Everything You Need To Know About Masterbatches - UFlex Blog

Everything you need to know about Masterbatches

Plastic has taken up every possible role in the consumer & industrial market, be it FMCG, White Goods, Medical or the Automotive segment, but can plastic alone, in its raw form, be this versatile and meet the varied expectations from such a diversified range of applications? The answer is no. It requires supporting additives to give it the shape, color and have the desired   characteristics so that the end product meets the intended functional requirements. This role is accomplished by addition of masterbatches / filler compounds. It is one of the most economical ways for coloring and adding various additives to the base polymer during various plastic processing operations such as Injection Moulding, Blow Moulding, Extrusion, etc.

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Essentially, Masterbatch is a supplementary ingredient that is added to plastic polymers to impart properties such as color, coloring effects, strength, fire retardant properties and other traits. The Masterbatches / filler compounds have a base polymer in which a high concentration of pigments / additives is embedded during compounding which essentially involves extruding and granulating the mix so as to get the granules. 

How are masterbatches made?

It is important to understand that masterbatches are different from plastics in the way that plastics are complex and long chains of polymers, while masterbatches are simple polymers or resins along with very high concentrations of desired chemicals. These are highly concentrated mixtures of pigments and additives that are added during final plastic processing in the required proportions.

Masterbatches are made using either simple polymers like high density polyethylene (HDPE) or more complex carbon-fiber composites. Manufacturers are normally tailored and manufactured as per customer specific requirements and involve the following steps:

• Mixing: The polymers, additives, chemicals are mixed to get a homogenous consistency.
• Extrusion: Polymers undergo the extrusion process, where they're heated and passed through smaller apertures in extruders. The pigments and additives are added over time to the mixture in specific dosages to get the desired properties.
• Wetting: To avoid clumping and even dispersion of the pigments, the mixture is moistened periodically.
• Cooling: The mixture is then cooled off completely and passed through a pelletizer or pulverizer to make granules, pellets, or powder as per the requirements. In certain cases the Masterbatches may be supplied in liquid form also (Pigments used for Coloring PET Preforms.
• Later, the mixture is packaged to be stored or transported conveniently.

Different Types of Masterbatches

Masterbatches are classified depending upon the final application. 

• White Masterbatch:  White concentrates make the plastic opaque due to its Titanium Oxide content, which has the ability to scatter light and thus make the object appear opaque. It has many applications, such as lamination, protective filming, coating, pipes, thermo-forming, fibers, and primarily in blow moulded and injection moulded plastic components.

• Black Masterbatch: It is a very cost effective method to impart certain features like UV protection, conductivity and color with good performance by using carbon black to generate the black color in plastics. The carbon black gives a range of tones, from alcohol blue to warm brown. It makes the plastic durable and resistant to extreme weather. It has multiple applications in the plastic and engineering industries like laminated tarpaulin, PE films, telecom duct pipes, HDPE pipes for agriculture, PP fibers and filaments, and Roto Moulded tanks.

• Color Masterbatch: Color concentrates are used to impart color effects to the plastic. It can be specific to the brand's specifications, or used to create a specific effect like marble, glitter, metallic, granite, wood, fluorescent effect, etc. These masterbatches find wide uses across industries and consumer products, for instance, in home appliances, toys, CDs, cosmetic bottles, plastic furniture, textiles, etc. Apart from color, these also provide thermal stability to the plastic products.

• Additive Masterbatches: These are added to the plastic to improve its heat resistance, impart fire retardant properties, provide slippage, anti bacterial properties, etc. By virtue of the additives added, the polymer becomes more heat conductive, takes less time to melt and cool off and has improved stability to sustain heat and shearing during processing. It becomes more rigid and durable and less susceptible to oxidation or UV exposure. These additives can be very specific in terms of their function, like optical brightener, flame retardant, UV stabilizer, anti static agent, PP clarifying agent, blowing agent, anti-oxidant, etc. These type of additive masterbatches find application in practically all applications wherein polymers are used like packaging, consumer goods, automotive, building and construction, agricultural equipment, etc.

• Filler Masterbatches: It is a compound of CaCO3, Talc, Glass Fibres, speciality compounds like Molybdeum di Sulphide, etc and primary plastic resin plus other additives as per customer specific requirements. Primary plastic polymers are costly and non-biodegradable. Filler masterbatches are mixed with the primary polymers to increase their range of functionality, cost-effectiveness, improve productivity, etc. CaCO3 fillers increase the rigidity and plasticity of the end product. Cost effective CaCO3 masterbatches find use in the production of ceiling panels, plastic frames, plastic doors, PVC pipes, electrical cables, films, fibers, blow moulding and injection moulding.

Why choose masterbatches?

Masterbatches are one of the most convenient methods to add a desired property to a polymer /  plastic product. It has a lot of advantages over concentrated pigments or additives while adding to the final product.

• Ease of blending additives: Since the masterbatches are premixed with carrier resins and additives of known concentration in the form of pallets or granules, it becomes easier to incorporate them directly into the polymer mixture without any specialized dosing equipment.
• Accuracy of Additives: The masterbatches have a predetermined percentage of dosage, therefore, calculating the amount to be added to the polymer is simpler and does not require much precision. Also, it reduces the chances of variation during the manufacturing of  products over course of time. 

• Better product consistency: Because masterbatches and polymers have similar physical properties, they easily blend together, giving the product a consistent color, opacity, or other characteristic. Due to uniform dispersion of additives, the complete manufacturing lot has the same characteristics, minimizing rejections and saving on cost.

• Safely Managing Hazardous Materials: Masterbatches are convenient and safe to handle since the additives or pigments are embedded into the inert resins. There is no chance of an airborne hazard, as well as no dust or powder spills, which could be a danger to both the environment and humans. Thus, requiring no specialized safety equipment or gear.

• Easy Handling of Material: Masterbatches are also easy to handle, store, and transport, with no risk of spills or dust accumulations on the surfaces. As a result, there is no cross-contamination, cleaner work floors, and a quick transition to different production lines.

• Better shelf life: Once the additives are encapsulated in the resins, they lose their reactivity and become stable. Also, they are less affected by external factors like temperature, humidity, and UV exposure, thus increasing their stability and shelf life.

Masterbatches are simple compounds with exceptional qualities, which make the manufacturing process a lot simpler, cost-effective and much more efficient. With the reduction in complicated procedures, handling equipment, and the dire need of accuracy, manufacturers can achieve higher levels of quality, consistency, and reliability in their final products with better productivity.

Due to the materbatches, polymers have been used to manufacture a diverse range of products for varied applications thus improving the overall quality of life of human beings and making many products easily available at affordable prices.

In the plastics industry, masterbatch is essential for achieving the desired colours and special properties in plastic products. Particularly in specialized industries such as cables and PVC, masterbatches are crucial to meet the required levels of quality and performance.

This article provides a detailed analysis of what a masterbatch is, its advantages, the different types available for the PVC and cable industries, as well as the dispersion and dilution processes that are fundamental to its effectiveness.

Definition of Masterbatch

A masterbatch is a highly concentrated mixture of raw materials, characterized by excellent pigment dispersion and easy dilution in the base polymer. Its primary purpose is to provide colour or specific properties to plastics, allowing for precise and efficient control over the final product. Masterbatches come in different forms and sizes, such as pellets and micropellets, depending on their application and manufacturing process needs, and are designed for various industrial applications, including PVC products and cables.

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The composition of a masterbatch mainly includes pigments, additives, and a polymer base. Pigments can be organic or inorganic and determine the colour and some properties of the final material. Additives, on the other hand, provide additional characteristics such as UV resistance, anti-static properties, or flame retardancy. The polymer base acts as a carrier for the pigments and additives, facilitating their incorporation into the plastic material during the manufacturing process. This combination ensures uniform coloration and consistent properties in the final product, which is key in industries that depend on high precision in color and material properties.

Advantages of Using Masterbatch

Using masterbatch in plastic product manufacturing offers numerous advantages:

• Customized formulations for each application: In the plastics industry, each application has specific requirements. Masterbatches can be custom-formulated to meet these needs, ensuring that the final products have the exact properties required. This customization not only optimizes product quality but also enhances functionality and performance.
• Elimination of airborne particles: Unlike other materials, masterbatches do not generate airborne particles during handling. This contributes to a cleaner and safer work environment by reducing health risks for employees.
• Improved safety with no risk of skin contact: Masterbatches are safer to handle as they do not pose dermal contact risks. This is particularly important in the plastics industry, where frequent handling of materials can pose a safety challenge in the workplace.
• Precise and clean dosing: Masterbatches facilitate a more efficient production process thanks to their easy and clean dosing. This not only minimizes waste but also ensures efficient incorporation of color and additives into the base polymer, improving the quality and consistency of the final product.
• Prevention of cross-contamination: Masterbatches ensure that the colors and properties of products remain consistent and are not affected by cross-contamination. This is essential in production lines that handle multiple products and colors simultaneously.
• Complete pigment dispersion: Pigments in masterbatches are fully dispersed in the base polymer, ensuring uniform coloration and consistent properties in the final product, without imperfections or color variations.
• Perfect color consistency: Perfect color consistency ensures not only that all products have a uniform and high-quality appearance but also reduces batch variability, improves production repeatability, and better compliance with technical specifications.

Types of Masterbatch for the PVC and Cable Industry

In the PVC and cable sectors, masterbatch additives play a crucial role. Below are some notable types:

Masterbatches for the PVC Industry

PVC is one of the most versatile polymers and is used in a wide range of applications, from pipes to coatings and flooring.

Using masterbatch in PVC allows for customization of both color and physical properties of the final product.

• DELTAVINIL Standard Pellet → Developed for all types of applications in the PVC manufacturing sector. It is used in cables, profiles, pipes, and films. This type of masterbatch provides excellent dispersion and easy dilution in the base polymer.
• DELTAVINIL Micropellet → Used in cables, profiles, pipes, and films, this product range is designed to improve masterbatch dilution in the compound, ensuring a homogeneous mix and uniform distribution of color and additives.
• DELTAVINIL Small Micropellet → Developed for all types of applications in the rigid PVC manufacturing sector where rapid dilution and good homogeneity are required.
• DELTAVINIL Criopellet → Specially developed for the calendering industry and compounds to produce their own color formulations.
• DELTAVINIL Super Small Micropellet → An even smaller pellet that optimizes dispersion, incorporates more efficiently, and significantly improves the quality of the final product without visual irregularities.
• DELTAPLAST Powder → Mixed pigments, primarily dispersed in PVC or CaCO3, in powder form. Used in the PVC manufacturing industry, this type of masterbatch offers rapid and efficient pigment dispersion.

Masterbatches for the Cable Industry

In cable manufacturing, color masterbatch is essential for identification and coding. Cables must be easily identifiable to comply with standards and ensure safe and efficient installation. Additionally, masterbatches play a crucial role in providing properties such as fire resistance, UV protection, and thermal stability.

Delta Tecnic develops specific masterbatch ranges designed to cover the technical color needs of various cable industry applications: Automotive, Energy, Telecommunications, and Additives.

• DELTAPLAST Standard Pellet → Developed for the cable industry, its spherical shape improves dosing compared to traditional cylindrical pellets. It provides excellent size consistency for inline dosing in fast production lines.
• DELTAPLAST Micro Bead → Designed to improve colour dilution where traditional spherical masterbatches do not achieve good color homogenization. The spherical shape and small size improve dosing compared to traditional cylindrical pellets. This shape and formulation help eliminate scratches and uneven color areas in cable manufacturing where conventional masters fail to achieve good dilution.

Importance of Dispersion and Dilution in Masterbatches

Dispersion and dilution are key processes in manufacturing plastic products using masterbatches. Good dispersion ensures that pigments are distributed uniformly, while proper dilution ensures perfect colour homogeneity and the highest quality.

• Dispersion is the process by which agglomerated pigments, which often appear in pure powder pigments, are mechanically separated into crystalline units, preventing them from re-agglomerating. A well-dispersed masterbatch provides better quality when used in the plastic transformation process. Poor dispersions can cause defects in the final product, such as unwanted color spots or areas with different physical characteristics.
• Dilution is the process by which a masterbatch is incorporated into the compound during the plastic transformation process. A well-diluted masterbatch provides perfect colour homogeneity and maximum quality. Several factors influence dilution quality, such as the formulation and pellet size of the masterbatch. Rapid dilution of the masterbatch helps achieve high production speeds.

A well-dispersed and diluted masterbatch is essential to avoid defects such as color variations or inconsistencies in material properties.

Masterbatch vs. Pigments: Clear Advantages in Plastic Manufacturing

The use of masterbatches offers significant advantages over powder pigments, not only in terms of final product functionality but also in optimizing production processes.

• Superior dispersion and homogeneity: Masterbatches ensure uniform dispersion of color and additives in the base polymer, avoiding inconsistencies and stains that are common when using pure pigments.
• More efficient production processes: Thanks to their presentation in pellets or micropellets, masterbatches are easier to handle and incorporate into the production process, eliminating dust generation and minimizing contamination.
• Greater workplace safety: By being encapsulated in a polymer matrix, masterbatches eliminate health risks associated with handling powder pigments, creating a safer work environment.
• Precise dosing control: Masterbatches allow for precise dosing control, reducing material waste and ensuring uniform consistency in the final product.
• Improved product quality: The color consistency and homogeneous distribution of additives provided by masterbatches ensure high-quality final products with a uniform appearance across production batches.
• Adaptability and customization: Masterbatches can be formulated to meet specific performance requirements, such as UV resistance or fire resistance, offering superior versatility compared to powder pigments.

Conclusion

Masterbatch is an essential component in the plastics industry, providing not only color but also critical functional properties for a wide range of products, from cables to PVC applications such as films, pipes, profiles, calendering, and flooring, among others. Its ability to enhance quality, safety, and functionality across various sectors makes it an indispensable tool for manufacturers. By offering customized formulations and uniform dispersion, masterbatches help optimize production processes, ensuring high-quality products that meet the most demanding technical standards.

As technology and market demands evolve, the future of masterbatch is oriented towards sustainability and innovation. Growing environmental awareness drives the development of masterbatches based on recycled and biodegradable materials, which are expected to play a key role in the market. Additionally, enhanced customization capabilities allow manufacturers to design highly specialized products tailored to the specific needs and requirements of their customers.

This focus on sustainability and advanced customization will not only strengthen the position of masterbatch in the plastics industry but also foster the creation of innovative solutions that address future challenges. Companies that adopt these trends will be better positioned to offer high-quality products with a lower environmental impact and greater added value for the end consumer.

Contact us to discuss your requirements of colorful masterbatch. Our experienced sales team can help you identify the options that best suit your needs.