Filler Masterbatch Extruder

Filler Masterbatch Extruder

Applications

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

a) 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 masterbatches in injection & blow-moulding applications can be up to 50 %, however, most usual levels are between 5-30 %.

b) 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 masterbatches in film applications is 2-20 %.

c) 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 masterbatches in tapes is 3-8 %.

d) 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 due to its excellent cold resistance
◆ Usual addition rate of FILLER masterbatches in tapes is 5-30 %.

Processing of Filler Masterbatch

We design the extruders for filler masterbatch, according to the output, formula and final application as your request.

a) 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.

b) Technical Specifications of Extruder
According to your application & output, there’re many different choice on extruders.

Twin Screw Extruder

Model Diameter(mm)  L/D Speed(rpm) Power(kw) Torque T/A3 Output(kg/h)

GTE-52C 

GTE-52D 

51.4 32~60

500 

600
800
1000

75 

90
110
132

675 

675
620
594

8.5 

8.5
7.8
8.5

225~375 

270~450
330~550
400~660

GTE-65C  

GTE-65D 

62.4 32~60

400
500 

600
800
1000

110
132 

160
200
250

1240
1190 

1200
1125
1125

8.8
8.5 

8
8
8

330~500
400~660 

480~800
600~1000
750~1250

GTE-75C  

GTE-75D 

71 32~60

400
500 

600
800
1000

160
200

250
310
400

1800
1800 

1875
1770
1800

8.3
8.3 

8.7
8.2
8.3

480~800
600~1000 

750~1250
945~1575
1200~2000 

GTE-85C  

GTE-85D 

81 32~56

400
500 

600
800 

220
280 

350
450

2485
2520 

2625
2530

7.9

8.3
8.1 

660~1100
840~1400 

1050~1750
1350~2250 

GTE-95C  

GTE-95D 

93 32~56

400
500 

600  

350
450 

550

3940
4050 

4125 

8.3
8.5 

8.7 

1050~1750
1350~2250 

1650~2750 

GTE-135C  

GTE-135D 

133 32~48

300
400 

600  

750
1000 

1500

11250
11250 

11250 

8.5
8.5 

8.5 

2250~3750
3000~5000 

4500~7500

Production flow chart of filling masterbatch

When filling masterbatch blending and granulation, the raw material part can adopt a variety of raw material treatment processes, such as high mixer mixing treatment or weight loss metering feeding.
The treated raw materials are distributed and mixed in a twin-screw or triple-screw extruder, dispersed and mixed, and finally is cut into granules, and then experiences drying, cooling, screening and bagging.

Filler masterbatch showcase

Purchase Guidance

A filler masterbatch extruder operates based on the principles of extrusion. The process involves several key components that work together to achieve efficient filler dispersion.

1.Feed Hopper: The feed hopper is where the raw materials, including the polymer resin and fillers, are loaded into the extruder.

2.Screw and Barrel: The heart of the extruder, the screw and barrel, facilitate the melting and mixing of the raw materials. The rotating screw conveys the materials forward while exerting pressure and generating heat through friction.

3.Heating Elements: Heating elements are strategically placed along the barrel to melt the polymer resin and maintain the desired temperature throughout the extrusion process.

4.Die: The die is a specially designed opening located at the end of the extruder barrel. It shapes the molten polymer into the desired form, such as sheets, rods, or pellets.

The utilization of a filler masterbatch extruder offers several significant advantages for the production of plastic products:

● Enhanced dispersion of fillers in the polymer matrix
Filler masterbatch extruders ensure efficient and uniform dispersion of fillers within the polymer matrix. The extrusion process facilitates the thorough blending of fillers, eliminating agglomeration and achieving a homogenous mixture. This leads to enhanced mechanical properties and improved product performance.

● Improved mechanical properties of the final product
The incorporation of fillers through a masterbatch extruder enhances the mechanical properties of the final plastic products. Fillers contribute to increased stiffness, impact resistance, and dimensional stability, allowing manufacturers to produce high-quality and durable plastic components.

● Cost-effective solution for filler incorporation
Using a filler masterbatch extruder offers cost advantages by enabling efficient utilization of fillers. The extrusion process ensures proper dispersion of fillers, minimizing the required filler content while maintaining the desired product performance. This leads to cost savings by reducing material expenses.

Different types of fillers can be incorporated into a masterbatch extruder, including calcium carbonate, talc, mica, and various mineral fillers. The selection depends on the desired properties of the final product and the specific industry application.

● Throughput and Production Capacity: Consider the required production volume and throughput rate to select an extruder with suitable processing capabilities.

● Screw Design and Configuration: The screw design and configuration should be chosen based on the desired dispersion quality, melt homogeneity, and overall processing requirements. Different screw designs, such as single-screw or twin-screw, can offer specific advantages for filler dispersion.

● Temperature Control and Heating System: The extruder should have an efficient temperature control system to maintain the desired processing temperature. Consider the heating capacity, heating zones, and control accuracy of the extruder.

● Material Compatibility: Ensure that the extruder is compatible with the specific polymer resin and fillers being used. Different polymers have varying melt characteristics, and the extruder should be capable of processing them effectively.

While filler masterbatch extrusion offers numerous benefits, certain challenges can arise during the process. Understanding and addressing these challenges is essential for smooth and efficient production.

● Poor dispersion and agglomeration issues
Inadequate filler dispersion or agglomeration can negatively impact the mechanical properties and appearance of the final product. To overcome this challenge, optimization of process parameters such as screw speed, temperature profile, and shear rate is necessary. Additionally, incorporating proper mixing elements in the extruder can aid in achieving better dispersion.

● Inconsistent melt flow and pressure
Inconsistent melt flow and pressure can result in variations in product dimensions and quality. This issue can be mitigated by ensuring proper screw design, maintenance of consistent melt temperature, and regular inspection of the extruder components for wear or damage.

To achieve optimal performance and quality, certain best practices should be followed when operating a filler masterbatch extruder.

● Preparing the raw materials
Thoroughly pre-mix the polymer resin and fillers in the correct ratio before feeding them into the extruder. This ensures a homogenous blend and improves the dispersion efficiency during extrusion.

● Setting the process parameters
Optimize the process parameters such as screw speed, temperature profile, and residence time to achieve the desired filler dispersion and melt quality. Regular monitoring and adjustment of these parameters are crucial for consistent and efficient production.

● Maintenance and cleaning procedures
Regular maintenance and cleaning of the extruder are essential to prevent buildup and contamination, which can affect product quality and equipment performance. Follow the manufacturer’s guidelines for maintenance intervals, lubrication, and cleaning procedures to ensure smooth operation.

Filler masterbatch extruders find extensive applications in various industries, including:

● Packaging industry
In the packaging industry, filler masterbatch extruders are used to produce plastic films, sheets, and containers. The incorporation of fillers enhances the mechanical strength, barrier properties, and printability of the packaging materials.

● Automotive industry
Filler masterbatch extruders play a vital role in the automotive industry by producing plastic components such as bumpers, dashboards, and interior trims. The addition of fillers improves the structural integrity, impact resistance, and heat stability of these components.

● Construction industry
In the construction sector, filler masterbatch extruders are utilized for manufacturing pipes, profiles, and other building materials. The incorporation of fillers enhances the strength, weatherability, and fire resistance of these construction products.

The fundamental equipment setup for producing Filling masterbatch includes:

Raw material handling system
● Gravimetric feeder/premixer + volumetric feeder
● For a higher proportion of fillers, it is recommended to use an exhaust side feeder.

Twin Screw Extruder:
The Twin Screw Extruder is the optimal choice for producing filling masterbatch due to its numerous advantages, including continuous production, stable quality, high production efficiency, low energy consumption, low labor intensity, and a favorable operating environment. For higher output, it is advisable to use a high torque gearbox and select a screw volume that provides ample capacity while remaining cost-effective.

Strand Pelletizing System/Water Ring Pelletizing System:
● The strand pelletizing system is suitable for filler proportions below 70%.
● The water ring pelletizing system is suitable for filler proportions exceeding 70%.

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