the clearance between screw and barrel should be minimum. So small extruder is better
3. PET Base Color Masterbatch for PSF
PSF is always made from recycle PET
The dispersion inquiry is less than the Color Masterbatch for POY
The most popular formula: bottle flakes (with the size less than 10mm) compounding with 25-40% carbon black powder by split feeding and water cooling strand pelletizing
Split feeding by two loss-in-weight feeder, with minimum dust pollution
Prefer to use Under Water Strand Pelleting System for more output: the strands go into the pelletizer automatically by the water flow, even the strands break during changing the filter. So there will be almost no waste during the manufacturing process.
4. Special-Effect Masterbatch
Effect pigments are used in the decorative area of plastics as well as in the functional area and have become an essential part of modern product designs. Social developments and associated colour trends are constantly being researched. Selected colours are refined by special effect pigments and make the end product unique and worthy.
The main type of Special Effect Masterbatch:
· Pearlescent effect
· Metallic effect
· Fluorescent effect
· Marble/Granite effect
· Phosphorescent (Glow in Dark)
· Fragrance
The Effect pigments have a layer structure and with particle size up to 170 micron. It is sensitive to shearing, so the best process is thus split-feed — feeding into the fifth barrel of extruder by side force feeder
Need special kneading elements with more effect of distribution than dispersion
Need less shearing force but more mixing
5. Micro Pellets Color Masterbatch
Micro pellets are pellets with a size of ≤ 1mm, made by using underwater pelletizing system
Advantages
Due to their small particle size micro pellets spread much more uniform and distribute finer as the conventional raw polymer. In contrast, conventional master batches with “normal” sized pellets must be used in higher dosages to achieve the desired effect. Therefore, using micro pellets, less colorants are required, which lead to significant cost savings as master batches are extremely expensive compared to crude polymers, Master batches in shape of micro pellets are easier to handle, better to dose and dust free.
The barrel can be opened in minutes. This makes product changeover, maintenance and research fast and easy. Both screws and barrels are designed using the building block principle. The screw configuration, barrel setup, feeding and venting, screen changing, way of pelletizing and process requirements, in consideration of the machine’s versatility in other general applications.
Applications:
Various plastic inorganic filler, polymer blending (plastic alloy), plastic coloring, ect
Various plastic inorganic filler, polymer blending (plastic alloy), plastic coloring, ect
Various engineering plastic reinforcement of glass fiber, flame-retartant pellets
Various antibacterial, insulated, toughening materials for specific uses
Light/biology degradable film materials, amylum degradable plastics and multi-functional anti-fog film materials, etc.
Specific material for automobiles and household appliance and cable materials, etc
Themoplastic elastomers, such as TPR, TPE, and SBS, etc
Regenerate pellets for PVC airproof pieces, thermo-soluble glue, etc
FILLER masterbatches are used in injection, blow-moulding, film(One layer or Multiple layer), sheet and tapes applications. They offer the following advantages:
a) Injection & blow-moulding
Lower raw materials cost, as they are usually more economic than polymer resins
Increased output due to faster mould cooling
Reduction of colour masterbatch requirement
Higher resistance to heat deflection, higher rigidity and stiffness
Improved dimensional stability, weldability and printability
Addition rate of FILLER masterbatches in injection & blow-moulding applications can be up to 50 %, however, most usual levels are between 5-30 %.
b) Film, sheet, sacks, bags, raffia
Lower raw materials cost, as they are usually more economic than polymer resins
Reduction of colour masterbatch requirement
Higher stiffness, paper-like effect
Improved weldability and printability
Improved anti-blocking properties
Better bubble stability
Addition rate of FILLER masterbatches in film applications is 2-20 %.
c) PE & PP tapes
Antifibrillation (also known as anti splitting)
Lower raw materials cost, as they are usually more economic than polymer resins
Reduction of colour masterbatch requirement
Higher stiffness
Improved weldability and printability
Improved anti-blocking properties
Improved weaving ability
Easier processing
Usual addition rate of FILLER masterbatches in tapes is 3-8 %.
d) HDPE & PP Pipe
Replacing expensive white masterbatch with its high white degree
Lower raw materials cost, as they are usually more economic than polymer resins
Higher stiffness
Smooth pipes with lower coefficient of friction to better prevent them from blocking
Being less possible to be brittel in low temperature due to its excellent cold resistance
Usual addition rate of FILLER masterbatches in tapes is 5-30 %.
In the process of compounding , in order to reduce costs, many film, sheet, profile and pipe manufacturers are adding more and more mineral fillers to their material formulations. For compounding processors, increasing filler content is a new challenge. If the screw and the machine are damaged and corroded by the filling products, it will directly affect the normal operation of the equipment, production efficiency and product quality. For such problems, if you only try to increase the grade of the filler in the single-screw extruder, it is not better to disperse the filler. The twin-screw extruder provided by Nanjing Haisi can make the percentage of calcium carbonate up to 85%, therefore, a large proportion of fillers are added to the product, which can save a big amount of resin per year and fully recover the cost of the extruder equipment.
Calcium Carbonate additives, filler masterbatches contain an optimal combination of fine calcium carbonate (CaCO3), titanium dioxide (TiO2), UV stabilizers and antioxidants in the processing of polyolefins.
Hemu Precision Machinery Co., Ltd. © 2021