Do You Know The Advantages, Disadvantages, Process And Recommended Addition Amount of Filler Masterbatch?

Filler masterbatch refers to the granules and powders obtained by mixing and kneading various additives and fillers with a small amount of carrier resin in the process of plastic processing and molding for the convenience of operation. The main component of filler masterbatch is filler, which is mainly used for the processing and molding of polyolefins (polyethylene and polypropylene), and is also called polyolefin filler masterbatch.

Advantages of Filler Masterbatch

First, it is to reduce costs, which is the most common reason for manufacturers to choose.

Second, it is to reduce the shrinkage rate of products. Many manufacturers choose this performance. For example, PP has a large shrinkage rate. When making a product with reinforced ribs and thick walls, shrinkage marks will generally appear on the surface, affecting the aesthetics of the product. Adding fillers can effectively reduce the shrinkage rate and greatly improve the flatness of the product surface.

Third, it is to increase the specific gravity. There are relatively few manufacturers who choose this reason, especially the products may be sold by weight. In fact, this is also a disguised way to reduce costs.

Fourth, it is to increase the hardness of the product. Generally, such manufacturers recommend the use of talcum powder filling masterbatch, which can increase the hardness by about 20%. There are still quite a few such manufacturers.

Disadvantages of Filler Masterbatch

First, it affects the product quality, mainly toughness.

Second, it increases the specific gravity of the product.

Third, it affects the color of the product. Even if it is a transparent filler masterbatch, it can more or less affect the transparency. The more you add, the greater the impact, and the thicker the product, the greater the impact.

That’s basically it. It mainly depends on the product to choose the filler masterbatch.

Composition of filler masterbatch

Polyolefin filler masterbatch is composed of three parts: carrier resin, filler and various additives, among 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 talcum powder, 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 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 filler masterbatch mainly depend on the carrier resin. Usually, depending on the purpose of the masterbatch, the carrier resin generally contains 10%~20%. The carrier resin used in polyolefin filler masterbatch should have good compatibility with the plastic matrix resin to be filled. From this aspect, it is best to use the matrix resin as the general carrier resin. In addition, when selecting the carrier of the filler masterbatch, its melting point and melt fluidity should also be considered. The melting point of the carrier resin should not be higher than that of the matrix resin.

Additives: The additives used in polyolefin filler masterbatch are mainly dispersants and surface treatment agents. The function of dispersants is to improve the processing fluidity of masterbatch and facilitate a more uniform dispersion of masterbatch in the matrix resin. Commonly used dispersants include: white oil, paraffin, polyethylene wax, coupling agent and stearic acid.

Filler masterbatch processing technology

The processing technology and related equipment of polyolefin filler masterbatch have also changed with the continuous change of carrier resin.

The carrier resin used in the first generation of polyolefin filler masterbatch (APP masterbatch) is domestic random polypropylene (actually a by-product of polypropylene production). The processing technology is: mixing-opening and pulling-water cooling pelletizing. It is intermittent production, and the equipment used includes internal mixer, open mixer and flat pelletizer.

The second generation of polyolefin filler masterbatch uses LDPE (1F7B) as the carrier resin, and the masterbatch produced is called PEP masterbatch. This process must use a specially designed single-screw extruder with a large aspect ratio and high mixing performance to achieve better results.

The filler masterbatch with polypropylene powder as the carrier, that is, PPM masterbatch, is called the third generation of filler masterbatch in my country. Generally, the method of using a blend of polypropylene and polyethylene as the carrier resin will have a good effect. The product not only maintains the characteristics and scope of use of PPM masterbatch, but also can use the die surface hot cutting and air cooling process, which improves production efficiency and reduces the cost of raw materials.

The best processing equipment for making filler 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 for workers and good operating environment.

Recommended addition amount of filler masterbatch in application products

Blown film PE (agricultural film, ground film, co-extruded film, civil film) --8%~10%.

Disposable lunch boxes, milk and yogurt boxes, strapping PP --30~60%.

Cast film, food packaging film, garbage bags, woven bags, shopping bags-- 20~50%.

Extrusion molding, hollow molding LDPE --10~40%.

Machine/hand strapping tape, self-adhesive coating, paper coating, injection molding LDPE-- 10~40%.

Foam sheets, foam products PP-- 20-30%, PE-- 15~30%.

Hollow blow molding products, oil drums, plastic barrels, plastic bottles HDPE-- 10~40%, PP-- 20~40%.

Plastic trays, plastic basins, switch boxes, plastic toys, cosmetic boxes HDPE 10~30%, PP----20~30%.

Plastic curtains, plastic pipes, sheets, and table mats PS---15~30%, ABS----10~25%.

The above are some reference addition ratios for conventional products. The specific ratios depend on product requirements and the quality of the filling masterbatch.

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