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MasterbatchSHAKT I NADARPACKAGING DE VELOPMENTCAV INKARE PVT. LTD .26 T H AUG 2015

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Contents1. Masterbatch & its types

2. Importance of Distribution & Dispersion

3. Masterbatch Manufacturing Process - https://youtu.be/0j3-GY-B6vk

4. Effect Pigments

5. Additive MB’s

6. Fillers

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Definitions Polymer Compounding : Combining a base plastic resin with Colours, Modifiers, Reinforcements, Fillers or other polymers by Melting & Mixing in an Extruder to convert the base resin properties to deliver a better performance, low cost, ease of manufacturing & more attractive appearance.

Agglomeration : to form a mass

Pigments : Colouring matter

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Masterbatch Polymer granules with a high percentage of additives (higher than in the end use)

Additives are optimally dispersed & encapsulated in a carrier material

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Types of Masterbatch1. Colour Masterbatch – for colouring plastic products

2. Additive Masterbatch – for certain chemical & physical properties for end product

3. Filler Masterbatch – for cost reduction

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Goal of Masterbatch Production The Aim is the ideal dispersion of pigment/additives in the polymer matrix.

The powdery feed material tends to agglomerate.

Dispersive & Distributive Mixing: Dispersion : incorporation of pigment/additives into binder or carrier

Distributive mixing : distribution of the material without destroying the single components

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Mixing Bad DISPERSION & Bad DISTRIBUTION

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Mixing Bad DISPERSION & Good DISTRIBUTION

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Mixing Good DISPERSION & Bad DISTRIBUTION

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Mixing Good DISPERSION & Good DISTRIBUTION

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Production Process Premix consisting of:

Polymer, Pigment & dispersion additive

is fed to the extruder

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Polymer is plasticized first

Pigment & dispersion additive

via separate feeder

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Methods of Producing Masterbatch

Single Stage ProcessAll the components are combined in one processing step

Process can be either Pre-mix or Split

Can be applied for all 3 types of Masterbatch

Two Stage Process

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Methods of Producing Masterbatch

Two Stage ProcessSingle pigment are produced in the same manner as single stage

Followed by second extrusion step, that combines required ratio of colourant & additive

Can be applied only for Colour Masterbatch

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Methods of Producing Masterbatch

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Colour Masterbatch Colour Pigments (20-90%) + Carrier Polymer (>10%) (Carrier polymer selection is basis compatibility of the Raw Polymer which is used for the Plastic product)

Universal Masterbatch

(these are polymer less masterbatch)

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Effect Pigments Iriodin® (Merck)• Pearl luster pigment• Glittery as well as silk matte luster

Colorstream® (Merck)• Achieves multicolour effect

Xirallic® (Merck)• Crystal Clear pure white lustre

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Effect Pigments Firemist Colourmotion (BASF)• Glittering effect

Santa Fe (BASF)• Earth tone added desert like hue• Specular property (mirror like)

Dynacolour (BASF)• Gives high degree of colour purity & intensity

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Additive MasterbatchAnti-Static:• Reduces static charges developed in the plastic products

Anti-Block:• Plastic film layers tend to stick together, this phenomena is called Blocking.• Anti-block MB create small space between the 2 layers (surface roughness) preventing blocking.• Additionally this imparts Slip properties & Scratch resistance• Allows smooth unwinding of Rolls

Anti-Fogging :• Fogging refers to condensation of water-vapours on the surface of the plastic film

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Additive MasterbatchAnti-Oxidant :• Used to protect polymers from Degradation, during processing & during use• During polymer degradation free radicals are formed, resulting in uncontrolled chain reactions• Anti-Oxidants are used to decrease the amount of free radicals

Cling Agent :• Used during the manufacturing of stretch films

UV Masterbatch :• These are PE filled with Ultra Violet Stabilizers (hindered amine light stabilizers)• Harmful UV rays from sunlight degrade & discolour the exposed plastic products• UV MB avoids discolouration & chalking

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Additive MasterbatchOptical Brightener Masterbatch :• Used to impart whiteness & brightness to plastic products without any blue tone

Silicon Masterbatch :• Enhances abrasion resistance

Processing Aid Masterbatch :• Improves the extrusion ability of the polymer

Clarifying Masterbatch :• Lowers the haze & improves the transparancy in Injection moulded items

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Fillers Fillers are materials added to plastic to lower the consumption of expensive polymers.

Eg.

Calcium Carbonate (CaCO3)

Talc

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Benefits Optimum Dispersion of pigments/additives

Low Stock holding compared to pre-compounded materials

Dust free, no health or safety risk

Reduction in purging cost

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Thank You