What is the latest technology to produce Filler Masterbatch?

Highly-filled masterbatch contains more than 50 % by weight of fillers that are dispersed in a polymer matrix. Different process set-ups are possible depending on the type and amount of filler. The most common fillers include calcium carbonate or talcum.

There are two main reasons why CaCO₃ is used in plastic: it acts as a functional filler or mineral modifier (e.g. to produce breathable films) or it is used to reduce the costs of the compound.
What is important when using CaCO₃ is its very good incorporation into the polymer matrix. Coated CaCO₃ types are the most suitable. At MASKA GLOBAL, we use uncoated CaCO3 types to control the quality of CaCO3 with the right amount of acid and assure the surface coating adjusts the surface tension of the mineral to that of the polymer, greatly facilitating its incorporation and dispersion.

There are two main reasons why CaCO₃ is used in plastic: it acts as a functional filler or mineral modifier (e.g. to produce
breathable films) or it is used to reduce the costs of the compound.
What is important when using CaCO₃ is its very good incorporation in the polymer matrix. Coated CaCO₃ types are the most
suitable because the surface coating adjusts the surface tension of the mineral to that of the polymer, greatly facilitating its
incorporation and dispersion.

1. Advantages of CaCO3 Filler Masterbatch for each application in plastic industries:

Filler masterbatch are used in injection, blow-moulding, film(One layer or Multiple layer), sheet and tapes applications. They offer the following advantages:

1.1 Injection & blow-moulding

Lower raw materials cost, as they are usually more economic than polymer resins
Increased output due to faster mould cooling
Reduction of colour masterbatch requirement
Higher resistance to heat deflection, higher rigidity and stiffness
Improved dimensional stability, weldability and printability
Addition rate of Filler masterbatch in injection & blow-moulding applications can be up to 50 %, however, most usual levels are between 5-30 %.

1.2 Film, sheet, sacks, bags, raffia

Lower raw materials cost, as they are usually more economic than polymer resins
Reduction of colour masterbatch requirement
Higher stiffness, paper-like effect
Improved weldability and printability
Improved anti-blocking properties
Better bubble stability
Addition rate of FILLER masterbatch in film applications is 2-20 %.

1.3 PE & PP tapes

Antifibrillation (also known as anti splitting)
Lower raw materials cost, as they are usually more economic than polymer resins
Reduction of colour masterbatch requirement
Higher stiffness
Improved weldability and printability
Improved anti-blocking properties
Improved weaving ability
Easier processing
Usual addition rate of Filler masterbatchin tapes is 3-8 %.

1.4 HDPE & PP Pipe

Replacing expensive white masterbatch with its high white degree
Lower raw materials cost, as they are usually more economic than polymer resins
Higher stiffness
Smooth pipes with lower coefficient of friction to better prevent them from blocking
Being less possible to be brittel in low temperature adue to its excellent cold resistance
Usual addition rate of Filler masterbatch in tapes is 5-30 %.

2. How to produce Filler Masterbatch?

2.1 Feeding System

There two feeding system:
- Volumetric feeding system
Weight the raw material separately according to the formula
Then put all the material into high speed mixer for 5~10minutes mixing
Discharge the material into spiral loader
Loading the material into the hopper of volumetric feeder
- Loss-in-weight feeding system (automatically and higher accuracy)
Put the raw material into each tank on the ground.
Vacuum loader will convey each component into the storing silo.
The raw material will fall into the loss-in-weight feeder automatically. The feeding system will feed the material separately into extruder according to your formula setting one the HMI.