Application masterbatch
Polymer history
The polymer industry has experienced many changes in the beginning of the years with the discovery of natural polymers and evolving into a specialized industry in which it is. Today, organic polymers such as beeswax and bitumen are used. For centuries, however, these materials were unable to be used for general applications because they were too brittle or soft and did not work well with other materials. A few other organic polymers were animal horns or hooves that could only be molded. Natural rubber is soft and sticky in hot weather and very brittle in cold weather. To solve this problem, rubber modified with sulfur and heat, which is called aerating, is used. Bitumen is obtained through the distillation of crude oil and was used for the first time as a sealant and glue for decorative applications. The resulting mixtures require additive masterbatches to be industrially useful. The discovery of natural polymers for polymer modification requires additive masterbatches with properties to be used so that the masterbatches can have a wider range of improved properties. For example, cellulose was considered the first semi-synthetic In order to make it practical for commercial use, the polymer was improved by adding camphor to reduce brittleness. Today, both natural and synthetic polymers rely on additive masterbatches for processing. and create new mixes, additive masterbatches and polymer resins are mixed together to improve Standard mixes are produced that can be customized by adding Various additive masterbatch is created to create various types of selected materials and meet the needs of individual processes. The inclusion of polymer additives allows manufacturers to create personalized mixes and prepare a highly specialized product to meet the needs of their customers. For the packaging industry, this means more materials are available with increased capacity for unique blends for products with specific needs.
what is masterbatch
Masterbatches are intermediate products of the polymer industry, which are used in order to color and create different properties in the form of granules in combination with the raw materials of each final product.
Types of masterbatch
- Colored masterbatch
- Additional masterbatch
- Filler masterbatch
Colored masterbatch
This type of masterbatch is formulated in different bases for mixing with the raw materials of a final product in order to induce the desired color with the following components.
Components of a color masterbatch
Pigments: Color powders (pigments) are mineral substances (such as titanium dioxide and red iron oxide) or organic substances (such as green phthalocyanine) which are present in different percentages in various shades and most of the time in a combined form for coloring. A color masterbatch is applied to the final product in the formulation.
Polymer matrix: because the pigment (colored powder) that is responsible for coloring can be combined with the raw materials of a final product, the color masterbatch must be mixed in a suitable and compatible polymer base before that process. The choice of polymer base in PE, PP, PS, PET, etc. matrices completely depends on the final product or actually the raw materials in which the color masterbatch is supposed to be mixed.
Process aids (compatibilizers): due to the two mineral phases (pigment) and organic phase (polymer matrix) and their incompatibility to an intermediate product for better integration and mixing in the masterbatch production process, the selection of an agent depends on the type of extruder machine. It has two phases. These factors, on the one hand, cause better distribution of pigment, and on the other hand, create a shiny and smooth masterbatch surface. Also, one of the new and ever-developing methods of the polymer industry is the use of additive masterbatches to create better performance and engineered chemical and physical properties in the final product.
You can contact us to order a color masterbatch at Armen Polymer Company with a variety of at least 100 fixed color shades and to order a masterbatch with your desired color and pigment color with the numbers listed in the contact section.
Components of an add-on masterbatch:
1- The agent or the property-giver: which is in the form of minerals such as Optikta Bryzero anti-blocking and chemical such as (anti-static) that by choosing each agent we will achieve the desired properties in Iran, unfortunately, most of these agents are supplied from foreign sources. Armen Polymer Company has always tried to produce world-class products for its customers by providing the best raw materials from the most reliable companies in the world.
2- Compatibilizers: In the formulation: additive masterbatches, in order to preserve the properties and strengthen it during the process until its use in the final product, compatibilizers and regulators are used, which have the role of compatibility and increasing the usability of the product.
3- Basic materials: Every additive masterbatch has an important step to present its role in the products, and that is the selection of the optimal polymer to combine the agent and compatibilizer and finally for the best performance in the final materials. Agents are very sensitive and destructible, and sometimes they give negative results. A suitable polymer will deliver the best product to the market through an engineering process using suitable machinery.
Advantages of using masterbatch
It is easy to feed and solve the problems of using powders and additives in the past and weak mixes and ultimately poor quality production and ultimately better quality control.
More stability of properties and colors and better integration
. Improved melting and mixing operations
Easier and cheaper transportation as well as optimal consumption with dosing systems
Greater cleanliness of the work environment and no spreading of powders in the air and help to maintain the health of the personnel and prevent respiratory diseases and complications of toxic substances.
The percentage of use of color masterbatches and additives function of shape and form guarantee
The amount or percentage by weight of using masterbatch:
First, it depends on the number of agents and pigments in the masterbatch. The higher their percentage, the lower the percentage of masterbatch consumption, and it is affordable for the consumer.
Therefore, percentage as well as quality is the main additive factor
Product warranty (piece) or wrapper and packaging film
Customer taste
The importance of coverage in terms of standard and light transmission of products
In general, the amount of masterbatch in the additive sometimes varies from below 0.5% (in solubilizers and antioxidants, etc.) to over 50% (in some flame retardants and calcium carbonate masterbatch). It is also the usual percentage in masterbatches. Color is between 1 and 3 percent.
. The distinction of color and the property it gives to the product to attract customers
Types of additional masterbatch:
Armen Polymer Company currently produces the most complete basket of additive products in Iran with more than 30 grades. To view the complete technical specifications (TDS) and comprehensive explanations about the identity of the additives, please refer to the datasheets section of the site.
. English-Persian dictionary of polymer engineering and paint engineering
. Sharing
. Create a telegram on the web page
. Presentation in another language
. Activities in projects and technical consultations
. MFI (melt global index), identification of polymers, products
Masterbatch of antioxidants
Additive Masterbatch Antioxidants eliminate oxidation when exposed to substances.
The second category of masterbatch stabilizers are those that resist UV light. Ultraviolet rays damage the chemical bonds of polymer materials. Therefore, in addition, masterbatch of UV stabilizers is very important to produce materials that provide good performance when exposed to UV radiation over a long period of time. This fixative masterbatch absorbs high energy UV radiation And then it releases it to a lower energy level that is less harmful to the polymer. For example, titanium dioxide has a high refractive index, enhances long-term stability and protects against material discoloration.
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The third category of stabilizers prevent thermal damage of materials and maintain aesthetic properties. These are known as heat-stabilized masterbatches.
A fourth batch of flame retardant stabilizer masterbatches formulated to promote the quenching of a polymer. Many polymers can be used in their pure form. Therefore, adding flame retardants can help protect materials and their contents. Flame retardants work by interfering with the combustion process in a combustion reaction that produces less heat.
Masterbatch of lightening/illuminating agents
Nucleating/transparent agents are chemical structures that increase overall and masterbatches can be used to increase stiffness, hardness, impact properties, tensile strength, and control pore size and distribution. Increasing the degree of crystallization leads to the production of more crystals in the same space of this product, therefore, the crystals that tend to be smaller use And they reflect less light, so they have a much higher resolution. High speed helps a polymer to solidify faster when cooled, which can lead to reduced machine cycle times and increased production.
The add-on masterbatch allows for faster processing and improved clarity, glossiness, etc. It provides clarity in polypropylene packaging and is much cheaper than using materials such as polyethylene terephthalate, which is usually used for products that require high clarity.
mfi masterbatch
Masterbatch lubricants are used to improve flow and processing properties.
There are different types with different properties that can improve mixing, extrusion, etc. Internal lubricant masterbatch is a type of additive masterbatch that works by modifying the viscosity of the masterbatch.
Today’s use of masterbatch of internal lubricants is of added value and can also change other characteristics. By achieving multiple goals, masterbatch of lubricant additives can be more economical.
The sliding additive is a kind of internal lubricant masterbatch that creates a better processing process and reduces the internal friction and adhesion of the polymers. The sliding additive masterbatch is used to reduce the surface friction of polymers in the film industry. They are very common because the slip additive helps the film layers so that the film layers roll over each other, which is very useful. Rapid packaging processes Anti-blocking additives are another type of internal lubricant masterbatch that can be improved during production. Anti-blocking additives prevent film layers from sticking together. There are different types of anti-blocking additives that reduce the anti-slip effect.
Anti static masterbatch
The choice of antistatic is very important and is determined by a wide range of factors such as: type of polymer, processing conditions and final application of additives. The masterbatch is determined to be anti-static, allowing the polymer material to dissipate static electricity and static charges can attract dust. An additive masterbatch can act quickly to reduce dust and is an attractant and can be formulated to provide long-lasting effects in on-demand applications. And this product is a combination of anti-blocking and anti-slip products that are often used in the film industry and has the ability to maximize effectiveness and reduce cost and high efficiency.
Masterbatch of connection agents
The main purpose of masterbatch bonding agents is to increase the interaction between the polymer and the carbonate compound to improve the bond between the chemical molecules. Masterbatch Coupling Agents Can Promote Adhesion When They Bind to Polymers Masterbatch Coupling Agents Masterbatch Coupling Agents Because they enhance coupling agents, they can be used to encourage materials that would not normally bond together. This effect can be very useful for experimenting with creating new polymer blends and reusing old polymer materials.
Masterbatch of antibacterial additives
Masterbatch antibacterial additives are used to create resistance against microorganisms so that polymeric materials are protected from bacterial growth. Additives by interfering with the metabolism of microorganisms to block the enzyme systems of being an effective additive must be able to migrate to the surface of the material to be able to interact with microorganisms.
white masterbatch
The effect of components on the hiding power of white masterbatch
Cover strength is one of the most important characteristics of white masterbatch, and the most important influencing factor is titanium dioxide. The effect of the types and content of white masterbatch and the dispersion and change of the fourth component on the strength coating were investigated. The results showed that when the masterbatch carrier resin was of short branch chain structure of low linear density polyethylene, the masterbatch dispersion was better.
Masterbatch dryer
Masterbatch dryer can be used to control the humidity between the layers. This process is done using an extrusion head on a molding machine to create a multi-layered wall in the package. A combination of DryKeep developed made with magnesium sulfate and HDPE / LDPE blow molding. One of the advantages of having a masterbatch dryer in the packaging layers is that it can absorb moisture from inside or outside the bottle.
Add-on masterbatch changing color
Masterbatch Color changing additives can be added to polymers to make them change with their environment, such as temperature changes or exposure to UV light. An example of the use of the Masterbadge additive is the changing color of the coffee cap. Change color when heated so that consumers can identify when the product is to be used. It is handled with care. The manufacturing process is the same except that plastic is embedded. With thermochromic paint during production. Its color change technology is safe and food contact compliant and FDA compliant. Polymers can also change color when exposed to UV light. Other examples of color-changing additive masterbatch Sunscreen lotion bottles can act as sensors that cause the color to change in the sun, so consumers know when to use the product.
Polyethylene wax additive masterbatch
Production process and processing technology of polyethylene wax
Polyethylene wax is a by-product of the polyethylene process. After that, in a surface reactor, the polymerization operation is carried out in two main and secondary processes. In the main process stage, the derivative of polyethylene (polymer) is reacted with an amount of solvent, and in the secondary process stage, the wax is reacted with a certain amount of solvent. The solvent and polyethylene wax are evaporated in several stages. And then they enter special containers in the form of a molten stream, which must be cooled with water and become wax. The composition of this product is very complex and its main source is oil.
Masterbatch equipment
There is a small amount of basic equipment and machinery necessary for processing, the most important being additive masterbatches, filterers, and volumetric or gravity mixers. Devices that hold and combine the additive masterbatch in polymer mixtures. Volumetric devices using gravity devices, the amount passed. From the measuring disc measure and control the weight and additives dispensed over a certain period of time. Gravity types are recommended for cases where there are two or more additive master batches.
