MASTER BATCH PIGMENT COMPOUNDING LINE
MASTER BATCH PIGMENT COMPOUNDING LINE
Master batch pigment compounding line is a comprehensive solution for efficiently mixing and processing pigments into a uniform master batch, ensuring consistent color quality in various plastic manufacturing applications.
Definition of masterbatch:
A highly concentrated, high-efficiency color preparation is achieved by uniformly loading a super-normal amount of pigment into plastic particles in the resin.
Classification of masterbatch:
1. Filling masterbatch
Mainly fillers to reduce costs and appropriately improve product performance
2. Masterbatch
Composed of colorants, carriers and dispersants; it can reduce the use of colorants and improve color uniformity.
3. Modified masterbatch:
Flame retardant masterbatch
Defoaming masterbatch
Toughening masterbatch
Antioxidant masterbatch
The composition of masterbatch:
Colorant:
Organic pigments: macromolecular yellow, phthalocyanine blue, phthalocyanine red, etc.
Inorganic pigments: cadmium red, cadmium yellow, titanium dioxide, carbon black
Carrier:
As the matrix of the masterbatch, the special masterbatch generally uses the same resin as the product resin as the carrier. The general masterbatch should choose a resin with high heat resistance and strong adaptability. Common ones are: PP, PE, ABS, PBT, PET, etc.
Dispersant:
To promote the uniform dispersion of raw materials and no longer agglomeration, the melting point of the dispersant should be lower than the carrier resin, generally PE wax, white oil, etc.
Advantages of using masterbatch:
1. Better dispersion of pigments in products
The masterbatch will refine the pigment during the production process to improve the dispersion and tinting power of the color.2. Helps ensure the chemical stability of pigments
Pigments may oxidize and absorb water during storage. After being made into masterbatch, oxygen and moisture will be isolated to protect the pigments.
3. Ensure product color stability
The size of the masterbatch particles is similar to that of the raw material particles, making it easier to mix evenly and less likely to cause material accumulation and sticking. The measurement is accurate.
4. Keep the environment clean
During the use of pigments, powder will fly. Using color masterbatch will avoid this phenomenon.
Production of masterbatch:
Masterbatch production process-high mixer premixing process:
High mixer – feeder – extruder – granulator
Advantages: simple process and relatively small investment.
Disadvantages: low degree of automation and inaccurate measurement.
Masterbatch production process – loss-in-weight scale split feeding process:
Feed bin – loss in weight scale – extruder – pelletizer
Advantage:
Accurate measurement and high degree of automation.
Shortcoming:
The investment is relatively high and it is difficult to clean the pipelines when changing colors.
Masterbatch production process – based on internal mixer process:
Feed bin – weighing scale – internal mixer – feeder – extruder – pelletizer
Advantage:
Protect material properties and prevent degradation.
It can achieve a higher proportion of filling, especially suitable for the high quality requirements of black masterbatch.
Shortcoming:
Investment is relatively high.
Intermittent production requires multiple internal mixers when output is high.
other devices:
Reciprocator
It combines the advantages of single screw and twin screw, with uniform shearing, high dispersion, high filling and stretching melt, especially suitable for PVC cable materials and high filling ratio carbon black masterbatch; the disadvantage is high cost, low output, suitable for some high Products with added value and high quality requirements.
Continuous internal mixer
Double rotors continuously feed, with high degree of automation, energy saving and high output; the disadvantage is that the material residence time is short,
It needs to be used with an extruder. The cost is high and the popularity is not high. It is more used in the rubber industry.
Masterbatch equipment selection principles:
What products the customer makes determines whether to use a twin-screw extruder or other equipment such as an internal mixer.
Customers’ quality and output requirements, such as whether to make ordinary color masterbatch or special color masterbatch, and how high the output requirement is.
According to the customer’s particle size, shape and other requirements, for example, when making fine particles (1mm), the die and pelletizer are completely different from ordinary ones (3mm).
Customers have requirements for the dispersion of color masterbatch. The index to evaluate the dispersion of color masterbatch is FPV, which is the filter pressure value.
Machine model and output analysis-black and white masterbatch and color masterbatch:
Black mother:
1. The pigment of black masterbatch is carbon black, and the added amount is generally more than 30%. Since the feeding and dispersion of carbon black are extremely difficult, when the carbon black content is more than 35%, it is recommended that customers use an internal mixer to add double (single) ) screw granulation.
2. Black masterbatch is the color masterbatch with the highest demand, so larger models are generally chosen, with 52-inch machine starting and 75-inch machine being the mainstream, otherwise the income will be affected.
White mother:
1. The white mother pigment is titanium dioxide, which is TiO2. The added amount is very high, ranging from 30% to 80%. Some customers will also add some calcium powder. Generally, twin-screws are used, which have high production capacity, good quality and continuous production.
2. The amount of white masterbatch is also very large, so the models are generally larger, with 52 machines starting and 75 machines being the mainstream, otherwise the income will be affected.
Color mother:
There are many kinds of master colors, but the quantity of each color is not large, the customer order is small, and in order to facilitate switching, the general model is smaller, ranging from 25 to 65 machines, and the maximum choice is 65 machines.
Machine model and output analysis-black and white masterbatch:
Host model-Aspect ratioL/D-Rotating speed-Reference yield
52-44-56-600-800rpm-300-500kg/hr
65-44-56-600-800rpm-400-800kg/hr
75-44-56-600-800rpm-500-1000kg/hr
95-44-56-600-800rpm-600-1500kg/hr
Note: The above are conventional models and are twin-screw. Depending on the specific application, customers may choose to add a single mixer (twin-screw) or other options. If you encounter specific projects, you are welcome to discuss them together.
Machine model and output analysis-color masterbatch
Host model-Aspect ratioL/D-Rotating speed-Reference yield
35-44-56-600-800rpm-100-200kg/hr
40-44-56-600-800rpm-150-250kg/hr
52-44-56-600-800rpm-300-500kg/hr
65-44-56-600-800rpm-400-800kg/hr