So-called plastic masterbatch for easy operation, is the granules or powder fiiled and mixed with resin. Main content of filling masterbatch is the filler, which is mainly applied for PP or PE processing and we also called it PP or PE filling masterbatch.
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Advantage
Firstly, manufacturers choose filling masterbatch for cutting cost.
Secondly, filling masterbatch can decrease shrinkage ration. For example, since large shrinkage ration performed by PP, dent may appear on the surface of product when producing good with high thickness, which influences the appearance of product.
Thirdly, filling masterbatch can increase the ration. This reason, however, does not approved by consumers, because it another kind of way to cut cost.
Fourthly, filling masterbatch is able to strength hardness. It is common that many factories use talcum filling for strength the hardness with 20% increase.
Disadvantage
Compounds
Filling masterbatch is composed of 3 parts as resin, fillers and additives. Fillers account for the largest percentage reaching 90%.
Filler: the main filler can be heavy CaCO3，talcum, kaolin calcium powder and other inorganic fillers. Granules diameter and distribution are the important standards. Generally, the smaller diameter is, the better filler effect takes. Besides, filling result is also influenced by distribution. That is to say, since the distribution is more and more difficult with the diameter becoming smaller and smialler, the price will be higher and higher.
Resin: performance and cost of filling masterbatch is depended on resin. According to application, the content of resin can be 10%~20%. Media resin should be compatible with foundation filling resin. From this view, general resin usually use foundation resin. Besides, melting point and liquidity should be considered. Nowadays, PE and PP have been used widely.
Additives: additives can be divided into dispersing agent and surface treating agent. Dispersing agent takes the performance of improving liquidity, which shows benefit on resin distributing. General dispersing agent can be white oil, paraffin, tissuemat, coupling reagent, stearic acid and so on.
Processing Craft
Processing craft and related equipment has been developed with the changing of resin.
Resin for the first generation masterbatch (APP) adopts domestic Processing craft: kneading→open milling→water pelletizing. And the machine can be kneader, open miller and plate pelletizer.
Resin for the second generation masterbatch is LDPE with masterbatch produced called PEP masterbatch. For reaching high need, this craft need sing screw extruder with lage L/D, high mixing capacity and special design.
The third generation masterbatch, PPM masterbatch, uses PP powder as the resin. The result will be better if using mixture of PP and PE as the design. Product can not only guarantee the feature and application scope of PPM, but also can be cut by air cooling face cutting, which improves producing efficiency and cutting raw material cost. It is the best if using twin screw extruder as the processing equipment, which take the performance of continuous producing, stable quality, high producing efficiency, low consumption, low labor intensity and better operation environment.
Filler masterbatch refers to the granules and powders obtained by mixing and kneading various additives and fillers with a small amount of carrier resin in the process of plastic processing and molding for the convenience of operation. The main component of filler masterbatch is filler, which is mainly used for the processing and molding of polyolefins (polyethylene and polypropylene), and is also called polyolefin filler masterbatch.
Advantages of Filler Masterbatch
First, it is to reduce costs, which is the most common reason for manufacturers to choose.
Second, it is to reduce the shrinkage rate of products. Many manufacturers choose this performance. For example, PP has a large shrinkage rate. When making a product with reinforced ribs and thick walls, shrinkage marks will generally appear on the surface, affecting the aesthetics of the product. Adding fillers can effectively reduce the shrinkage rate and greatly improve the flatness of the product surface.
Third, it is to increase the specific gravity. There are relatively few manufacturers who choose this reason, especially the products may be sold by weight. In fact, this is also a disguised way to reduce costs.
Fourth, it is to increase the hardness of the product. Generally, such manufacturers recommend the use of talcum powder filling masterbatch, which can increase the hardness by about 20%. There are still quite a few such manufacturers.
Disadvantages of Filler Masterbatch
First, it affects the product quality, mainly toughness.
Second, it increases the specific gravity of the product.
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Third, it affects the color of the product. Even if it is a transparent filler masterbatch, it can more or less affect the transparency. The more you add, the greater the impact, and the thicker the product, the greater the impact.
That’s basically it. It mainly depends on the product to choose the filler masterbatch.
Composition of filler masterbatch
Polyolefin filler masterbatch is composed of three parts: carrier resin, filler and various additives, among which filler accounts for the main component, up to 90%.
Filler: The filler used in polyolefin filler masterbatch is mainly heavy calcium carbonate, followed by inorganic fillers such as talcum powder, kaolin, and calcium powder. For any inorganic filler, particle size and particle size distribution are important technical indicators. Generally, the smaller the particle size and the narrower the distribution, the better the filling effect. In addition, the filling effect is also related to dispersibility. The smaller the particle size, the more difficult it is to disperse and the higher the price.
Carrier resin: The performance and cost of polyolefin filler masterbatch mainly depend on the carrier resin. Usually, depending on the purpose of the masterbatch, the carrier resin generally contains 10%~20%. The carrier resin used in polyolefin filler masterbatch should have good compatibility with the plastic matrix resin to be filled. From this aspect, it is best to use the matrix resin as the general carrier resin. In addition, when selecting the carrier of the filler masterbatch, its melting point and melt fluidity should also be considered. The melting point of the carrier resin should not be higher than that of the matrix resin.
Additives: The additives used in polyolefin filler masterbatch are mainly dispersants and surface treatment agents. The function of dispersants is to improve the processing fluidity of masterbatch and facilitate a more uniform dispersion of masterbatch in the matrix resin. Commonly used dispersants include: white oil, paraffin, polyethylene wax, coupling agent and stearic acid.
Filler masterbatch processing technology
The processing technology and related equipment of polyolefin filler masterbatch have also changed with the continuous change of carrier resin.
The carrier resin used in the first generation of polyolefin filler masterbatch (APP masterbatch) is domestic random polypropylene (actually a by-product of polypropylene production). The processing technology is: mixing-opening and pulling-water cooling pelletizing. It is intermittent production, and the equipment used includes internal mixer, open mixer and flat pelletizer.
The second generation of polyolefin filler masterbatch uses LDPE (1F7B) as the carrier resin, and the masterbatch produced is called PEP masterbatch. This process must use a specially designed single-screw extruder with a large aspect ratio and high mixing performance to achieve better results.
The filler masterbatch with polypropylene powder as the carrier, that is, PPM masterbatch, is called the third generation of filler masterbatch in my country. Generally, the method of using a blend of polypropylene and polyethylene as the carrier resin will have a good effect. The product not only maintains the characteristics and scope of use of PPM masterbatch, but also can use the die surface hot cutting and air cooling process, which improves production efficiency and reduces the cost of raw materials.
The best processing equipment for making filler masterbatch is a co-rotating twin-screw extruder. The advantages of this machine are continuous production, stable quality, high production efficiency, low energy consumption, low labor intensity for workers and good operating environment.
Recommended addition amount of filler masterbatch in application products
Blown film PE (agricultural film, ground film, co-extruded film, civil film) --8%~10%.
Disposable lunch boxes, milk and yogurt boxes, strapping PP --30~60%.
Cast film, food packaging film, garbage bags, woven bags, shopping bags-- 20~50%.
Extrusion molding, hollow molding LDPE --10~40%.
Machine/hand strapping tape, self-adhesive coating, paper coating, injection molding LDPE-- 10~40%.
Foam sheets, foam products PP-- 20-30%, PE-- 15~30%.
Hollow blow molding products, oil drums, plastic barrels, plastic bottles HDPE-- 10~40%, PP-- 20~40%.
Plastic trays, plastic basins, switch boxes, plastic toys, cosmetic boxes HDPE 10~30%, PP----20~30%.
Plastic curtains, plastic pipes, sheets, and table mats PS---15~30%, ABS----10~25%.
The above are some reference addition ratios for conventional products. The specific ratios depend on product requirements and the quality of the filling masterbatch.
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