We have heard a lot about masterbatch products, but do we understand them correctly? Find out more through the article below!
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Masterbatch (MB) is a solid or liquid additive for plastic used for coloring plastics (color masterbatch) or imparting other properties to plastics (additive masterbatch). So, Masterbatch is a concentrated mixture of pigments and/or additives encapsulated during a heat process into a carrier resin which is then cooled and cut into a granular shape. They allow the processor to colour raw polymer economically during the plastics manufacturing process.
The alternatives to using masterbatches are buying a fully compounded material (which may be more expensive and less open to e.g. color variability of the product), or compounding from raw materials on site (which is prone to issues with achieving full dispersion of the colorants and additives, and prone to preparing more material than what is used for the production run).
In comparison with pure pigments, masterbatches require more storage space and their lead times are longer. Another disadvantage is additional exposure of heat (“heat history”) to both the carrier and the additive; this may be important e.g. for marginally thermally stable pigments.
As masterbatches are already premixed compositions, their use alleviates the issues with the additive or colorant clumping or insufficient dispersion. The concentration of the additive in the masterbatch is much higher than in the end-use polymer, but the additive is already properly dispersed in the host resin. In a way their use is similar to uses of ferroalloys for adding alloying elements to steels.
The use of masterbatches allows the factory to keep stock of fewer grades of the polymer, and to buy cheaper natural polymer in bulk. The carrier material of the masterbatch can be based on a wax (universal carrier) or on a specific polymer, identical or compatible with the natural polymer used (polymer-specific).
The usual ratio of masterbatch to the base resin is 1 to 5 percent. Several masterbatches (color and various additives) can use together. The carrier can also double as a plasticizer (common for liquid masterbatches) or a processing aid.
The machines are usually fed with premixed granules of the host polymer and the masterbatch. The final mixing then gets done in the screw and extrusion part of the machine. This is sometimes prone to adverse effects, e.g. separation of the masterbatch and the base material in the machine’s hopper.
1. Weighing
2. Mixing
3. Twin-screw extruding
4. Cutting and cooling
5. Sieving
6. Bagging
The masterbatch can also add directly to the machine’s screw, as a free-flowing solid or in case of a liquid masterbatch by e.g. a peristaltic pump. Such use of liquid masterbatches allows highly accurate dosing and quick change of color between machine runs. Masterbatches can be used in most processes, except rotational molding and Plastisol and other liquid resin systems.
Masterbatch brings many advantages for the final plastic products:
Masterbatch can increase volumetric output (as a result of thermal conductivity & volumetric expansion to temperature). In addition, it has the ability to downgauge due to higher film physical properties.
With the large percentage of CaCO3 powder in component, masterbatch helps manufacturers reduce material cost by using less energy to run the machine due to higher CaCO3 specific heat.
Masterbatch helps plastic improve a lot of physical property such as Higher toughness; Flexural stiffness; Adhesion; Printability
Additive masterbatches modify various properties of the base plastic:
ultraviolet light resistance ; flame retardant; anti-fouling; anti-static; lubrication; anti-slip; corrosion inhibitors for metals packaged in plastic; anti-microbial; anti-oxidants; extrusion aids; phosphorescence; anti-counterfeit; product security
Masterbatch in the following areas:
Blown film & lamination; PP raffia/Yarn; PP non-woven fabric; Blow molding; Injection molding; Thermoformed sheet; HDPE/PP pipe extrusion; Polyester and Nylon yarn
FILLPLAS Masterbatches has many types such as Filler masterbatch, White Masterbatch, Black Masterbatch, and other Color Masterbatch.
In the realm of manufacturing and product design, color is a critical element that significantly influences consumer perception and marketability. From household items to automotive components, the right shade can make a product stand out, convey a brand’s identity, and even affect purchasing decisions. This is where color masterbatch comes into play, offering a versatile and efficient solution for infusing products with vibrant and consistent colors. In this article, we’ll delve into what it is, its properties, and why it’s an excellent choice for manufacturers seeking to enhance their products with a spectrum of hues.
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Color masterbatch is a concentrated mixture of pigments and additives encapsulated in a carrier resin. It is used to impart color to natural polymers during the manufacturing process. This masterbatch is then diluted in the polymer matrix in specific proportions, ensuring that the final product attains the desired color and characteristics.
The development of color masterbatch involves careful selection of pigments and additives to achieve precise color matching and stability. This process is crucial for maintaining consistency across production batches, ensuring that each item produced has the exact shade intended by the designer or manufacturer.
Read more: Masterbatch: Your Ultimate Guide (Applications & Trends)
Color masterbatch offers several properties that make it indispensable in the manufacturing industry:
The primary advantage of using it is the high concentration of pigments it contains. This ensures that even a small amount of masterbatch can provide a strong and vibrant color, which is both cost-effective and efficient.
Uniform dispersion of pigments within the carrier resin is crucial for consistent color application. Color masterbatch ensures that pigments are evenly distributed, preventing issues such as streaking, spotting, or color variations in the final product.
Color masterbatches are designed to be compatible with a wide range of polymers, including polyethylene, polypropylene, polystyrene, and more. This versatility allows manufacturers to use it in different production processes, from injection molding to extrusion.
Additives in color masterbatch can enhance the stability and durability of the pigments, making them resistant to heat, light, and chemical exposure. This is particularly important for products exposed to harsh environments or requiring long-term color retention.
Manufacturers can work with masterbatch producers to create custom colors that match specific requirements. This customizability extends to creating effects such as metallic, pearlescent, or fluorescent finishes, enabling unique and innovative product designs.
Using this masterbatch is a cost-effective solution for coloring plastics. Since the masterbatch is highly concentrated, only a small amount is needed to achieve the desired color, reducing the overall cost of pigments and additives. Additionally, it minimizes waste and enhances production efficiency.
Color consistency is crucial for brand integrity and customer satisfaction. This masterbatch ensures uniform color distribution, maintaining consistency across different production batches. This reliability in color reproduction helps in upholding quality standards and reduces the risk of defective products.
Color masterbatch can be an environmentally friendly option. By using high-quality pigments and additives, manufacturers can reduce the need for excessive colorant use, which in turn reduces waste. Moreover, many masterbatches are designed to comply with environmental regulations and can be used in the production of recyclable products.
The customizability of color masterbatch provides manufacturers with immense flexibility in product design. Whether aiming for a specific brand color or experimenting with new shades and effects, masterbatch allows for precise color matching and innovative finishes. This flexibility extends to various manufacturing processes, making it suitable for a wide range of applications.
Color masterbatch can improve the processing characteristics of polymers. Additives included in the masterbatch can enhance the performance of the final product, such as improving UV resistance, thermal stability, or mechanical properties. This dual benefit of coloration and enhanced performance makes masterbatch a valuable component in manufacturing.
Color masterbatch revolutionizes manufacturing by providing vibrant, consistent, and durable colors for plastic products. Its high pigment concentration, uniform dispersion, and compatibility with various polymers enhance product appeal and quality. This cost-effective and eco-friendly solution allows manufacturers to create custom colors and effects, giving their products a competitive edge. By adopting color masterbatch, brands can produce visually appealing, reliable, and durable items that meet consumer expectations and stand out in the market.
As one of the world’s leading filler masterbatch manufacturer, EuP Egypt proudly brings customers unique plastic raw material solutions to help their factories optimize production costs and improve the competitiveness on the market.
EuP Egypt has 17 years of experience in the plastic industry, working in different international business.