Masterbatch

What is masterbatch

What is masterbatch

Masterbatch is a thick mixture. This material is obtained by distributing dyes and other additives in a polymer carrier. Masterbatch is a material obtained during heat treatment and extrusion in high-shear mixing. After cooling, the said mixture is directed to a machine called a pellet maker and finally turns into granules.

The masterbatch allows the processor to economically and cost-effectively color the raw polymer during the plastic manufacturing process.

Another explanation that can be given about masterbatch is that masterbatch, color or color concentrate, is a granule used for coloring thermoplastics. This material consists of one or more colors and a special carrier resin for the polymer.

Masterbatch is known as composite or calcite in the plastic industry.

Masterbatch components

Masterbatches have three main components: base polymers, additives such as masterbatch additives, and compatibilizing agents.

Base polymer

The consumable polymer base is often made of the following materials:

  • Types of polyethylene
  • Polypropylene
  • Polystyrene
  • Ethylene-vinyl acetate
  • Low molecular weight waxes
  • Alkyd polymer
  • Special polymers
  • Etc

additive

To change the properties of polymers, additive chemicals are added to the masterbatches, which include additives that improve properties, pigments, and fillers. According to the type and strength of the additive and polymer base, the amount of additive feeding in the master batch is different.

Adapting agent

Compatibilizers, with the scientific name of amphiphilic compounds, have a hydrophilic end and an organic end, and due to their specific chemical nature, cause:

  1. Increased thermal stability
  2. Adaptation of polyolefins and engineering polymers
  3. The formation of a stable layer on the surface of the additive, pigment, or filler through interaction with them and connecting them to the polymer matrix.

On the one hand, the presence of compatibilizer causes more formation on the surface of the pigment and as a result, better distribution of the pigment, on the other hand, without affecting the color quality of the product, it also stabilizes the polymer.

What are the benefits of masterbatch?

The most important point in using a product is a complete knowledge of its raw materials. These technical specifications can include the melting point, moisture percentage, and melting temperature of the products. The standards that help you choose an important composition are:

  1. The specificity of colors
  2. Having appropriate technical specifications
  3. Not causing problems in the production of the final product
  4. Having a uniform concentration and the right percentage of additives
  5. Using a small amount of raw materials to produce the product
  6. Maintaining color stability and material properties in the number of times used
  7. Coordination of polymer compounds with materials and products to be produced

Getting to know the masterbatch production process

It is better to know that a machine called a double screw extruder is used to produce a masterbatch. Also, this process includes four stages formulation, mixing, feeding, and sieving. We will get to know each of these production processes in brief.

feeding

After the formulation stage, it is time for the feeding stage, in which the feeding amount of the components is adjusted according to the output of the machine.

to sift

For the final consumer to be able not to face feeding problems during the production phase, the final masterbatch must have the right size and be strong enough. Therefore, for a better work result, sieves with the appropriate size of granular masterbatch should be used, and masterbatches with very small or out-of-size sizes should not be used.

Formulation

The first and one of the main stages of masterbatch production is the additive amount and color formulation. It is not bad to know that in the formulation stage, the exact weighing of all the components is done with special precision. Also, in some cases, to get a better and more appropriate result, it is necessary to mix the ingredients well with each other at a high speed.

mixing

Since the inappropriate temperature causes disturbances in the distribution of powder and granule cutting, therefore, the mixing of the melt at the temperature of the tank is well adjusted so that the mixture melts well. It is better to know that the mixing stage includes four stages wetting of pigment, additive and filler, physical mixing (mixing and dispersion of pigment and additive in the base polymer), distribution (distribution of pigment, additive, and filler in the polymer melt) and dispersion to stabilize this Mix and prevent clumping.

What are the types of masterbatch?

  • Color masterbatch
  • Black masterbatch
  • White masterbatch
  • Smoothing masterbatch
  • Masterbatch Antiblock
  • Antistatic Masterbatch
  • UV Masterbatch (Anti UV)
  • Process Help Masterbatch
  • Your antioxidant masterbatch
  • Fireproof masterbatch
  • Anti-fog masterbatch (anti-vapor)
  • Masterbatch cleaner
  • Clarifying masterbatch
Color masterbatch

Color masterbatch

Colored masterbatch or colored granules are the main part of the production of colored plastic products, because polymer base materials are rarely used alone due to the lack of a specific color, and usually they are produced in colored form for the sake of beauty and attracting the attention of consumers of plastic products. They say that this requires additives called color masterbatch, which today, with the growth of the plastic industry in the world and the increasing use of these products, the amount of attention to these products is also increasing.

The most common method of producing colored plastic parts is the use of colored granules, which are used to color the raw polymers during the production process with certain percentages. Color masterbatch is a concentrated polymer mixture of a high percentage of pigments, which is optimally mixed in a certain amount in a base resin during heat treatment, which, based on its chemical structure, absorbs part of the visible spectrum and reflects the other part. they do.

Negin Rose Sepahan company's masterbatch unit has been in operation since 1375 to supply the company's required masterbatch of polypropylene fibers. Currently, this group has put the development of the masterbatch unit for the production of textile-grade masterbatches, film, and pipe injection parts on its agenda by using the expert power of consultants in the masterbatch production industries, polymer compounds, and synthetic fibers.

The color process of matching the samples received from customers is possible in the shortest possible time and by using the quality control equipment available in the masterbatch unit with high precision and accuracy.

Negin Rose Sepahan company, by employing a specialized consulting team and relying on the capabilities of its research and development unit, can match the colors of samples received from customers and provide masterbatch products in industries.

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Black masterbatch

Black masterbatch

Black masterbatch is used as black pigments for coloring plastic industries. In its compositions, black components are used, which have the property of resisting UV rays and light. These materials are used in the process of molding plastic items, production of polyethylene pipes, wire and cable packaging films, etc.

Black masterbatch includes raw materials and carbon black. This masterbatch can be mixed from 5% soot to 42%. Of course, it is possible to mix up to 50%, or 60% with certain formulations, but this is not customary and the most common soot for mixing is 42%, which is used by most companies and manufacturers.

Black alone is divided into several categories:

  • shiny
  • matte

Black masterbatch ingredient

In general, a combination of carbon black and polymers is used to produce a black masterbatch.

The standard for using carbon black in plastic industries is only plastic-grade carbon black, which is special for use and compounding with polymer and therefore does not change the properties of the polymer.

polymer

As mentioned, polymers alone cannot solve all the needs of industries. In this way, by adding compounds to them, certain properties of them are strengthened. This means that polymer is known as the main base of masterbatches. Among the types of these polymers, we can mention polystyrene, polyethylene, polypropylene, alkyl polymers, etc.

additive

Since the properties of polymers must be changed or strengthened, additives must be added to them. In general, these additives include pigments, fillers, and additives that enhance the properties of the desired polymers. In black masterbatch, carbon black is mainly added as an additive to polymers.

Adapting agent

One of the questions that concern the minds of many manufacturers is how to paint polymer compounds and additives. In general, for these compounds to receive their color, a combination of dye and additive must be distributed in the base polymer through a polymer compatible with the final product, which is mainly present as a melt. Of course, it can be said that the quality of the existing device and equipment has a great impact on the produced master batch.

What characteristics should the equipment used to produce black masterbatch have?

In general, the equipment used to produce high-quality masterbatch should be able to mix the existing compounds by creating the right force. Also, this equipment should be able to control the temperature of the compounds well. Because at low temperatures, the polymer and additives are not well combined and will not have the required quality.

At high temperatures, polymers become pasty and molten, in which case the probability of breaking their main chains will increase, and in this way, the material will lose its adhesion and viscosity. In general, the best time to add additives to black masterbatches is when the desired polymer has a very high viscosity. Because it is only at this time that the additives are well combined and the material will have a good viscosity.

White masterbatch

What is a white masterbatch? It is a type of color masterbatch that consists of grades of titanium dioxide (TiO2), polymer base, and other additives. It is a very high-quality pigment that is used on plastics.

It is used to improve the whiteness of finished plastic products and is particularly suitable for polymer films, injection molding, and other products. Depending on the needs of the products, the master batch contains 10% to 75% TiO2 pigment.

White masterbatches contain special additives that make the polymer compatible with the titanium pigment and give an ideal color to the final product. Depending on the percentage of titanium dioxide, we have many types of white masterbatch.

What are the advantages of white masterbatch?

Thanks to the use of titanium dioxide (TiO2) in the masterbatch, the final products are transparent and shiny white. White masterbatches have countless advantages, here are some of them:

  1. It can maintain the chemical stability of pigments
  2. It is easy to work with
  3. They do not harm the environment.
  4. They blend easily and spread well
  5. They are suitable for food.
  6. Due to its high quality, it can be used for air and injection molding.
  7. The final products drain well and are effective
  8. It has excellent color acceptability
  9. High and durable quality with excellent whiteness
Smoothing masterbatch

Smoothing masterbatch

When polymer films are stored for a long time or when you use them, they cause an unwanted adhesion due to interlayer pressure. Once this adhesion occurs, it will be very difficult to open the rolled films. To prevent this from happening, they add anti-blocking and lysing agents to it.

Friction is very high on polymer surfaces and this causes problems during the production or wrapping of film rolls and packaging and release of plastic molds. If we use the smoothing masterbatch, it will make the surfaces polished and the adhesion of the surfaces will decrease, and it will also reduce the wear and tear of the process machinery.

Masterbatch Antiblock

This master batch consists of polyethylene powder in the amount of 60% of the total ingredients, dried magnesium silicate in the amount of 30%, and eroic acid amide in the proportion of 10%. In this way, all components are measured in the gravimeter part of the extruder, and then polyethylene and magnesium silicate are poured into the mixer to obtain a homogeneous mixture.

At this stage, eroic acid is also added to the ingredients in the mixer and all the ingredients are mixed again. In the next step, the combined materials enter the extruder funnel to melt under the influence of the heat of heaters surrounding the feeding area to the end of the die. After passing through the die filter and separating the impurities, the molten material enters the cooling section. After the cooling and cutting stage, the manufactured product is ready to be released to the market.

Antistatic masterbatch

Antistatic masterbatch

Antistatic masterbatch is a type of antistatic material that is used to neutralize the charges on the surface of the polymer. By using anti-static additives, problems caused by static electricity charging such as dust, damage to equipment, etc. are reduced or eliminated.

Antistatic Masterbatch creates a type of electrical charge that moves across the surface with significant friction to eliminate the effect of static electricity by contacting moisture in the air. The surface of the material interacts with the hydrophilic surface, on the other hand, the moisture in the air also performs a process that results in water molecules being connected.

Many plastic products must have antistatic properties to fulfill their purpose or to be user-friendly. This is achieved during the manufacturing process by mixing antistatic additives into the raw polymer to create an antistatic polymer. Antistatic Masterbatch can also be used on the external surface of the product as a surface coating.

Plastic objects that have an electrical charge attract particles floating in the environment such as dust. The constant dust on the TV screen is the result of this factor. Antistatic masterbatch solves these problems in the industry and cleans materials from foreign particles.

Antistatic masterbatch is used between 1 and 18% in materials according to the type of industry. They also come in both migrating and non-migrating categories to support a static charge base. In this way, masterbatches can solve one of the big problems in the process of processing and packaging electronic components.

Anti-UV masterbatch

Polymers change color and shape after a long period, especially when exposed to sunlight. This factor may change the main property of the object and affect its function.

For this reason, polymer materials should be such that they do not react against sunlight. In this case, by using this technology and applying scientific methods, a solution can be found for this issue. Another type of plastic additive is masterbatch anti-UV.

Masterbatch Anti-UV is a very good protection against UV rays for all kinds of plastics. Anti-ultraviolet masterbatches are designed to protect the plastic from deterioration caused by exposure to the sun’s ultraviolet rays.

You should note that this technology is widely used in fields such as agriculture and food packaging. The sun’s rays destroy and break the polymer chains.

Ultraviolet rays destroy colored materials and lead to color changes in polymer products. Therefore, the presence of anti-ultraviolet stabilizers in these products and devices is essential.

Plastics are sensitive to degradation due to ultraviolet rays and therefore they degrade when exposed to sunlight, and the rate and speed of this degradation are influenced by various parameters such as weather conditions, thickness of the part and plastic, type of polymer, and presence of additives in the construction. Plastic and… it depends.

For more information about Negin Rose Sepahan Masterbatch (Rose Masterbatch) and its price, you can contact the following number.

Process Help Masterbatch

Masterbatch Polymer Processing Aid (PPA) is specially designed to increase the extrudability of plastics (polyethylene films, pipes, tubes, etc.) and improve production and/or quality. Process aids are based on fluoroelastomers and are widely used for It is recommended to improve the processability of the polymer at higher cutting speeds, reduce wear and tear of machines, improve and facilitate the production process, reduce temperature and pressure, and increase the life of machines, make the surface of the film more polished and shiny, increase the transparency of the film surface, improve printability, reduce wear and tear of the machine. devices, reducing time and waste when changing color, reducing process temperature and pressure, eliminating the phenomena of accumulation of burnt materials in the mold (Die Buildup) and melt fracture (Melt Fracture), increasing production speed, reducing energy consumption costs, and finally, reducing the finished price. , one of the effects of using Masterbatch is to help the process.

In other words, by using the masterbatch process aid, which is used in the production of PE, PP, thin films, normal and thick films, agricultural films, sacks, jumbo and cartons, PP fibers and tubes, and polyolefins, it is possible to produce without reducing the speed of production. , performed the production processes at a lower temperature, which led to the improvement of the properties of the final product.

Aria Polymer’s process-aided masterbatch eliminates melt breakage, reduces the build-up of solids, improves film surface, eliminates the fish-scale effect, reduces gel formation, and increases production output. Masterbatch, a process aid additive, by creating a suitable layer between molten polymer materials and the metal wall of the machines, prevents combustion and burning, as well as the uniformity of the product surface

Antioxidant Masterbatch

Considering the resistance of polymers against high temperatures and also the process of oxidation when exposed to oxygen, Negin Rose Sepahan’s Anti-Oxidant Masterbatch with the combination of two generations of Model 1 stabilizers (initial) to preserve the polymer during the masterbatch production process and production The final product as well as model 2 (secondary) of stabilizers are formulated to preserve the product after production. And since the combination of several thermal stabilizing agents simultaneously has a synergistic and intensifying effect. Several antioxidant agents have been used in this product, and one of the salient features of this product is the recovery of 30-40% of the lost properties of the polymer due to the repetition of processes and recycled products. Highly recommended. that the antioxidant additive masterbatch used in polymers before entering the extruder is uniformly mixed with grinding materials and raw polyethylene so that its impressive and positive effect on the OIT of the whole product can be seen uniformly.

Fireproof masterbatch

What is a fireproof masterbatch?

In general, a fireproof masterbatch is used in the market as a fireproof device. This type of masterbatch is made using a special formulation and makes the product extinguish against fire. Masterbatches are often used in the construction, textile, home appliance, and various product manufacturing industries and increase the heat resistance of materials. On the other hand, this product is sold in different types and volumes and has a specific way of consumption.

Application of fireproof masterbatch

All types of polymers and plastics have low resistance to fire and catch fire quickly. The use of this type of fire retardant additive helps slow down the burning of polymers and prevents them from being damaged. Fireproof masterbatches are often produced in various bases of polyethylene, special polyamide, and polypropylene.

This product is used in pipes and sewer connections to maintain stability against ignition. For example, halogen fire retardant is one of the types of fireproof masterbatch and consists of chlorine and bromine. This type of masterbatch significantly reduces the ignition factor and prevents fire. On the other hand, the halogen-free flame retardant is another example of a masterbatch that is used in various industries. Also, a low-halogen masterbatch is often used in the automotive, electrical, and home appliance industries and has a suitable and unique performance.

anti-fog

Anti-fog agents are chemicals that prevent water from condensing into small droplets on surfaces such as glass and forming fog. For the first time, NASA used the anti-fog masterbatch in the Gemini project; During this project, the chemical was developed into a compound that is used today on plastic and glass surfaces, and for optical applications such as lenses for mirrors found in eyeglasses, cameras lenses, and binoculars.

The main function of the anti-fog material is to minimize the surface tension and thus prevent the formation of moisture layers on the desired surface. The existing technology in the anti-fog production process is to use a surfactant layer or create a hydrophilic surface.

Anti-fog masterbatch

Specifically, anti-fog masterbatch is a polymer compound used in food packaging and greenhouse coatings. This anti-fogging material causes water to drip on the nylon cover of the greenhouse so that the right light and heat reach the plants.

Purging Masterbatch

Masterbatch cleaning additive is used to clean the device from previous paint and materials as quickly as possible, along with reducing waste.

Benefits of masterbatch cleaner

Clarifying masterbatch

Clarifying Masterbatch is produced based on polypropylene polymer, which helps in creating transparency and the socalled vitrification of products such as disposable containers. In terms of efficiency, masterbatch nucleation by enlarging the photocells allows more light to pass through the sheet or film, making it transparent. The isotactic type of homopolymer polypropylene has a semicrystalline structure. The presence of this crystalline structure will increase the hardness as well as mechanical, chemical, and thermal resistance properties of polypropylene.

This masterbatch is used to remove the turbidity of the product, which gives more brightness to the polymer plastic due to the passage of more light in the product. Among the uses of clarifying masterbatch, the following can be mentioned:

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