Masterbatch is a chemical substance in which organic powders, mineral powders, colour powders (pigments), and other additives are integrated with a thermoplastic base during the melting process in an optimised way.
Introducing Masterbatch
Polymers can have many applications in various industries and production such as auto parts, household appliances, wires and cables, types of pipes and fittings, packaging, etc. Of course, depending on the application of the polymer, a specific sample is selected.
However, choosing a specific sample of polymers does not guarantee obtaining the final product optimally, therefore, materials such as reinforcement, filler, colour, and additives must be added to the polymers to prepare them for various uses, hence, the resulting composition is called Masterbatch granules. Therefore, when producing appliances and parts, users fully know with what percentage of their types they can create the desired properties.
In general, chemicals and polymers are the main bases of compounds or Masterbatch types that determine the properties desired in the final product of the polymer base.
Depending on the required properties of the final product, being coloured or reinforced, chemicals are prepared from organic or inorganic colours and enhancers, the basic materials in the production of all kinds of masterbatches are all thermoplastic grades along with related resins. Among the thermoplastics used as basic materials are: POE, PP, PS, EVA, LLDPE, HDPE, LDPE, WAX, PBE, etc.
Masterbatch types
Nowadays, there is a wide range of Masterbatch types in different industries, examples of which are:
Various colour Masterbatches such as white, black, titanium, etc.
Types of Masterbatch granules for biodegradation
- Clarifier
- Cleaning products
- Flame retardancy
- Calcium carbonate
- Gray fireproof
- Anti-steam and anti-fog
- Antioxidants
- UV and anti-ultraviolet
- radiation
- Anti-static and anti-static
- Anti-block
- Lubricating
The amount of Masterbatch granule consumption
Masterbatch types are used based on the concentration of different additives existing in thermoplastic bases. Of course, the final application of the Masterbatches will be communicated to the consumers by the producer and the customer's need is the main criterion for determining the consumption of Masterbatch varieties. The second most important factor in the consumption amount of Masterbatch granules in addition to quality is pricing.
The manufacturer can choose a suitable base of raw materials and produce a desirable product based on a special mixture plan using appropriate process machinery according to the market's needs and help lead the consumer group towards creating proper added value.
High-price Masterbatch
Some granule Masterbatches have much higher prices than the raw materials, and at first glance, consumers may not be very inclined to use this additive, this is despite the fact that the increase of some of these products can increase the quality of final product, depreciation of equipment and production costs. It is interesting to know that there are several factors to improve the mixing process in the preparation and production of final products, choosing thermoplastic base materials compatible with the final product base is among them.
Due to the volume of additives which might contain organic compounds, colour pigments or mineral additives, an effective mixing design, can create the ability to prepare and produce a Masterbach with specific properties. Accurate and appropriate distribution of the base and raw material has a significant impact on the final quality.
The compatibility of raw materials with additives is one of the other important indicators that can have a great impact on the distribution of additives in the final product.
Introducing coloured Masterbatch granules
The most common method of producing coloured parts from plastic materials is to add coloured Masterbatch granules. These additive types, cause the mechanical and physical properties to be modified and improved in addition to obtaining the desired colour of the final products. Usually, a plastic mixture combined with the colour Masterbatch contains a significant percentage of pigment, which is a smaller percentage in polymers and gives the final product the desired colour. Of course, changing the colour percentage of additives makes it possible to obtain different colour samples.
Introduction of lubricating Masterbatche granules
After the production of plastic films, it is difficult to separate the film layers and they cause many problems during packaging. Also, in medical supplies production and some equipment such as syringes, friction has made it difficult for two parts to move on top of each other. Therefore, Masterbatch is used to solve such problems. These products reduce adhesion and make it easier for surfaces such as metal parts, sheets and films to slide against each other.
Introducing other Masterbatch types
- Antiblock products are used to reduce adhesion on the surfaces of polymer films and cause slippage in film layers from the production to the use of films.
- Antistatic products prevent the formation of static electricity and the absorption of dust on the surface of the products. Process aids are a type of Masterbatch that plays a role in polymer processes and improves product properties.
- Fireproof products make products resistant to any kind of ignition.
- Stabilizer additives prevent the discolouration and destructive effects of polymer products against UV radiation and UV rays.
- Antioxidant additives are one of the Masterbatches that prevent polymer products from being destroyed and affected by oxidation. This product is used to stabilize the polymer against oxidizing agents in the production stages.
- Anti-steam and anti-fog products are Masterbatches that prevent steam from forming in greenhouse covers, food packaging, and film production.
- Cleaning products are Masterbatch used to clean the machinery from previous materials and paint to produce new products. These masterbatches reduce the residual waste from changing colours.
- Clarifying products are used to remove the turbidity of products and cause more polish and light transmission in plastic products. This material is mostly used in disposable containers, thick, thin and normal films and other plastic products.
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