What is the latest technology to produce Filler Masterbatch?

Highly-filled masterbatch contains more than 50 % by weight of fillers that are dispersed in a polymer matrix. Different process set-ups are possible depending on the type and amount of filler. The most common fillers include calcium carbonate or talcum. There are two main reasons why CaCO₃ is used in plastic: it acts as a functional filler or mineral modifier (e.g. to produce breathable films) or it is used to reduce the costs of the compound. What is important when using CaCO₃ is its very good incorporation into the polymer matrix. Coated CaCO₃ types are the most suitable. At MASCOM GLOBAL, we use uncoated CaCO3 types to control the quality of CaCO3 with the right amount of acid and assure the surface coating adjusts the surface tension of the mineral to that of the polymer, greatly facilitating its incorporation and dispersion.

There are two main reasons why CaCO₃ is used in plastic: it acts as a functional filler or mineral modifier (e.g. to produce breathable films) or it is used to reduce the costs of the compound. What is important when using CaCO₃ is its very good incorporation in the polymer matrix. Coated CaCO₃ types are the most suitable because the surface coating adjusts the surface tension of the mineral to that of the polymer, greatly facilitating its incorporation and dispersion.

1. Advantages of CaCO3 Filler Masterbatch for each application in plastic industries:

Filler masterbatch are used in injection, blow-moulding, film(One layer or Multiple layer), sheet and tapes applications. They offer the following advantages:

1.1 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 masterbatch in injection & blow-moulding applications can be up to 50 %, however, most usual levels are between 5-30 %.

1.2 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 masterbatch in film applications is 2-20 %.

1.3 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 masterbatchin tapes is 3-8 %.

1.4 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 adue to its excellent cold resistance
• Usual addition rate of Filler masterbatch in tapes is 5-30 %.

2. How to produce Filler Masterbatch?

2.1 Feeding System

• There two feeding system:
  • Volumetric feeding system
  Weight the raw material separately according to the formula Then put all the material into high speed mixer for 5~10minutes mixing Discharge the material into spiral loader Loading the material into the hopper of volumetric feeder
  • Loss-in-weight feeding system (automatically and higher accuracy)
  Put the raw material into each tank on the ground. Vacuum loader will convey each component into the storing silo. The raw material will fall into the loss-in-weight feeder automatically. The feeding system will feed the material separately into extruder according to your formula setting one the HMI.

2.2 Technical Specifications of Extruder

• Twin Screw Extruder
• Triple Screw Extruder

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