The advantages and disadvantages of filler masterbatch and processing technology in film blowing process
The concept of filler masterbatch:
Filling masterbatch refers to the mixing and kneading of various auxiliaries, fillers and a small amount of carrier resin during the plastic processing and molding process, and the granules and powders obtained are called masterbatch. The main component of filler masterbatch is filler, which is mainly used for the processing and molding of polyolefin (polyethylene and polypropylene), also known as polyolefin filler masterbatch. In the production process of plastic film, most manufacturers also add a certain proportion of filler masterbatch.
The advantages of filling masterbatch:
One is to reduce costs. This is the reason why manufacturers choose the most. Because the filler masterbatch is cheap, it is not recommended to use the material below 5000 yuan/ton.
The second is to reduce the shrinkage rate of the product. Manufacturers who choose this performance also account for a large proportion. For example, when the shrinkage rate of PP is large, when a product with stiffeners and meaty walls is made, generally the upper surface will have shrinkage dents on the product. The product is beautiful, and the addition of fillers can effectively reduce the shrinkage rate and greatly improve the flatness of the product surface.
The third is to increase the proportion. Relatively speaking, there are not many manufacturers selected for this reason. In particular, the products may be sold in larger quantities. In fact, this is a disguised way of reducing costs.
Fourth is to increase the hardness of the product. Generally, such manufacturers recommend using talc filler masterbatch, which can increase the hardness by about 20%. There are still many such manufacturers.
Disadvantages of filling masterbatch:
One is to affect product quality, mainly refers to toughness.
The second is to increase the proportion of products.
Third, it affects the color of the product. Even the transparent filler masterbatch can affect the transparency more or less. The more you add, the greater the impact, and the thicker the product, the greater the impact.
That's about it, mainly depends on the product and how to choose which filler masterbatch.
The composition of the filler masterbatch:
Polyolefin filler masterbatch is composed of three parts: carrier resin, filler and various additives, of which filler accounts for the main component, up to 90%.
Filler: The filler used in polyolefin filler masterbatch is mainly heavy calcium carbonate, followed by inorganic fillers such as talc, kaolin, and calcium powder. For any inorganic filler, particle size and particle size distribution are important technical indicators. Generally, the smaller the particle size and the narrower the distribution, the better the filling effect. In addition, the filling effect is also related to the dispersibility. The smaller the particle size, the more difficult it is to disperse and the higher the price.
Carrier resin: The performance and cost of polyolefin filled masterbatch mainly depend on the carrier resin. Usually, the carrier resin generally contains 10%-20% depending on the purpose of the masterbatch. The carrier resin used in the polyolefin filled masterbatch should have good compatibility with the filled plastic matrix resin. From this point of view, it is generally better to use matrix resin as carrier resin. In addition, when selecting the carrier of the filled masterbatch, its melting point and melt fluidity must be considered, and the melting point of the carrier resin should not be higher than that of the matrix resin. At present, most companies use polyethylene (PE), polypropylene (PP), and resins that match polyethylene and polypropylene with equivalent melt index.
Auxiliary agent: The main types of auxiliary agents used in polyolefin filler masterbatch are dispersant and surface treatment agent. The function of the dispersant is to improve the processing fluidity of the masterbatch, which is conducive to the more uniform dispersion of the masterbatch in the matrix resin. Commonly used dispersants are: white oil, paraffin wax, polyethylene wax, coupling agent and stearic acid.
Filling masterbatch processing technology:
Polyolefin filler masterbatch processing technology and related equipment also change with the continuous change of carrier resin.
The carrier resin used in the first generation of polyolefin filler masterbatch (APP masterbatch) is domestic atactic polypropylene (actually a by-product of polypropylene production). The processing technology is: mixing-open refining and drawing-water-cooled pelletizing. Intermittent production, using equipment such as internal mixer, open mixer and flat pelletizer.
The second-generation polyolefin filler masterbatch uses LDPE (1F7B) as the carrier resin, and the masterbatch produced is called PEP masterbatch. This process must adopt a specially designed single-screw extruder with large aspect ratio and high mixing performance to obtain better results.
The filler masterbatch with polypropylene powder as the carrier, namely PPM masterbatch is called the third generation filler masterbatch in my country. Generally, polypropylene and polyethylene blends are used as carrier resins, and the effect is very good. The product not only maintains the characteristics and scope of use of PPM masterbatch, but also adopts die-face hot-cutting air cooling process, which improves production efficiency and reduces raw material costs.
The best processing equipment for making filling masterbatch is a co-rotating twin-screw extruder. The advantages of this machine are continuous production, stable quality, high production efficiency, low energy consumption, low labor intensity of workers, and good operating environment.
The recommended addition amount of filler masterbatch in application products:
Blown film PE (agricultural film, mulching film co-extrusion film, civilian film) --8%~10% In the film blowing process, we can use filler masterbatch to reduce costs. The blown film machine adopts A and B double main engines. After the machine head, the two materials of the two mainframes are formed into a three-layer film. The ABA structure has a strong blown film, hard hand feeling, good brightness, high output and strong puncture resistance. And the middle layer can be added with cheap materials to reduce costs.
The three-layer co-extrusion blown film machine only needs two main machines, one squeezes the inner and outer layers (layer A), and one squeezes the middle sandwich layer (layer B) using recycled materials or other cheap materials, even adding 50% calcium carbonate. Its strength, weldability, and printability are unaffected, and the middle layer is cooled faster by the addition of calcium carbonate or low pressure polyethylene.
Because the die of the three-layer co-extrusion blown film machine has three channels to reduce the pressure loss, the thickness of the film is more uniform, and the power consumption is more economical. Moreover, there are only three main channels and three channels, and each ton of film is installed with the inverter in the blower. It can save about 200 kWh than a single blown film. This is unprecedented in the production of single-machine single-die or three-story old-fashioned three-host. Undoubtedly bring the gospel to the sustainable development of the blown film industry.ABA film blowing machine can add filler masterbatch to the greatest extent, which can minimize the cost of raw materials, but the machine price is cheaper than ABC film blowing machine, which is the best choice!. If you want to know more about the ABA blown film machine, Please contact us.
Filling masterbatch refers to the mixing and kneading of various auxiliaries, fillers and a small amount of carrier resin during the plastic processing and molding process, and the granules and powders obtained are called masterbatch. The main component of filler masterbatch is filler, which is mainly used for the processing and molding of polyolefin (polyethylene and polypropylene), also known as polyolefin filler masterbatch. In the production process of plastic film, most manufacturers also add a certain proportion of filler masterbatch.
The advantages of filling masterbatch:
One is to reduce costs. This is the reason why manufacturers choose the most. Because the filler masterbatch is cheap, it is not recommended to use the material below 5000 yuan/ton.
The second is to reduce the shrinkage rate of the product. Manufacturers who choose this performance also account for a large proportion. For example, when the shrinkage rate of PP is large, when a product with stiffeners and meaty walls is made, generally the upper surface will have shrinkage dents on the product. The product is beautiful, and the addition of fillers can effectively reduce the shrinkage rate and greatly improve the flatness of the product surface.
The third is to increase the proportion. Relatively speaking, there are not many manufacturers selected for this reason. In particular, the products may be sold in larger quantities. In fact, this is a disguised way of reducing costs.
Fourth is to increase the hardness of the product. Generally, such manufacturers recommend using talc filler masterbatch, which can increase the hardness by about 20%. There are still many such manufacturers.
Disadvantages of filling masterbatch:
One is to affect product quality, mainly refers to toughness.
The second is to increase the proportion of products.
Third, it affects the color of the product. Even the transparent filler masterbatch can affect the transparency more or less. The more you add, the greater the impact, and the thicker the product, the greater the impact.
That's about it, mainly depends on the product and how to choose which filler masterbatch.
The composition of the filler masterbatch:
Polyolefin filler masterbatch is composed of three parts: carrier resin, filler and various additives, of which filler accounts for the main component, up to 90%.
Filler: The filler used in polyolefin filler masterbatch is mainly heavy calcium carbonate, followed by inorganic fillers such as talc, kaolin, and calcium powder. For any inorganic filler, particle size and particle size distribution are important technical indicators. Generally, the smaller the particle size and the narrower the distribution, the better the filling effect. In addition, the filling effect is also related to the dispersibility. The smaller the particle size, the more difficult it is to disperse and the higher the price.
Carrier resin: The performance and cost of polyolefin filled masterbatch mainly depend on the carrier resin. Usually, the carrier resin generally contains 10%-20% depending on the purpose of the masterbatch. The carrier resin used in the polyolefin filled masterbatch should have good compatibility with the filled plastic matrix resin. From this point of view, it is generally better to use matrix resin as carrier resin. In addition, when selecting the carrier of the filled masterbatch, its melting point and melt fluidity must be considered, and the melting point of the carrier resin should not be higher than that of the matrix resin. At present, most companies use polyethylene (PE), polypropylene (PP), and resins that match polyethylene and polypropylene with equivalent melt index.
Auxiliary agent: The main types of auxiliary agents used in polyolefin filler masterbatch are dispersant and surface treatment agent. The function of the dispersant is to improve the processing fluidity of the masterbatch, which is conducive to the more uniform dispersion of the masterbatch in the matrix resin. Commonly used dispersants are: white oil, paraffin wax, polyethylene wax, coupling agent and stearic acid.
Filling masterbatch processing technology:
Polyolefin filler masterbatch processing technology and related equipment also change with the continuous change of carrier resin.
The carrier resin used in the first generation of polyolefin filler masterbatch (APP masterbatch) is domestic atactic polypropylene (actually a by-product of polypropylene production). The processing technology is: mixing-open refining and drawing-water-cooled pelletizing. Intermittent production, using equipment such as internal mixer, open mixer and flat pelletizer.
The second-generation polyolefin filler masterbatch uses LDPE (1F7B) as the carrier resin, and the masterbatch produced is called PEP masterbatch. This process must adopt a specially designed single-screw extruder with large aspect ratio and high mixing performance to obtain better results.
The filler masterbatch with polypropylene powder as the carrier, namely PPM masterbatch is called the third generation filler masterbatch in my country. Generally, polypropylene and polyethylene blends are used as carrier resins, and the effect is very good. The product not only maintains the characteristics and scope of use of PPM masterbatch, but also adopts die-face hot-cutting air cooling process, which improves production efficiency and reduces raw material costs.
The best processing equipment for making filling masterbatch is a co-rotating twin-screw extruder. The advantages of this machine are continuous production, stable quality, high production efficiency, low energy consumption, low labor intensity of workers, and good operating environment.
The recommended addition amount of filler masterbatch in application products:
Blown film PE (agricultural film, mulching film co-extrusion film, civilian film) --8%~10% In the film blowing process, we can use filler masterbatch to reduce costs. The blown film machine adopts A and B double main engines. After the machine head, the two materials of the two mainframes are formed into a three-layer film. The ABA structure has a strong blown film, hard hand feeling, good brightness, high output and strong puncture resistance. And the middle layer can be added with cheap materials to reduce costs.
The three-layer co-extrusion blown film machine only needs two main machines, one squeezes the inner and outer layers (layer A), and one squeezes the middle sandwich layer (layer B) using recycled materials or other cheap materials, even adding 50% calcium carbonate. Its strength, weldability, and printability are unaffected, and the middle layer is cooled faster by the addition of calcium carbonate or low pressure polyethylene.
Because the die of the three-layer co-extrusion blown film machine has three channels to reduce the pressure loss, the thickness of the film is more uniform, and the power consumption is more economical. Moreover, there are only three main channels and three channels, and each ton of film is installed with the inverter in the blower. It can save about 200 kWh than a single blown film. This is unprecedented in the production of single-machine single-die or three-story old-fashioned three-host. Undoubtedly bring the gospel to the sustainable development of the blown film industry.ABA film blowing machine can add filler masterbatch to the greatest extent, which can minimize the cost of raw materials, but the machine price is cheaper than ABC film blowing machine, which is the best choice!. If you want to know more about the ABA blown film machine, Please contact us.
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