Masterbatch

S H A KT I N A D A R
PA C K A G I N G D E V E L O P M E N T
C AV I N K A R E P V T. LT D .
26TH AUG 2015

Contents
1. Masterbatch & its types
2. Importance of Distribution & Dispersion
3. Masterbatch Manufacturing Process - https://youtu.be/0j3-GY-B6vk
4. Effect Pigments
5. Additive MBs
6. Fillers

Definitions
Polymer Compounding : Combining a base plastic resin with Colours,

Modifiers, Reinforcements, Fillers or other polymers by Melting & Mixing in an

Extruder to convert the base resin properties to deliver a better performance,
low cost, ease of manufacturing & more attractive appearance.

Agglomeration : to form a mass

Pigments : Colouring matter

Masterbatch
Polymer granules with a high percentage of additives (higher than in the end
use)
Additives are optimally dispersed & encapsulated in a carrier material

Types of Masterbatch
1. Colour Masterbatch for colouring plastic products
2. Additive Masterbatch for certain chemical & physical properties for
end product

3. Filler Masterbatch for cost reduction

Goal of Masterbatch Production

The Aim is the ideal dispersion of pigment/additives in the polymer matrix.
The powdery feed material tends to agglomerate.

Dispersive & Distributive Mixing:

Dispersion : incorporation of pigment/additives into binder or carrier
Distributive mixing : distribution of the material without destroying the single
components

Mixing
Bad DISPERSION & Bad DISTRIBUTION

Mixing
Bad DISPERSION & Good DISTRIBUTION

Mixing
Good DISPERSION & Bad DISTRIBUTION

Mixing
Good DISPERSION & Good DISTRIBUTION

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Production Process
Premix consisting of:
Polymer, Pigment & dispersion additive
is fed to the extruder

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Polymer is plasticized first

Pigment & dispersion additive
via separate feeder

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Methods of Producing
Masterbatch
Single Stage Process
All the components are combined in one processing step
Process can be either Pre-mix or Split
Can be applied for all 3 types of Masterbatch

Two Stage Process

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Methods of Producing
Masterbatch
Two Stage Process
Single pigment are produced in the same manner as single stage
Followed by second extrusion step, that combines required ratio of colourant
& additive
Can be applied only for Colour Masterbatch

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Methods of Producing
Masterbatch

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Colour Masterbatch
Colour Pigments (20-90%) + Carrier Polymer (>10%)
(Carrier polymer selection is basis compatibility of the Raw Polymer which is
used for the Plastic product)

Universal Masterbatch
(these are polymer less masterbatch)

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Effect Pigments
Iriodin (Merck)
Pearl luster pigment
Glittery as well as silk matte luster

Colorstream (Merck)
Achieves multicolour effect

Xirallic (Merck)
Crystal Clear pure white lustre

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Effect Pigments
Firemist Colourmotion (BASF)
Glittering effect

Santa Fe (BASF)
Earth tone added desert like hue
Specular property (mirror like)

Dynacolour (BASF)
Gives high degree of colour purity & intensity

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Additive Masterbatch
Anti-Static:
Reduces static charges developed in the plastic products

Anti-Block:
Plastic film layers tend to stick together, this phenomena is called Blocking.
Anti-block MB create small space between the 2 layers (surface roughness)
preventing blocking.
Additionally this imparts Slip properties & Scratch resistance
Allows smooth unwinding of Rolls

Anti-Fogging :
Fogging refers to condensation of water-vapours on the surface of the plastic film
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Additive Masterbatch
Anti-Oxidant :
Used to protect polymers from Degradation, during processing & during use
During polymer degradation free radicals are formed, resulting in uncontrolled
chain reactions
Anti-Oxidants are used to decrease the amount of free radicals

Cling Agent :
Used during the manufacturing of stretch films

UV Masterbatch :
These are PE filled with Ultra Violet Stabilizers (hindered amine light stabilizers)
Harmful UV rays from sunlight degrade & discolour the exposed plastic products
UV MB avoids discolouration & chalking
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Additive Masterbatch
Optical Brightener Masterbatch :
Used to impart whiteness & brightness to plastic products without any blue tone

Silicon Masterbatch :
Enhances abrasion resistance

Processing Aid Masterbatch :

Improves the extrusion ability of the polymer

Clarifying Masterbatch :
Lowers the haze & improves the transparancy in Injection moulded items

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Fillers
Fillers are materials added to plastic to lower the consumption of expensive
polymers.
Eg.
Calcium Carbonate (CaCO3)
Talc

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Benefits
Optimum Dispersion of pigments/additives
Low Stock holding compared to pre-compounded materials
Dust free, no health or safety risk
Reduction in purging cost

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Thank You
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