What is Masterbatch?
Masterbatch is an important additive material used in the plastics industry. Masterbatch is a raw material which is present in high concentration in the form of granules produced by impregnating a polymer carrier with color pigments or curative additives. Less preferred than granule is available in liquid masterbatch. Any plastic manufacturer takes a standard masterbatch additive or a specially made product for it, mixes it in its own raw material at the appropriate rate, and reveals the final product. Masterbatch use of the manufacturer offers many advantages over using direct color pigment or healing additive.
-With the masterbath, the color formulation is stabilized to ensure continuity,
-Provides operational cost advantage,
-Instead of using powdered pigment, cleaner masterbatch granules are used in production,
-It saves time during production.
Masterbacth is produced by blending the selected carrier polymer suitable for the final product raw materials with color pigment or healing additive (uv, antislip, etc.) at appropriate temperatures in the extruder machine and then cutting in granular form in the cutting machine after cooling process. The two most important criteria in masterbatch production are: pigment or healing additive is prevented from clumping in the carrier to provide high dispersion and distribution. In the picture below, the red pigments are spread homogeneously with the polymer particles in the center. In this regard, the adhesive wax material can be used as an aid in the production of masterbatches for the purpose of improving the spread. Thanks to the wax, the polymer retains better pigment on the surface.
WHAT SHOULD BE CAREFULLY IN MASTERBATCH SELECTION
-The raw material used must be compatible with the masterbatch carrier.
-The maximum value must be specified at the machine operating temperatures.
-Information on the use of hot runner on the production line must be specified.
-Print time must be specified.
-If the final product size is variable, it should be done according to the largest part.
-If the final product is too detailed, it should be indicated.
-Masterbatch usage rate should be used in the recommended range. Otherwise there is a problem of tone difference and covering.
-The same dye can be in different tones when the form of production changes.
-Film thickness affects opacity and color.
-If the final product is to be exposed to the sun, pigments with high light fastness should be used.
-Whether food and RoHS compliance is desired or not is indicated.
-The type of light to which the product is controlled should not be variable.
-Pull information must be specified.
-Migration value should be specified.
-When the parameters present in the masterbatch run change, it is absolutely necessary to test-manufacture before use on the other run.
-The volumetric (volumetric) or gravimetric (weighing) of the dosage changes the color power.
-Our work is carried out according to the gravimetric production method unless otherwise stated.
-If the magnet used in the production line is available, this information should be given.
-It should be noted if there are previous problems with the distribution.
CONSIDERATIONS DURING USE
-Particularly the fillings used in PVC production are changing color tone.
-The difference in cable production shapes affects the color of the paint.
-The fact that the machines are not cleaned well causes discoloration and scars. Stopping the operation of the machines may cause the theme with the material that already exists in the field outside the remaining flow path. This, in turn, manifests itself in trace problems. In cases where machine contamination is suspected, only a few prints with raw material should be taken and the cleaning of the flow line should be controlled at every stage.
-The first prints should be checked when the machine is stopped and restarted for more than 10 minutes.
-Burning can occur because the material has been exposed to heat for a long time.
-Especially when raw materials used in film production and micron changes, trial production must be made.
-When working at the melting point of the used carrier at low temperatures, the final product will not melt.
-Humidity-sensitive raw materials must be conditioned before production