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Filler Masterbatch Production

Filler masterbatches are widely used as a solution, enhancing certain product properties such as hardness and impact resistance. Adding fillers to polymers not only improves polymer performance but also reduces the cost of compounds.

Polyolefin high-filled masterbatch is a commonly used high-filled material, typically incorporating inorganic fillers such as calcium carbonate, talcum powder, etc., with filler content reaching up to 85%.They improve stability during the processing, enhance printing performance, and refine surface quality of the products.

High-filling masterbatches can be used as substitutes in any field where powdered fillers are used. Filler masterbatches enhances the production environment for plastic modification and processing, improves processing efficiency, increases the automation level of production line and boosts labor productivity. For instance, CaCO3 filler masterbatch, it can be used in the production of breathable films, diapers, pipes, and other applications.

Fillers Used In Masterbatch Production

	Properties	^_Application
Minerals
CaCO₃	reinforcing , water and gas barrier	Package:PE-base film,PP woven sacks,biodegradable bags PS refrigerator liners
Talc	hydrophobic,softest ,increasing HDT , rigidity and wear resistance	Automotive(used with PP):bumper household appliances,engineering plastic hard ware Anti-block additive
Kaolin/clay	non-reinforcing, good electrical properties,increasing heat preservation	PE greenhouse film Improve the flow properties of glass-reinforced compounds
Mica	reinforcing,increasing tensile strength, flexural modulus, and HDT	Automotive(usually with PP):Motor fan blades
BaSO4	increasing acid,alkali resistance and opacity increasing the density	Automotive ：used with PP/PS in proportions up to 70%
Fibers
natural	coir/palm/bamboo/sisal/asbestor…	Building application etc;
Synthetic	glass/carbon/ceramic/boron…	Engineering plastic: glass fiber used with PA

Manufacture Process For

Filler Masterbatch

Feeding process
At present, there are two processes for filler masterbatch production: premix and split-feed.When choosing the suitable process for manufacturing filler masterbatch,it mainly depends on the percentage of additives in the formulation.

Generally,When the amount above 4%, the premix is efficient for high output.When the content of additives is less than 4%, the additives cannot cover all calcium carbonate powder in a high speed mixer, and the calcium powder cannot be dispersed efficiently.Based on the compatibility principle of activated calcium carbonate with plastics, calcium carbonate powder is fed seperately through loss-in-weight feeder along the twin screw extruder to ensure uniform dispersion of the calcium powder.

The pre-mix process can effectively mix calcium carbonate powder, solve the feeding problem, improve productivity.Currently,a majority of filler materbatches in the market are manufactured through this process and enjoy a intense competition. Compared to pre-mix process,the masterbatch through split-feed process is more competitive with high quality however the initial investment will be higher.

Compounding the martix on twin screw extruder
The co-rotating twin-screw extruder has long been the equipment of choice for filler masterbatch compounding.The high compounding capacity of twin screw extruder will make up for the unsufficient surface modificaiton and adhesion of matrix/filler.

There are two main process tasks for the twin screw extruder:
1.Be able to intake a large amount of calcium carbonate powder to the extruder.
2.Be able to highly disperse and mix the filler with the polymer carrier

It involves five steps in the compounding process:
1.Melting of polymer matrix.
2.Wetting of the filler by the melt of polymer matrix.
3.Dispersion of agglomerates and clusters (dispersive mixing).
4.Uniform distribution of filler in the polymer matrix.
5.Degassing and homogenization of the melt.

The extruder should have as much free space as possible to allow the intaking of the high loading level of filler. The screw should have a higher torque, the barrel should have efficient heating and cooling system, and the barrel&screw design of the processing section should be reasonable to meet the process requirements. This should achieve excellent dispersion and distribution effects while ensuring high production, safe and reliable equipment operation, and efficient energy savings.

Important Things For

Filler Masterbatch Production

Feeding with high filler loading

When feeding low-bulk density filler particles, feed limitations are often encountered,reducing the output . To remove the air for efficiently feeding the powder filler, it is neccassary to design a open-type first barrel for venting. The filler will be introduced into the twin screw extruder through the second barrel.

Distribution and Dispersion of the filler particles into polymer matrix

For reinforcement to be effective, Minerals,fibers,depending on their structure, need to be distributed and/or dispersed. This is the basis for high quality final product.Surface modification of filler is essential,it will:
Increase adhesion of matrix/filler,prevent void coalescence, which would affect physical properties thermal behavior and mechanical properties.
Decrease of particle-particle interaction,prevent particle agglomerate,which would cause dispersion and performance problems

To fully meet the above process requirements and complete the process steps, the entire production line must be scientifically designed. This includes material handling and conveying systems, a formula-controllable pre-mixing system, as well as a stable loss-in-weight feeding system. The extruder process section should be designed, including venting and vacuum venting. Downstream equipment should be matched, such as gear pumps, screen changers, underwater pelletizers, and control systems.

Jieya Extruder For Filler Masterbatch

Enhanced feeding systems allows high loading of low-bulk-density mineral filler and still maintain an economically viable production rate.Mechanical shearing by two co-rotating screws with segmented elements faciliate dispersion and distribution of filler particles into polymers.

High filler loading
Excellent Dispersion at High Throughput Rate

Reliable performance

Low Cost, Long Lifetime of Spare Parts

Equipped with CNC machining centers, extruder screws and barrels are manufactured by ourselves, enabling a tight control of quality and cost.Meanwhile,the delivery time is flexible and reliable.