Colored masterbatch blending is one of the main applications of the two-screw extruder. Colored masterbatch is used for any polymer and all types of products. In general, there are three types of colored masterbatch: single pigment concentrates (SPC): polymer blending with a pigment and often without wax and additives, custom masterbatch or custom paint: mixing monochrome masterbatch tablets to prepare the colored desired by the customer And modified masterbatch: mixing polymers and multi-pigments and additives In the continuation of this PETROPROVIDERS article, join us to show you the types of colored masterbatch and their applications.

Introducing the types of masterbatches and their applications

  1. Single colored and custom PP base for filament yarns (BCF and CF)
  2. PBT base colored masterbatch for POY and FDY yarns
  3. PET-based colored masterbatch for polyester (PSF) fibers
  4. Optical brightener masterbatch

These materials have different applications in different industries. for example:

  • Fibers (carpets, textiles, home furnishings, etc.)
  • Film (shopping bags, casting film, multilayer film, etc.)
  • Blow molding (cosmetic containers, oil and paint containers, etc.)
  • Extrusion molding (sheets, pipes, wires and cables, etc.)
  • Injection molding (automobile, electronics, manufacturing, furniture, furniture, toy accessories, etc.)

Monochrome and custom PP base for filament yarns (BCF and CF)

There are more than 20,000 colors for PP base carpets and BCF and CF filament yarns. So it is better to prepare a single colored masterbatch first and then to produce a custom masterbatch to achieve the final product.

Production of types of colored masterbatch; Monochrome masterbatch:

Production of types of colored masterbatch

Production of types of colored masterbatch

An extruder is required for any color (for example, light red to dark red). Most pigments require a pre-mixing process for better dispersion. A separate chamber and dust collection system are required for the mixer, and PP in powder form is required for one-time mixing. If the two-step blending process is performed or the feed-sharing system is used for the first time, PP in tablet form will be required.

It is recommended to use a three-screw extruder for better distribution and higher output, due to 40% higher production volume and an additional screw for mixing.

Production of types of colored masterbatch custom masterbatch:

The process is clean and has a high degree of automation. It only needs high torque and high screw speed for more output. A fast-cleaning filament to change color without a heater only takes 2 minutes to change the direction of the other color.

Two types of processes are needed:

  • Mixer + two screw extruder + stringing system with water cooling
  • Weight feeding system + two-screw extruder + stringing system with water cooling

Production of PBT based colored masterbatch for POY and FDY yarns

The viscosity of PBT is lower than PP, so it requires a special screw design. PBT is in powder form, premixing is required to perform the process and requires a separate room and dust collection system. In addition, a strong vacuum system is required to remove moisture and minimal IV droplets.

It is recommended to use a three-screw extruder for better distribution and higher output.

The space between the two screws as well as between the screw and the cylinder should be as small as possible. So the smaller the extruder, the better.

Production of PET-based colored masterbatch for polyester fibers (PSF)

PSF is always made from recycled PET. Dispersion for polyester fibers is less than for colored masterbatch for POY. Its most famous and widely used formula is a mixture of PET bottle caps (less than 10 mm in size) with 25-40% black carbon powder, which is produced by feed sharing and cooling system by water.

Feed sharing with two weight feeders with minimal contamination in the form of dust

It is preferable to use an underwater threading system for higher output. In this method, the strings are automatically inserted into the cutter with water. Even if they are disconnected when replacing the filter or string, they are re-inserted into the cutter by a stream of water without the need for an operator. So almost no waste is generated during this process.

Optical brightener Masterbatch

In addition to the practical context, effect pigments are also used in the decoration of plastics and have become an essential part of the design of new products. Social developments and color trends are constantly being studied. Selected colors are refined with Optical brightener pigments, making the final product unique and valuable. Types of Optical brightener masterbatch:

  • Colorful effect
  • Metallic-effect
  • Fluorescent effect
  • Marble / granite effect
  • Phosphorescent (glow in the dark)
  • Create fragrance

Optical brightener pigments have a layered structure and their particle size varies up to 170 microns. They are sensitive to shear force, so the best process is to feed the fifth zone of the extruder through a feeder with lateral force. In addition, special weaving elements are required with a greater distributive effect than diffusion. Requires less shear force and more mixing.

Colored masterbatch with micron granules

Micron granules are less than or equal to 1 mm in size and are produced by an underwater filament system.

Colored masterbatch Advantages

Colored masterbatch uses

Colored masterbatch uses

Because of their small particle size, micronized tablets disperse more evenly and, like traditional crude polymers, are better distributed. In comparison, older masterbatches with “normal” size granules should be used in higher doses to have the desired effect.

Therefore, less pigment is required when using micron granules, which leads to significant cost savings; Because masterbatches are much more expensive than raw polymers. In addition, masterbatch in the form of micron granules is much easier to work with, dosing is easier and does not lead to dust.

A summary of the review of types of colored masterbatch

In this article, we saw the types of colored masterbatch. This material is produced in different grades and types and is used in industries. Masterbatch is a concentrated mixture containing three components of a polymer base, additive chemicals, and an active compatible agent as a dispersant.

Masterbatch additives are large amounts of pigments, mineral fillers, or chemicals that are added to a polymer for three different purposes: to produce the dye, to improve the properties, or to reduce the cost. The polymer base of the masterbatch usually has to be similar to the original injected plastic and its appearance is granular.

There are several ways to produce types of colored masterbatch. These methods must be done following the standards to produce the best product.

What do you think about types of colored masterbatch? Can it replace the world’s most popular polymers? In the comments section, you can tell us your opinions about types of colored masterbatch. In addition, to buy the best polymeric materials, you can contact our experts.

What is the most important method of producing masterbatch?

It is an important chemical made from a combination of calcium carbonate and polypropylene.

How is colored masterbatch produced?

This grade of masterbatch is produced by observing standard conditions and by various methods.

Is masterbatch a chemical?

It is an important chemical used to produce various plastics in global industries.

Is Masterbatch dangerous to human health and the environment?

No! Many studies have been done on this substance, but none of them have confirmed the toxicity of masterbatch.