| Customization: | Available |
|---|---|
| After-sales Service: | Field Installation, Commissioning and Training |
| Warranty: | 1 Year Warranty |
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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.
| 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.
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.
| Model | Screw Diameter (mm) | L/D | Screw RPM | Main motor KW | Torque Grade T/N3 | Capacity kg/h |
| SHJ-20 | 21.7 | 32-68 | 400/500/600 | 4 | 5.8 | 0.5-15 |
| SHJ-30 | 30 | 32-68 | 400/500/600 | 11 | 5.8 | 5-50 |
| SHJ-36 | 35.6 | 32-68 | 500/600/700/800 | 15-18.5-22 | 5.7 | 20-80 |
| SHJ-42 | 41.2 | 32-68 | 500/600/700/800 | 22-30-37 | 5.7 | 50-120 |
| SHJ-50 | 50.5 | 32-68 | 500/600/700/800 | 37-45-55 | 5.8 | 80-200 |
| SHJ-63 | 62.4 | 32-68 | 500/600/700/800 | 55-75-90 | 5.8 | 150-350 |
| SHJ-72 | 71 | 32-68 | 500/600/700/800 | 90-110-132-160 | 5.7 | 300-600 |
| SHJ-85 | 82 | 32-68 | 500/600 | 160-200 | 5.7 | 600-1000 |
| SHJ-92 | 91 | 32-68 | 500-600 | 250 | 5.8 | 840-1600 |
| SHJ-135 | 133 | 32-68 | 650-750 | 400-500 | 5.8 | 1950-3250 |
| Filling modification | PE, PP, EVA, ABS, PC, PS, etc+calcium carbonate, talc, glass beads, SiO2, aluminum hydroxide. Magnesium hydroxide, brocade oxide, sulfuric acid |
| PP, PA, ABS, etc. + iron powder, magnetic powder, aluminum powder, stainless steel wire, ceramic powder | |
| Blending modification(rubber and plastic compounding, plastic alloy | PE, PP, PS+SBS, PP, PA+EPDM, POE, PP+NBR, EVA + silicone rubber, etc. |
| PA, PC+ABS: ABS+TPU: PBT+PET: PP+PE, etc. | |
| Masterbatch | PE, PP, ABS, EVA, PS, PBT, PET, etc. + pigments and other additives |
| Functional masterbatch | Biodegradable masterbatch: PE, PS, PP + starch, etc. |
| Flame retardant masterbatch: PE, PP, PA, ABS, PBT, etc. + flame retardants and other additives | |
| Polyethylene master batch,anti-fog and anti-aging, high thermal insulation masterbatch, cooling masterbatch, rheology modified masterbatch, anti-rust masterbatch, stiffening masterbatch, antistatic masterbatch, antibacterial masterbatch | |
| Carbon black masterbatch: PE, EVA, ABS, PET, etc. + carbon black | |
| Glass fibre (Carbon fibre)Reinforcement (MD model short fibre) | PP, PBT, ABS, AS, PA, PC, POM, PET, PEEK, PPO, PES, etc. + long glass fiber or short glass fiber |
| PP, PBT, ABS, AS, PA6, PA66, PC, POM, PET, etc. + long carbon fiber or short carbon fiber | |
| Thermoplastic elastomer | TPR, TPU, TPV, SBS, SEBS, SIS, etc |
| Special material | EVA, PU hot melt adhesive, silicone adhesive, UHMWPE spinning |
| Fluororubber, fluoroplastics, LCP, PEEK, PES, PL, PSU, etc. | |
| Optical cable covering material, acetate fiber, PP cigarette filter material, conductive plastic | |
| TPR, PU, EVA foam sole material | |
| Luminous plastics, antibacterial plastics, anti-UV plastics, PE cross-linkable pipe materials food, pet feed | |
| Various cable materials | HDPE, LDPE, LLDPE, MDPE, PP, EVA Insulation material, sheath material, PF Radiation cross-linked cable material, PE Silane cross-linked cable material |
| Flame retardant polyolefin cable materials, low smoke halogen-free flame retardant cable materials | |
| Low smoke and low halogen flame retardant PVC cable material | |
| Reactive extrusion | Polyamide polycondensation reaction, polyester melt polymerization reaction, polyurethane polycondensation reaction, polycarbonate polycondensation reaction, polyoxymethylene bulk continuous polymerization reaction, PMMA polymerization |
| Devolatilization | Chlorinated polypropylene, chlorosulfonated polyethylene, fluorine rubber, butadiene rubber, SBS, EPDM, SEBS, SIS, etc. |
| Powder coating | Polyester type, epoxy type, acrylic vinegar type, polyurethane type, acrylic vinegar, phenol resin, etc. |
FAQ
1.Are you a factory or trading company?
We're a factory, located in Lishui, Nanjing city with 20 years experience.
2.What's your advantages over other vendors?
The greatest advantage over other vendors is our strong processing capability .
Core parts of the twin screw extruder is all manufactured at our own factory which makes the production cost controllable.That's why our machine enjoy a high performance to price ratio.
Other advantages include:
Excellent quality control
Professional Tech. and R&D team
Mega after-sale service
Sufficient spare parts
Fast delivery
Competitive price
3.Where is your factory located? How can I visit there?
Our factory is located in NO. 337 East Zhening Road, Zhetang Town, Lishui, Nanjing, Jiangsu Province, China.
(1) You can fly to Nanjing Lukou Airport directly. We will arrange to pick u up at Lukou airport.
(2) You can fly to Shanghai Pudong International Airport then come to Nanjing by High-speed bullet train, then we will pick you up at Nanjing south railway station.
4.How can I know the status of my order?
We will keep you updated by photos and videos. Once the machine is completed and ready for shipment, we will inform you to come to inspect the machine.
5.How long is the deliver time?
Normally, 45 days from the date we receive your deposit.
6.How long is the warranty?
One-year warranty for the whole machine.
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