Short introduction about Masterbatch & its production, uses, etc

1. Masterbatch
S H A K T I N A D A R
P A C K A G I N G D E V E L O P M E N T
C A V I N K A R E P V T . L T D .
2 6 T H A U G 2 0 1 5
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2. Contents
1. 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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3. 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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4. 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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5. Types of Masterbatch
1. 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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6. 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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7. Mixing
Bad DISPERSION & Bad DISTRIBUTION
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8. Mixing
Bad DISPERSION & Good DISTRIBUTION
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9. Mixing
Good DISPERSION & Bad DISTRIBUTION
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10. Mixing
Good DISPERSION & Good DISTRIBUTION
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11. 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

13. Methods of Producing Masterbatch
Single Stage Process
All 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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14. Methods of Producing Masterbatch
Two Stage Process
Single 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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15. Methods of Producing Masterbatch
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16. 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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17. 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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18. 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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19. Additive Masterbatch
Anti-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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20. Additive Masterbatch
Anti-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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21. Additive Masterbatch
Optical 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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22. Fillers
Fillers are materials added to plastic to lower the consumption of expensive polymers.
Eg.
Calcium Carbonate (CaCO3)
Talc
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23. 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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24. Thank You
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