What Is Masterbatch? A Comprehensive Guide
Let’s introduce the what is masterbatch? A comprehensive guide for you.
With the rapid development and innovation of polymer technology, plastic products have a large international market (From Wiki articles).
We can see the large-scale application of plastic products.
People’s requirements for products are getting higher and higher.
They not only put forward requirements in terms of safety, appearance, etc., but also require us to continuously improve the safety, quality, performance, etc. of our products;
Also because masterbatch can be more environmentally friendly and safer, it must have the same salt when cooking.
What is masterbatch?
Masterbatch is a color preparation.
It is a polymer compound obtained by uniform extrusion and compounding of twin-screws.
With the increase of production capacity, end products have higher and higher requirements for high-concentration and ultra-high-concentration, multifunctional color masterbatches.
In order to solve the key technical problems in the process of masterbatch processing in the past, we applied innovative technologies to key components such as the screw and barrel of the twin-screw extruder, which solved the problem of improving the quality of masterbatch products and reducing the switching process of different colors. The waste of raw materials and other key technical bottlenecks.
How to produce high quality masterbatch?
The feeding capacity of the screw is high, the thicker the material, the higher the filling rate and the greater the output;
As the material layer increases, the shear rate decreases, thereby reducing the shear rate of the screw on the material.
When the material advances, the closer the material is to the outer circle, the higher the linear speed, the stronger the shearing force, and the higher the material filling rate.
The closer the tall material is to the small circle, the lower the shear rate.
At the same time, the higher the material filling rate, the smaller the friction between the screw and barrel.
It achieves lower product energy consumption, higher product quality, longer equipment life, and better stability.
What are the precautions for using screws when producing masterbatch?
During the material extrusion process, if the final product has high requirements for residual impurities (such as film, XLPE cable), clean it before use to prevent carbonization and adhesion of the material.
On the screw surface, especially during masterbatch operation, it is often necessary to switch between different colors and quickly change raw materials.
The surface of the screw is sprayed with a wear-resistant lubricating layer: the surface hardness of the component reaches HV3500, the color is black gray, the coating thickness is 4.0-6.0 (UM), the maximum working temperature is 900°C, and the friction coefficient is 0.3.
While improving surface hardness, it also maintains good coating toughness, adhesion and lubricity.
What are the advancements in masterbatch processing technology?
Over the years, the barrels of twin-screw extruders have mainly adopted C-type bushing structures and integral bushing structures to accommodate various polymer formulations; seams may lead to cross-contamination of different colors.
There are joints between the C-shaped shells that run through the entire equipment, resulting in material residue; the cylinder is removed as an integral sleeve. The end faces of the bushing, sleeve and barrel are no longer on the same plane.
During the production process of the cylinder block, the thermal expansion coefficients of the cylinder block and the cylinder liner are different.
There are seams between them, which will also cause material residue. To address the above problems, we developed a metal sintered wear-resistant cylinder.
The alloy powder forms a uniform and dense alloy layer on the surface of the eight-shaped hole of the cylinder.
This alloy layer has better corrosion resistance and wear resistance.
It effectively solves the seam problem and improves the efficiency of switching between different materials.
How to reduce the energy consumption of masterbatch?
The new cylinder cooling and heating structure adopts a new radial cooling channel design and imported heating elements.
It not only improves temperature control efficiency, but also reduces deformation.
Localized shear heat and hardware wear can increase the service life of equipment and parts.
About the Author:
Andy, sales manager of Qingdao Sunshine Machinery Co., Ltd., has been engaged in plastic machinery for 5 years. Familiar with the operation and product features of various types of machines, we can provide you with high-quality services. If you have any needs, you can contact me at any time and look forward to establishing a cooperative relationship!
