Masterbatch napredna tehnologija ekstruzije s dva vijka i sveobuhvatna rješenja za obradu

1. Pregled Masterbatch industrije i osnovnog znanja

1.1 Trenutna situacija i trend razvoja Masterbatch industrije

Masterbatch, također poznat kao kolor masterbatch ili koncentrat boje, je nova vrsta plastičnog materijala za bojenje visoke koncentracije, visoka disperzibilnost i pogodna upotreba. Izrađuje se ravnomjerno dispergirajućim pigmentima ili bojama, nosači i aditivi u specifičnom omjeru kroz profesionalnu tehnologiju miješanja i ekstruzijske granulacije. U poređenju sa tradicionalnom metodom direktnog bojenja (direktno dodavanje pigmenata plastičnim sirovinama), masterbatch ima prednosti zgodne upotrebe, ujednačeno bojenje, stabilne performanse, zaštita životne sredine i ušteda energije, koji je postupno zamijenio tradicionalnu metodu bojenja i postao glavno rješenje za bojenje u industriji plastike.

Poslednjih godina, potaknut brzim razvojem nizvodnih industrija kao što je pakovanje, automobilski, tekstil, elektronika, građevinskih i kućnih aparata, globalno tržište masterbatcha pokazalo je stalan i brz trend rasta. Prema relevantnim industrijskim podacima, veličina globalnog tržišta masterbatcha je premašena 30 milijardi američkih dolara, i očekuje se da će održati složenu godišnju stopu rasta od 6%-8% u narednih pet godina. Među njima, Asia-Pacific is the world’s largest masterbatch production and consumption market, obračunava više od 60% udjela na svjetskom tržištu, mainly due to the rapid development of the plastics industry in China, Indije i drugih zemalja, the continuous improvement of industrial supporting capacity, and the increasing demand for high-quality, functional and environmentally friendly masterbatch products.

Kina, as the world’s largest masterbatch producer and consumer, has a huge market demand and a complete industrial chain. The annual output and consumption of masterbatch are growing at a double-digit rate, especially in the fields of new energy vehicles, green packaging, high-end textiles and medical devices, the demand for high-performance masterbatch (such as high-temperature resistant masterbatch, vatrootporna masterbatch, environmental protection masterbatch) is showing an explosive growth trend. With the continuous improvement of global environmental protection policies (such as the ban on toxic and harmful pigments) and the upgrading of consumer demand for high-quality plastic products, the masterbatch industry is gradually developing towards high concentration, high dispersibility, funkcionalizacija, zaštita životne sredine i inteligencija.

The main development trends of the masterbatch industry are reflected in four aspects: prvo, environmental protection and low toxicity. With the strengthening of environmental protection awareness and the strictness of environmental protection policies, netoksičan, harmless, low-volatile and degradable environmental protection masterbatch will become the mainstream of the market, and toxic and harmful pigments (such as heavy metal pigments) will be gradually eliminated; drugo, funkcionalizacija. In addition to coloring, masterbatch is also developing towards functional integration, such as flame-retardant masterbatch, antistatic masterbatch, antibacterial masterbatch, UV-resistant masterbatch, which can meet the special use requirements of downstream products; treće, high concentration and high dispersibility. High-concentration masterbatch can reduce the addition amount, reduce production costs, and high dispersibility can ensure uniform coloring of plastic products, avoid color spots and color difference, which is the key to improving product quality; četvrto, intelligence and automation of processing. Masterbatch processing requires strict control of mixing uniformity, temperature and other parameters. Inteligentan, automatic twin-screw extrusion production lines will become the mainstream, realizacija praćenja u realnom vremenu, automatic parameter adjustment and mass production, improving production efficiency and product consistency.

As the core processing equipment of masterbatch, ekstruderi s dva puža igraju ključnu ulogu u razvoju masterbatch industrije. Masterbatch miješanje ima stroge zahtjeve u pogledu učinka miješanja i dispergiranja, kontrola temperature i efikasnost proizvodnje ekstrudera. Zhuoyue puna serija ekstrudera (HTS BASIC/PLUS/SUPER, ZTE, HTE) su posebno dizajnirani za obradu masterbatcha, sa ciljanim prednostima performansi, koji može efikasno zadovoljiti potrebe obrade različitih vrsta masterbatcha i pomoći proizvođačima da poboljšaju kvalitet proizvoda i efikasnost proizvodnje.

1.2 Osnovni sastav i princip rada masterbatcha

Masterbatch se sastoji od tri osnovna elementa: pigmenti ili boje, nosači i aditivi. Proporcije i performanse svakog elementa direktno određuju kvalitet i učinak upotrebe masterbatcha. Razumijevanje sastava jezgre i principa rada masterbatcha je osnova za savladavanje njegove tehnologije obrade i odabir odgovarajuće opreme za ekstruziju.

1.2.1 Pigmenti ili boje: The Core Coloring Component

Pigmenti ili boje su osnovne komponente koje daju performanse masterbatch bojenja, računovodstvo za 10%-80% sastava masterbatcha (specifična proporcija zavisi od vrste pigmenta, zahtjevi za bojenje i koncentracija masterbatcha). Pigmenti se dijele na organske pigmente i neorganske pigmente: organski pigmenti imaju svijetle boje, visoka čvrstoća nijansiranja, dobra transparentnost, ali slaba otpornost na toplinu i vremenske uvjete, uglavnom se koristi u niskotemperaturnoj preradi plastike (kao što je PE, PP) i proizvodi sa visokim zahtevima za boje (kao što je tekstil, folije za pakovanje); anorganski pigmenti imaju dobru otpornost na toplotu, weather resistance and chemical stability, but low tinting strength and poor transparency, mainly used in high-temperature processing plastics (such as engineering plastics) and outdoor products (such as building materials, automotive exterior parts).

Dyes are different from pigments. Dyes have good solubility in plastic raw materials, bright colors and high transparency, but poor heat resistance and light resistance, mainly used in transparent plastic products (such as PET bottles, PC sheets). The selection of pigments or dyes should be based on the type of plastic raw materials (temperatura obrade), product use environment (indoor/outdoor), coloring requirements (color brightness, transparentnost) and environmental protection requirements, to ensure that the masterbatch has stable coloring performance and meets the use requirements of downstream products.

1.2.2 Carriers: Komponenta disperzije i adhezije

Nosači su matrica masterbatcha, računovodstvo za 10%-80% sastava masterbatcha, uglavnom igraju ulogu dispergiranja pigmenata/boja i prianjanja na plastične sirovine. Nosač mora imati dobru kompatibilnost i sa pigmentima/bojama i sa ciljanim plastičnim sirovinama (plastične sirovine koje treba bojati), inače će utjecati na disperzibilnost pigmenata i učinak bojenja proizvoda. Uobičajeni materijali za nošenje uključuju polietilen (PE), polipropilen (PP), polivinil hlorid (PVC), poliamid (PA), polietilen tereftalat (PET), itd., koji se biraju prema vrsti ciljnih plastičnih sirovina: na primjer, PE nosač se koristi za bojenje PE plastike, PP nosač se koristi za bojenje PP plastike, i PA nosač se koristi za inženjering plastične PA bojenje.

Nosač takođe treba da ima dobru tečnost obrade, što pogoduje ujednačenoj disperziji pigmenata tokom obrade ekstruzijom i miješanja masterbatcha s ciljanim plastičnim sirovinama. Osim toga, tačka topljenja i temperatura obrade nosača treba da budu u skladu ili nešto niže od one za ciljne plastične sirovine, kako bi se izbjeglo raspadanje nosača ili ciljne plastike tokom obrade.

1.2.3 Aditivi: Pomoćna funkcionalna komponenta

Aditivi su pomoćne komponente koje se dodaju radi poboljšanja performansi obrade, disperzibilnost i performanse upotrebe masterbatcha, računovodstvo za 1%-10% sastava masterbatcha. Vrsta i doza aditiva određuju se prema vrsti masterbatcha i zahtjevima obrade. Uobičajeni aditivi uključuju:

• Disperzanti: Najvažniji aditiv u masterbatchu, koji mogu smanjiti površinsku napetost pigmenata, sprečavaju aglomeraciju pigmenta, i prave pigmente jednoliko dispergovane u nosaču. Uobičajeni disperzanti uključuju polietilenski vosak, polipropilenski vosak, stearinska kiselina, kalcijum stearat, itd. Dodavanje disperzanata može značajno poboljšati disperzibilnost masterbatcha, osigurati ujednačeno obojenje proizvoda, i smanjiti trošenje opreme za ekstruziju.
• Kompatibilizatori: Koristi se za poboljšanje kompatibilnosti između pigmenata i nosača, i između masterbatch i ciljnih plastičnih sirovina. Na primjer, kada noseća i ciljna plastika imaju lošu kompatibilnost (kao što su PE nosač i PA plastika), kompatibilizatori (kao što je polietilen cijepljen anhidridom maleinske kiseline) mogu se dodati kako bi se poboljšala sila veze između njih, izbjegavajte odvajanje matične smjese i ciljne plastike tokom obrade, i poboljšati mehanička svojstva proizvoda.
• Toplotni stabilizatori: Koristi se za sprečavanje raspadanja pigmenata, nosača i ciljne plastike tokom ekstrudiranja pri visokim temperaturama. Uobičajeni stabilizatori topline uključuju soli olova, kalcijum-cink stabilizatori, organski stabilizatori kalaja, itd., koji se biraju prema temperaturi obrade i zahtjevima zaštite okoliša.
• Svjetlosni stabilizatori i antioksidansi: Koristi se za poboljšanje otpornosti na vremenske uslove i otpornost na starenje masterbatch i obojenih plastičnih proizvoda, sprečavaju bledenje boje i degradaciju performansi proizvoda pod sunčevom svetlošću i kiseonikom, i produžiti vijek trajanja proizvoda.
• Maziva: Koristi se za smanjenje trenja između materijala i opreme za ekstruziju (vijak, bure, die head), poboljšati fluidnost obrade, smanjiti potrošnju energije, i izbjegavajte lijepljenje materijala za opremu, što je pogodno za nesmetani napredak obrade ekstruzijom.

1.2.4 Princip rada Masterbatch-a

The working principle of masterbatch is based on the uniform dispersion of high-concentration pigments in the carrier. During the processing of plastic products, a small amount of masterbatch (usually 1%-5%) is mixed with uncolored plastic raw materials. Under the action of high temperature and shear force during extrusion or injection molding, the carrier of the masterbatch melts and mixes with the target plastic raw materials, and the uniformly dispersed pigments are released and uniformly distributed in the target plastic matrix, thus achieving the purpose of coloring plastic products. The key of this process is that the pigments in the masterbatch must be uniformly dispersed without agglomeration, otherwise it will cause color spots, color difference and other defects in the colored products.

1.3 Common Classification of Masterbatch

Masterbatch can be divided into different types according to different classification standards, such as coloring type, carrier type, application field, functional type, itd. The correct classification helps to better understand the performance characteristics and processing requirements of masterbatch, and select appropriate extrusion equipment and processing techniques.

1.3.1 Classification by Coloring Type

According to the type of coloring component, masterbatch can be divided into color masterbatch, white masterbatch and black masterbatch.

• Color Masterbatch: The most common type of masterbatch, which uses organic or inorganic pigments of various colors (such as red, yellow, blue, green, orange) as coloring components, and is used for coloring plastic products of various colors. The tinting strength, color brightness and dispersibility of color masterbatch are the key indicators to measure its quality.
• White Masterbatch: Using titanium dioxide (TiO2) as the main coloring component, it is used for whitening plastic products or as a base color for light-colored masterbatch. The whiteness, covering power and dispersibility of white masterbatch are the key indicators. Titanium dioxide has high hardness, which has high requirements on the wear resistance of extrusion equipment.
• Black Masterbatch: Using carbon black as the main coloring component, it is used for black coloring of plastic products. Carbon black has good UV resistance and weather resistance, and can also improve the mechanical properties of plastic products. The dispersibility of carbon black is the key to the quality of black masterbatch. Poor dispersibility will cause black spots and streaks in products.

1.3.2 Classification by Carrier Type

According to the type of carrier, masterbatch can be divided into PE masterbatch, PP masterbatch, PVC masterbatch, PA masterbatch, PET masterbatch, itd.

• PE Masterbatch: Using PE as the carrier, it is suitable for coloring PE plastic products (such as PE films, PE cijevi, PE injection molding parts). It has good compatibility with PE raw materials, good processing fluidity and uniform coloring.
• PP Masterbatch: Using PP as the carrier, it is suitable for coloring PP plastic products (such as PP fibers, PP injection molding parts, PP listovi). It has good heat resistance and is suitable for high-temperature processing of PP.
• PVC Masterbatch: Using PVC as the carrier, it is suitable for coloring PVC plastic products (such as PVC pipes, PVC profili, PVC films). Potrebno ga je uskladiti sa PVC stabilizatorima kako bi se izbjeglo raspadanje PVC-a tokom obrade.
• Masterbatch inženjerske plastike: Korištenje inženjerske plastike (PA, PC, PBT, itd.) kao nosioci, Pogodan je za bojenje inženjerskih plastičnih proizvoda (kao što su automobilski dijelovi, električne komponente). Ima dobru otpornost na toplotu i kompatibilnost sa inženjerskom plastikom, i ima visoke zahtjeve za opremu za ekstruziju.

1.3.3 Klasifikacija prema području primjene

Prema području primjene masterbatcha, može se podijeliti na masterbatch vlakana, filmski masterbatch, masterbatch za oblikovanje puhanjem, masterbatch za ekstruziju, masterbatch za brizganje, itd., koji odgovaraju pet glavnih područja primjene masterbatcha.

• Fiber Masterbatch: Koristi se za bojenje hemijskih vlakana (kao što su poliesterska vlakna, najlonsko vlakno), koji se koristi u tepisima, tekstil, jastuci i drugi proizvodi. Zahtijeva visoku disperzibilnost i postojanost boje, i bez blijeđenja boje tokom predenja i tkanja.
• Film Masterbatch: Koristi se za bojenje plastičnih folija (kao što su torbe za kupovinu, casting filmova, višeslojnih filmova), što zahtijeva visoku transparentnost i ujednačenu boju, i bez mrlja u boji ili pruga na površini filma.
• Masterbatch za puhanje: Koristi se za bojenje proizvoda za duvanje (kao što su medicinski i kozmetički kontejneri, posude za ulje i boju za podmazivanje), što zahtijeva dobru tečnost obrade i ujednačeno obojenje, i bez deformacije ili razlike u boji kontejnera.
• Extrusion Masterbatch: Koristi se za bojenje ekstruzijskih proizvoda (kao što su listovi, cijevi, žice i kablovi), što zahtijeva dobru stabilnost dimenzija i ujednačenu boju, i nema razlike u boji na površini proizvoda.
• Masterbatch za injekcijsko prešanje: Koristi se za bojenje proizvoda za brizganje (kao što su automobilski dijelovi, elektronski proizvodi, građevinski materijali, kućni aparati, namještaj, igračke), which requires high dispersibility and stable performance, and no color difference between batches of products.

1.3.4 Classification by Functional Type

According to the additional functions of masterbatch, it can be divided into ordinary masterbatch (only coloring function) and functional masterbatch (bojanje + additional functions). Functional masterbatch is the development trend of the industry, and common types include flame-retardant masterbatch, antistatic masterbatch, antibacterial masterbatch, UV-resistant masterbatch, toughening masterbatch, itd. Functional masterbatch requires adding corresponding functional additives on the basis of ordinary masterbatch, which has higher requirements on the mixing and dispersing effect of extrusion equipment.

2. Core Processing Technology of Masterbatch: Twin-Screw Extrusion Technology

Masterbatch processing mainly includes mixing, ekstruzija, hlađenje, granulation and other processes, among which twin-screw extrusion technology is the core technology of masterbatch mixing and granulation. Compared with single-screw extrusion technology, twin-screw extrusion technology has the advantages of strong mixing and dispersing capacity, precizna kontrola temperature, kratko vreme boravka, high production efficiency and strong adaptability to raw materials, which can effectively solve the key problems of masterbatch processing (such as pigment agglomeration, uneven mixing, low production efficiency) and ensure the quality of masterbatch products.

Masterbatch mixing is one of the main applications of twin-screw extruders. The quality of masterbatch is directly determined by the performance of the twin-screw extruder and the rationality of the processing process. The key requirements of masterbatch processing for twin-screw extruders are: strong mixing and dispersing effect (to ensure uniform dispersion of pigments), precizna kontrola temperature (to avoid pigment decomposition and carrier degradation), appropriate shear force (to break pigment agglomerates without damaging pigment particles), high production efficiency (to meet mass production needs) and good wear resistance (to adapt to the wear of high-hardness pigments such as titanium dioxide and carbon black).

2.1 Processing Difficulties of Masterbatch and Requirements for Extrusion Equipment

Although twin-screw extrusion technology is suitable for masterbatch processing, due to the particularity of masterbatch composition (high pigment content, easy agglomeration of pigments) i zahtjevi obrade (uniform dispersion, stabilne performanse), there are still many difficulties in actual processing. The main processing difficulties and corresponding requirements for extrusion equipment are as follows:

2.1.1 Pigment Agglomeration and Poor Dispersibility

Pigments (especially inorganic pigments such as titanium dioxide and carbon black) have strong polarity and large specific surface area, which are easy to agglomerate into large particles during storage and mixing. If the agglomerates cannot be fully broken and dispersed during extrusion processing, the masterbatch will have poor dispersibility, and the colored plastic products will have color spots, color streaks and uneven coloring, which will seriously affect the product quality. This is the most common and key difficulty in masterbatch processing.

This requires the extrusion equipment to have strong mixing and dispersing capacity and appropriate shear force. The twin-screw extruder should adopt an intermeshing co-rotating structure, a vijak bi trebao biti opremljen s dovoljno elemenata za miješanje i smicanja za stvaranje jake sile smicanja i sile gnječenja tokom rotacije, koji može u potpunosti razbiti pigmentne aglomerate i učiniti pigmente ravnomjerno dispergiranim u nosaču. Osim toga, brzina šrafova i pritisak ekstruzije treba da se podese kako bi se prilagodili različitim vrstama pigmenata i koncentracijama masterbatcha.

2.1.2 Razgradnja pigmenta i degradacija nosača uzrokovana pregrijavanjem

Većina pigmenata (posebno organskih pigmenata) imaju slabu otpornost na toplotu, i nosioca (kao što je PE, PP) također ima određeno ograničenje temperaturne otpornosti. Ako je temperatura ekstruzije previsoka ili je vrijeme zadržavanja materijala u ekstruderu predugo, pigment će se razgraditi (što rezultira blijedim bojama, diskoloracija), i nosač će degradirati (što rezultira smanjenim mehaničkim svojstvima masterbatcha). Ovo je još jedna ključna poteškoća u obradi masterbatcha.

Ovo zahtijeva da oprema za ekstruziju ima precizan kapacitet kontrole temperature i kratko vrijeme zadržavanja. Cijev ekstrudera treba podijeliti na više sekcija za kontrolu temperature, a temperatura svake sekcije treba precizno kontrolisati unutar optimalnog raspona (obično 150-220℃ za običnu masterbatch, 200-280℃ za inženjering plastične masterbatch), sa preciznošću kontrole temperature od ±1℃. Strukturu vijka treba optimizirati kako bi se skratilo vrijeme zadržavanja materijala u ekstruderu (usually 1-3 minuta), izbjegavanje dugotrajnog kontakta između materijala i visoke temperature.

2.1.3 Habanje vijka i cijevi uzrokovano pigmentima visoke tvrdoće

Neorganski pigmenti kao što su titan dioksid i čađa imaju visoku tvrdoću (Mohsova tvrdoća 5-7), što će uzrokovati ozbiljno habanje zavrtnja i cijevi ekstrudera tokom ekstruzijske obrade. Ako vijak i cijev imaju slabu otpornost na habanje, brzo će se nositi, što rezultira smanjenom silom smicanja i kapacitetom miješanja ekstrudera, utiče na disperzibilnost matične smjese i smanjuje vijek trajanja opreme.

To zahtijeva da vijak i cijev ekstrudera budu izrađeni od visokokvalitetnih materijala otpornih na habanje i obrađeni naprednom tehnologijom proizvodnje. Na primjer, vijak i cijev mogu biti izrađeni od uvezenog legiranog čelika otpornog na habanje, i podvrgnuti tretmanu bimetalnim kompozitima ili tretmanu laserskog oblaganja, which can greatly improve the wear resistance and corrosion resistance of the screw and barrel, and adapt to the processing of masterbatch with high-hardness pigments.

2.1.4 Instability of Product Quality Between Batches

Masterbatch processing requires strict control of various parameters (such as formula ratio, mixing time, extrusion temperature, brzina zavrtnja, feeding speed). If the parameters fluctuate, the quality of the masterbatch (such as concentration, dispersibility, tinting strength) will be unstable, resulting in color difference between batches of colored products, which will affect the reputation of the manufacturer.

This requires the extrusion equipment to have intelligent control capacity and stable performance. The extruder should be equipped with a PLC intelligent control system, which can realize precise control of feeding speed, brzina zavrtnja, temperatura ekstruzije i drugi parametri, i pohraniti više skupova parametara formule. Prilikom proizvodnje različitih serija masterbatcha, potrebno je pozvati samo odgovarajuće parametre, izbjegavanje ponovnog otklanjanja grešaka, osiguravanje stabilnosti kvaliteta proizvoda između serija.

2.1.5 Visoki zahtjevi za tečnost obrade

Masterbatch ima visok sadržaj pigmenta, što će smanjiti fluidnost obrade materijala. Ako je fluidnost obrade preslaba, materijal će biti teško prenijeti i istisnuti, što rezultira niskom efikasnošću proizvodnje, nestabilan pritisak ekstruzije, pa čak i blokada opreme.

To zahtijeva da oprema za ekstruziju ima snažan transportni kapacitet i podesivu silu smicanja. Dvopužni ekstruder bi trebao imati razuman nagib zavrtnja, dizajn olova i kompresije, a vijak treba da bude opremljen sa dovoljno transportnih elemenata kako bi se osigurao nesmetan transport materijala. Osim toga, temperatura ekstruzije se može podesiti na odgovarajući način kako bi se poboljšala fluidnost obrade materijala, a mogu se dodati i maziva kako bi se smanjilo trenje između materijala.

2.2 Princip rada i tok procesa ekstruzije s dva vijka Masterbatch

Proces ekstruzije s dva vijka masterbatch je složen fizički proces miješanja, koji uglavnom uključuje prethodnu obradu sirovina, prethodno miješanje, hranjenje, topljenje, miješanje i striženje, ekstruzija, hlađenje, granulacija, skrining i pakovanje. Osnovna svrha je ravnomjerno dispergiranje pigmenata, nosači i aditivi za formiranje visokokvalitetnih granula masterbatch. Specifični princip rada i tok procesa su sljedeći:

2.2.1 Predtretman sirovina

Predtretman sirovina je temelj obrade masterbatch ekstruzije, which directly affects the mixing effect and product quality. The raw materials of masterbatch mainly include pigments/dyes, nosioci, aditivi (disperzanti, kompatibilizatori, heat stabilizers, itd.). The pretreatment steps are as follows:

• Drying Treatment: Some pigments (such as organic pigments) and carriers (such as PA, PET) have high water absorption. If the moisture content is too high, it will cause bubbles, agglomeration and other defects in the masterbatch during extrusion processing, and even cause hydrolytic degradation of the carrier. Stoga, sirovine se moraju osušiti prije obrade. The drying temperature and time are determined according to the type of raw material: na primjer, organic pigments are dried at 60-80℃ for 2-4 sati, PE/PP carriers are dried at 80-100℃ for 3-5 sati, and PA carriers are dried at 100-120℃ for 6-8 sati. Sadržaj vlage u osušenim sirovinama treba kontrolisati u nastavku 0.1%.
• Crushing and Sieving: For pigments with large particle size (such as titanium dioxide agglomerates) i nosači sa neujednačenom veličinom čestica, drobljenje i prosijavanje treba izvršiti kako bi se osigurala ujednačenost sirovina. Treba kontrolisati veličinu čestica zdrobljenih sirovina 20-40 mesh, što pogoduje ravnomernom mešanju sirovina i razbijanju aglomerata pigmenta tokom ekstruzije.
• Uklanjanje nečistoća: Sirovine mogu sadržavati nečistoće (kao što su metalne čestice, kamenje, prašina) tokom proizvodnje i transporta. Nečistoće ne utiču samo na kvalitet masterbatcha, ali također nosite vijak i cijev ekstrudera, pa čak i uzrokovati blokadu opreme. Stoga, sirovine se moraju filtrirati i ukloniti prije upotrebe, korištenjem filterskog sita odgovarajuće veličine mreže za uklanjanje nečistoća.

2.2.2 Prethodno miješanje

Premixing is the key step to improve the mixing and dispersing effect of masterbatch. Prema omjeru formule, the dried, crushed and impurity-removed pigments, carriers and additives are put into a high-speed mixer for premixing. The purpose of premixing is to make the pigments and additives uniformly adhere to the surface of the carrier particles, form a preliminary mixture, and lay a foundation for the uniform dispersion during extrusion.

The key parameters of premixing are mixing speed, mixing time and mixing temperature. The mixing speed is generally 800-1200 rpm, the mixing time is 5-10 minuta, and the mixing temperature is controlled at 40-60℃. The appropriate mixing temperature can improve the adhesion of additives (such as dispersants) to the carrier and pigments, promoting uniform mixing. For masterbatch with high pigment content (kao što su 50% gore), vrijeme prethodnog miješanja može se na odgovarajući način produžiti, i prva se može dodati mala količina disperzanta kako bi se poboljšala disperzibilnost pigmenata. Nakon prethodnog miješanja, smesa treba da bude jednolične boje, bez očiglednih aglomerata pigmenta i čestica aditiva.

2.2.3 Hranjenje i prenošenje

Prethodno izmiješana smjesa se šalje u rezervoar za punjenje dvopužnog ekstrudera kroz pužnu ili trakastu ubacivaču. Uređaj za napajanje ekstrudera obično je opremljen funkcijom regulacije brzine pretvaranja frekvencije, koji može podesiti brzinu uvlačenja prema brzini zavrtnja i brzini ekstruzije kako bi se osiguralo da materijali ulaze u ekstruzijsku šupljinu stabilno i ravnomjerno, izbjegavanje nakupljanja materijala ili nedovoljno hranjenje.

Spremnik za hranjenje je također opremljen uređajem za sušenje (kao što je jakna za električno grijanje) kako bi se spriječilo da sirovine ponovo upijaju vlagu tokom hranjenja. For masterbatch with high pigment content and poor fluidity, a forced feeding device can be selected to ensure the smooth feeding of materials. Osim toga, the feeding port of the extruder should be smooth, without dead corners, to avoid material sticking and accumulation.

2.2.4 Topljenje, Mixing and Shearing

Materijali koji ulaze u ekstruzijsku šupljinu dvopužnog ekstrudera kontinuirano se guraju naprijed pomoću rotirajućih vijaka. Šupljina za ekstruziju se sastoji od vijka i cijevi, a volumen ekstruzione šupljine postupno se smanjuje duž smjera ose. Kada se šrafovi okreću, materijali se postupno sabijaju pod djelovanjem vijaka i cijevi, a pritisak u ekstruzijskoj šupljini postepeno raste (generally 5-12MPa).

U isto vreme, materijali su izloženi jakoj sili smicanja i sili trenja koja nastaje relativnim kretanjem između vijaka i cijevi, kao i između vijčanih letvica. The shear force and friction force can fully break the agglomerates of pigments, make the pigments uniformly dispersed in the melted carrier, and promote the fusion and compatibility between the pigment, carrier and additives. Sila trenja također može stvoriti određenu količinu topline, koji je u kombinaciji sa vanjskim grijanjem cijevi (grijanje na struju ili parno grijanje) to make the carrier gradually melt and plasticize.

Cijev ekstrudera se obično dijeli na 4-6 sekcije za kontrolu temperature (odjeljak za hranjenje, sekcija za topljenje, dio za miješanje, homogenizujuća sekcija, presek glave matrice), and the temperature of each section is precisely controlled according to the type of masterbatch (carrier type, pigment type). Na primjer, when processing PE masterbatch, the temperature of the feeding section is 100-120℃, the melting section is 160-180℃, the mixing section is 170-190℃, the homogenizing section is 160-180℃, and the die head section is 150-170℃. The precise temperature control can ensure that the carrier is fully melted without thermal decomposition, and the pigments are not decomposed or discolored.

The screw of the twin-screw extruder adopts a modular design, which can freely combine different screw elements (such as conveying elements, elementi za mešanje, shearing elements) according to the type of masterbatch. Na primjer, when processing masterbatch with high pigment content and easy agglomeration, more mixing elements and shearing elements can be configured to enhance the mixing and dispersing effect; when processing masterbatch with good fluidity, more conveying elements can be configured to improve production efficiency.

2.2.5 Ekstruzija i oblikovanje

Potpuno istopljen, mješoviti i dispergirani materijal guraju se na glavu ekstrudera pomoću vijaka. The die head of the masterbatch extruder is usually equipped with multiple circular die holes (broj i veličina rupa u kalupu određuju se prema veličini čestica masterbatcha). The material is extruded from the die head at a high speed to form continuous strip-shaped semi-finished products (the diameter of the strip is usually 2-5mm, koji se može prilagoditi potrebama kupaca).

Temperatura glave matrice je nešto niža od temperature sekcije za homogenizaciju, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the strip. The extrusion speed is controlled according to the type of masterbatch and the particle size requirement, generally ranging from 1-3m/min. The extrusion pressure should be kept stable (fluctuation within ±0.5MPa), which can ensure the uniform diameter of the strip and the consistency of the masterbatch quality.

2.2.6 Hlađenje i učvršćivanje

The extruded strip-shaped semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method for masterbatch is usually water tank cooling, and the cooling water temperature is controlled at 20-30℃. The length of the cooling water tank is 3-5 meters, and the cooling time is 2-4 minuta. Rapid cooling can make the strip solidify quickly, maintain the shape and size of the strip, and avoid deformation and adhesion.

It should be noted that the cooling speed should be uniform. If the cooling speed is too fast, the internal stress of the strip will be too large, and the strip will be brittle and easy to break during granulation; if the cooling speed is too slow, the strip will be soft and easy to adhere, affecting the granulation effect. After cooling, the surface of the strip should be dry, smooth and free of bubbles and cracks.

2.2.7 Cutting and Granulation

After cooling and solidification, traka se šalje u granulator za rezanje kako bi se formirali granulirani masterbatch proizvodi. Granulator je opremljen rotirajućim nožem i fiksnim nožem, a brzina rezanja je podesiva (općenito 500-1000 rpm). Veličina čestica masterbatcha se kontrolira podešavanjem brzine rezanja i brzine transporta trake. Uobičajena veličina čestica masterbatcha je 2-5 mm (dužina i prečnik su u osnovi isti), koji je pogodan za mešanje sa plastičnim sirovinama tokom kasnije upotrebe.

Granulator treba da bude opremljen uređajem za sijanje za uklanjanje nekvalificiranih čestica (kao što je prevelika, premali, aglomerirane ili slomljene čestice). Kvalificirane čestice ulaze u sljedeći proces, a nekvalificirane čestice se drobe i recikliraju (nakon sušenja i prethodnog miješanja, ponovo se ekstrudiraju i granuliraju).

2.2.8 Screening, Pregled i pakovanje

The granulated masterbatch is sent to a vibrating screen for screening to further remove unqualified particles and impurities. The vibrating screen is equipped with a multi-layer screen (different mesh sizes), which can screen out masterbatch particles of different specifications according to customer needs.

After screening, the masterbatch needs to undergo quality inspection. The inspection items mainly include: boja (uniformity, consistency with the standard sample), dispersibility (observed by microscope or test piece coloring), concentration (tinting strength test), moisture content, particle size distribution, itd. Only the masterbatch that meets the quality standards can be packaged.

The packaging of masterbatch adopts sealed and moisture-proof packaging (such as plastic woven bags with inner plastic film, aluminum foil bags), a težina pakovanja je obično 25kg/vreći ili 50kg/vreći. Vrećica za pakovanje je označena nazivom proizvoda, model, boja, concentration, carrier type, datum proizvodnje, rok trajanja, proizvođač i druge informacije. Upakovani masterbatch treba čuvati na suvom mestu, hladno i ventilirano skladište, izbjegavanje direktne sunčeve svjetlosti i vlage, a rok trajanja je općenito 6-12 mjeseci.

2.3 Ključni faktori koji utječu na učinak ekstruzije s dva vijka Masterbatch

Efekat ekstruzije sa dva vijka direktno utiče na kvalitet masterbatcha (dispersibility, tinting strength, stabilnost). Mnogo je faktora koji utiču na efekat ekstruzije, uglavnom uključujući karakteristike sirovina, odnos formule, efekat premiksa, parametri ekstruzije i performanse opreme. Ovladavanje ovim ključnim faktorima i naučna prilagođavanja mogu osigurati stabilnost efekta ekstruzije i konzistentnost kvaliteta proizvoda.

2.3.1 Karakteristike sirovina

Tip, veličina čestica, sadržaj vlage i čistoća sirovina imaju veliki uticaj na efekat ekstruzije. Za pigmente, veličina čestica treba da bude ujednačena i fina (20-40 mesh), a stepen aglomeracije treba da bude nizak; organski pigmenti imaju slabu otpornost na toplotu, tako da temperaturu ekstruzije treba strogo kontrolirati; anorganski pigmenti imaju visoku tvrdoću, tako da ekstruder treba da ima dobru otpornost na habanje. Za prevoznike, the melting point and processing temperature should be consistent with the target plastic raw materials, and the compatibility with pigments should be good. For additives, the type and dosage should be reasonable, and the compatibility with carriers and pigments should be good.

Osim toga, the moisture content of raw materials must be strictly controlled below 0.1%; if the moisture content is too high, it will cause bubbles and agglomeration in the masterbatch. The purity of raw materials is also very important; impurities in raw materials will not only affect the product quality, ali također nosite vijak i cijev ekstrudera.

2.3.2 Formula Ratio

The formula ratio of masterbatch (the ratio of pigment, carrier and additive) is the key to determining the quality of the product. The pigment content should be determined according to the coloring requirements and the type of pigment: high-concentration masterbatch (pigment content 50%-80%) can reduce the addition amount and production cost, but requires better dispersibility; low-concentration masterbatch (pigment content 10%-30%) has better dispersibility, but the addition amount is large and the production cost is high.

The dosage of dispersants is generally 1%-5% of the pigment dosage; too little dispersant will lead to poor dispersibility of pigments, and too much dispersant will affect the mechanical properties of the masterbatch and the colored products. The dosage of other additives (kompatibilizatori, heat stabilizers, maziva) is generally 0.5%-3%, which should be adjusted according to the type of masterbatch and processing requirements. The formula ratio should be strictly controlled, and the error should be within ±1%, to ensure the consistency of product quality between batches.

2.3.3 Premixing Effect

Prethodno miješanje je osnova obrade ekstruzijom. Ujednačenost prethodnog mešanja direktno utiče na efekat mešanja i dispergovanja pigmenata tokom ekstruzije. Ako je prethodno miješanje neravnomjerno, pigmenti se ne mogu ravnomerno zalepiti za površinu nosača, što rezultira lokalnom aglomeracijom pigmenata, neravnomjerno miješanje materijala tokom ekstruzije, i smanjena disperzibilnost proizvoda.

Da bi se osigurao efekat prethodnog miješanja, potrebno je kontrolirati brzinu miješanja (800-1200 rpm), mixing time (5-10 minuta) i temperaturu mešanja (40-60℃). For masterbatch with high pigment content, vrijeme prethodnog miješanja može se na odgovarajući način produžiti, a disperzant se može dodati prvo i pomiješati sa pigmentom, zatim pomiješan s nosačem i drugim aditivima. Osim toga, prethodno izmiješanu smjesu treba pregledati; ako postoje očigledni aglomerati pigmenta, treba ga usitniti i ponovo izmiješati.

2.3.4 Parametri ekstruzije

Parametri ekstruzije su najvažniji faktori koji utiču na efekat ekstruzije, mainly including screw speed, extrusion temperature and extrusion pressure.

• Brzina zavrtnja: The screw speed of twin-screw extruders for masterbatch processing generally ranges from 200 to 800 rpm. The higher the screw speed, the greater the shear force and friction force received by the materials, the better the mixing and dispersing effect of pigments, and the higher the production efficiency. Međutim, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete melting of the carrier, insufficient mixing of materials, and uneven dispersibility; if the screw speed is too low, the shear force and friction force are insufficient, the pigment agglomerates cannot be fully broken, and the production efficiency is low.
• The screw speed should be adjusted according to the type of masterbatch: for masterbatch with high pigment content and easy agglomeration (such as black masterbatch, white masterbatch), a higher screw speed (500-800 rpm) is needed to ensure the uniform dispersion of pigments; for masterbatch with organic pigments (poor heat resistance), a moderate screw speed (300-500 rpm) is needed to avoid overheating and pigment decomposition.
• Extrusion Temperature: The extrusion temperature is the key to ensuring the melting of the carrier and the stability of the pigment. The temperature of each section of the barrel and die head must be precisely controlled according to the type of masterbatch (carrier type, pigment type). Temperatura odjeljka za hranjenje je niža (slightly higher than the drying temperature of the raw materials), što je uglavnom da bi se spriječilo zgrušavanje materijala i osiguralo nesmetano hranjenje; temperatura sekcije topljenja je srednja, which is mainly to promote the melting and plasticization of the carrier; temperatura sekcije za miješanje je viša, što je uglavnom za poboljšanje efekta smicanja i miješanja, and promote the uniform dispersion of pigments; temperatura sekcije za homogenizaciju je nešto niža od sekcije za miješanje, što je uglavnom za osiguranje ujednačene temperature i viskoznosti materijala, i izbjegavaju termičku razgradnju; temperatura preseka glave matrice je nešto niža od sekcije za homogenizaciju, which is to ensure the shaping effect of the strip.
• The temperature control precision should reach ±1℃. Na primjer, when processing PP masterbatch with organic pigments, the temperature of each section is: feeding section 110-130℃, melting section 170-190℃, mixing section 180-200℃, homogenizing section 170-190℃, die head section 160-180℃. If the temperature is too high, the pigment will decompose and the carrier will degrade; if the temperature is too low, the carrier will not be fully melted, and the pigment cannot be uniformly dispersed.
• Pritisak ekstruzije: The extrusion pressure of masterbatch twin-screw extrusion generally ranges from 5 to 12MPa. Pritisak u ekstruzijskoj šupljini uglavnom je određen omjerom kompresije vijka, veličina rupe i brzina zavrtnja. Što je veći pritisak ekstruzije, the better the mixing and dispersing effect of materials, and the denser the strip. Međutim, ako je pritisak previsok, to će povećati potrošnju energije i trošenje opreme, pa čak i uzrokovati blokiranje glave matrice; ako je pritisak prenizak, materijali se ne mogu u potpunosti komprimirati i pomiješati, the strip is loose, and the dispersibility is poor.
• The extrusion pressure should be adjusted according to the type of masterbatch and the die head size: for masterbatch with high pigment content and poor fluidity, a higher extrusion pressure is needed; for masterbatch with good fluidity, a moderate extrusion pressure is sufficient. The extrusion pressure should be kept stable, and the fluctuation should be within ±0.5MPa, to ensure the uniform diameter of the strip and the consistency of the masterbatch quality.

2.3.5 Equipment Performance

The performance of the twin-screw extruder directly determines the extrusion effect. The key performance indicators of the extruder include mixing and dispersing capacity, temperature control precision, otpornost na habanje, conveying capacity and intelligent control capacity. Zhuoyue puna serija ekstrudera (HTS BASIC/PLUS/SUPER, ZTE, HTE) su posebno dizajnirani za obradu masterbatcha, with excellent performance in these aspects, which can effectively meet the processing needs of different types of masterbatch.

3. Zhuoyue pune serije ekstrudera: Profesionalna rješenja za Masterbatch obradu

Zhuoyue se dugo bavi istraživanjem, razvoj i proizvodnja dvopužnih ekstrudera visokih performansi, i stekao je bogato iskustvo u oblasti obrade masterbatch-a. Prema karakteristikama obrade masterbatcha (high pigment content, easy agglomeration of pigments, strogi zahtjevi za kontrolu temperature, visoki zahtjevi otpornosti na habanje) i različite potrebe proizvođača (različite proizvodne skale, različite vrste masterbatcha, različita polja primjene), Zhuoyue je lansirao punu seriju ekstrudera pogodnih za obradu masterbatch-a, uključujući HTS BASIC seriju, HTS PLUS serija, HTS SUPER serija, ZTE serija i HTE serija. Svaka serija ima svoje karakteristike performansi i ciljane scenarije adaptacije, koji može pružiti personalizirana i efikasna rješenja za obradu za proizvođače masterbatch različitih razmjera.

3.1 Osnovne prednosti Zhuoyue ekstrudera za obradu Masterbatch

Whether it is the high-end HTS SUPER series or the cost-effective ZTE series, all Zhuoyue’s extruders have the following core advantages, which are specially optimized for masterbatch processing, ensuring high-quality, efficient and stable production:

3.1.1 Excellent Mixing and Dispersing Effect

The core requirement of masterbatch processing is the uniform dispersion of pigments. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, with a reasonable screw pitch, dizajn olova i kompresije. The intermeshing and rotating of the twin screws can generate strong shear force and kneading force, which can fully break the agglomerates of pigments (even small agglomerates of 100μm above), and make the pigments uniformly dispersed in the carrier. The mixing uniformity of the extruders can reach more than 95%, koji je mnogo veći od običnih ekstrudera s dva puža (85%-90%).

Osim toga, the screws of all series of extruders adopt a modular design, which can freely combine different types of screw elements (transportni elementi, elementi za mešanje, shearing elements) according to the type of masterbatch (such as color masterbatch, white masterbatch, black masterbatch) and pigment characteristics. Na primjer, when processing black masterbatch with carbon black (easy agglomeration), more mixing elements and shearing elements can be configured to enhance the mixing and dispersing effect; when processing color masterbatch with organic pigments (poor heat resistance), more conveying elements and fewer shearing elements can be configured to shorten the residence time and avoid pigment decomposition.

3.1.2 Precizna kontrola temperature, Avoiding Pigment Decomposition

Masterbatch processing has strict requirements on temperature control, and the temperature fluctuation must be controlled within ±1℃ to avoid pigment decomposition and carrier degradation. All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, which is composed of high-precision temperature sensors, heating elements and cooling elements. The barrel is divided into 4-6 independent temperature control sections, and the temperature of each section can be precisely adjusted and controlled in real time.

Sistem kontrole temperature je opremljen funkcijom praćenja i alarma u realnom vremenu: if the temperature of any section exceeds the set range, the system will issue an alarm prompt in time, and automatically adjust the heating power or start the cooling system to return the temperature to the set range. Osim toga, the barrel of the extruder adopts a double-layer jacket design, which can realize rapid heating and cooling, and improve the response speed of temperature control. The die head is also equipped with an independent temperature control device, which ensures the uniform temperature of the die head and the stable shaping of the strip.

3.1.3 Visoka otpornost na habanje, Dug radni vek

Neorganski pigmenti kao što su titan dioksid i čađa imaju visoku tvrdoću, što će uzrokovati ozbiljno habanje zavrtnja i cijevi ekstrudera tokom obrade. Zhuoyue-ovi ekstruderi usvajaju visokokvalitetne materijale otporne na habanje i naprednu tehnologiju proizvodnje kako bi osigurali otpornost osnovnih komponenti na habanje.

Vijci i cijevi HTS PLUS serije, Serija HTS SUPER i serija HTE izrađene su od uvezenog legiranog čelika otpornog na habanje (kao što je 38CrMoAlA), i podvrgnuti tretmanu bimetalnim kompozitima ili tretmanu laserskog oblaganja. Površinska tvrdoća vijaka i cijevi može doseći ≥65 HRC (HTS PLUS serija, HTE serija) i ≥70 HRC (HTS SUPER serija), koji ima izuzetno jaku otpornost na habanje i otpornost na koroziju, i može efikasno odoleti habanju uzrokovanom pigmentima visoke tvrdoće. Vijek trajanja vijaka i cijevi je 2-3 puta više od običnih ekstrudera, smanjenje učestalosti zamjene komponenti i troškova održavanja opreme.

Vijci i cijevi HTS BASIC serije i ZTE serije izrađeni su od visokokvalitetnog legiranog čelika otpornog na habanje sa tretmanom nitriranja, a površinska tvrdoća može doseći ≥60 HRC, koji može zadovoljiti potrebe obrade obične masterbatch (sadržaj pigmenta ≤50%) i ima razumne performanse troškova.

3.1.4 Visoka proizvodna efikasnost, Ušteda energije i zaštita životne sredine

Zhuoyue-ovi ekstruderi imaju mjenjač visokog okretnog momenta i optimiziranu strukturu vijaka, koji imaju snažan transportni kapacitet i visoku proizvodnu efikasnost. U poređenju sa običnim ekstruderima sa dva vijka, efikasnost proizvodnje Zhuoyue ekstrudera može se povećati za 20%-50%. Na primjer, kapacitet proizvodnje ekstrudera HTS SUPER serije može doseći 1000-3000 kg/h, koji je pogodan za masovnu proizvodnju velikih razmera; Kapacitet proizvodnje ekstrudera ZTE serije je 100-500 kg/h, koji je pogodan za malu i srednju serijsku proizvodnju.

Osim toga, svi Zhuoyue ekstruderi imaju visokoefikasne motore i grijaće elemente koji štede energiju, što može smanjiti potrošnju energije 15%-20% u poređenju sa običnim ekstruderima. Ekstruderi su opremljeni zatvorenom strukturom, što može smanjiti emisiju prašine i isparljivih materija tokom obrade, ispunjavanje zahtjeva za zaštitu okoliša industrije masterbatcha.

3.1.5 Inteligentna kontrola, Jednostavan rad i održavanje

Svi Zhuoyue ekstruderi imaju PLC inteligentni kontrolni sistem i radni interfejs sa ekranom osetljivim na dodir, koji je jednostavan i intuitivan, jednostavan za rukovanje. Sistem može pohraniti više skupova formula proizvoda i parametara obrade (do 100 setovi), i pri proizvodnji različitih vrsta masterbatcha, potrebno je pozvati samo odgovarajuću formulu i parametre, bez ponovnog otklanjanja grešaka, što štedi vrijeme i poboljšava efikasnost proizvodnje.

Sistem je takođe opremljen funkcijom praćenja u realnom vremenu, koji može pratiti ključne parametre procesa ekstruzije (kao što je temperatura, pritisak, brzina zavrtnja, feeding speed) u realnom vremenu, i zabilježiti proizvodne podatke (kao što je izlaz, vrijeme obrade) za kasnije ispitivanje i analizu. Za ekstrudere serije HTS SUPER, također pružamo funkciju upravljanja oblakom, koji može realizovati daljinsko podešavanje parametara, praćenje proizvodnih podataka i prediktivno održavanje opreme, ostvarivanje inteligentnog upravljanja proizvodnjom.

Osim toga, ekstruderi usvajaju razuman strukturalni dizajn, što održavanje čini praktičnijim. Vijci, cijevi i glave matrice mogu se brzo rastaviti i sastaviti, što smanjuje vrijeme održavanja i radni intenzitet. Zhuoyueov servisni tim će pružiti profesionalnu instalaciju, usluge puštanja u rad i obuke za kupce, osiguravajući da kupci mogu nesmetano koristiti opremu.

3.1.6 Širok raspon primjene, Jaka prilagodljivost

Zhuoyue puna serija ekstrudera ima širok raspon primjene, koji se može prilagoditi potrebama obrade različitih vrsta masterbatcha, uključujući masterbatch u boji, white masterbatch, black masterbatch, obična masterbatch, funkcionalni masterbatch (vatrootporna masterbatch, antistatic masterbatch), i masterbatch sa različitim nosiocima (PE, PP, PVC, PA, PET, itd.). The extruders can also adapt to the processing of masterbatch with different pigment contents (10%-80%), and can meet the processing needs of different application fields (fibers, filmovi, puhanje, ekstruzija, brizganje).

Whether it is a small and medium-sized manufacturer producing ordinary masterbatch, or a large-scale manufacturer producing high-end functional masterbatch, Zhuoyue can provide suitable extruder solutions. Osim toga, the extruders can be matched with different auxiliary equipment (kao što su mikseri velike brzine, dryers, coolers, granulators, screening machines, packaging machines) to form a complete automatic production line, realizing continuous production from raw material pretreatment to product packaging.

3.2 Detailed Introduction of Zhuoyue’s Extruder Series and Their Adaptation to Masterbatch Processing

Zhuoyue’s extruder series for masterbatch processing include HTS BASIC, HTS PLUS, HTS SUPER, ZTE and HTE, each series has its own unique performance characteristics and targeted adaptation scenarios. Manufacturers can select the appropriate extruder series according to their own production scale, tip proizvoda, masterbatch concentration, application field and budget.

3.2.1 Ekstruderi serije HTS BASIC: Flexible and Cost-Effective Choice for Ordinary Masterbatch

The HTS BASIC series extruders are a cost-effective product series designed for small and medium-sized masterbatch manufacturers or manufacturers that mainly produce ordinary masterbatch. Ova serija ekstrudera koristi mjenjače srednjeg obrtnog momenta vodećih europskih proizvođača, koje imaju prednosti stabilnih performansi, niska buka, visoka efikasnost i dug radni vek. The specific torque of the extruders is 10-12Nm/cm³, koji može zadovoljiti potrebe obrade obične masterbatch (sadržaj pigmenta ≤50%), such as PE/PP color masterbatch, low-concentration white masterbatch and black masterbatch.

U pogledu konstrukcijskog dizajna, ekstruderi serije HTS BASIC imaju paralelnu korotirajuću strukturu s dva vijka, sa prečnikom šrafa u rasponu od 30 mm do 65 mm, i omjer kompresije od 4～8, which can be adjusted according to the type of masterbatch. Cijev je izrađena od legiranog čelika otpornog na habanje sa tretmanom nitriranja, a vijak je izrađen od legiranog čelika otpornog na habanje i koroziju, koji ima dobru otpornost na habanje. Ekstruder je opremljen PLC kontrolnim sistemom i interfejsom za rad sa ekranom osetljivim na dodir, koji može da realizuje automatsko hranjenje, automatska kontrola temperature, automatska kontrola pritiska i automatsko rezanje, i jednostavan je i lak za rukovanje.

Kapacitet proizvodnje ekstrudera serije HTS BASIC kreće se od 100 kg/h do 500 kg/h, which is suitable for small and medium-sized masterbatch manufacturers that mainly produce ordinary masterbatch for films, injection molding and extrusion products. Jedna od najvećih prednosti ove serije je da može pružiti fleksibilne opcije kroz različite kombinacije konfiguracije. Kupci mogu izabrati različite vijčane elemente, die heads, feeding devices and post-processing equipment according to their own product types and production needs, so as to form a production line suitable for their own needs. The HTS BASIC series extruders have a reasonable price, which can help small and medium-sized manufacturers reduce the initial investment cost while ensuring the basic processing quality of masterbatch. It is an ideal choice for enterprises that are just entering the masterbatch industry or have limited production scale and budget. Osim toga, this series of extruders has simple operation and low maintenance cost, and its after-sales service support is consistent with other high-end series, which can fully meet the daily production needs of small and medium-sized manufacturers.

3.2.2 HTS PLUS Series Extruders: High-Torque Solution for Engineering Plastics and Filler Masterbatch

The HTS PLUS series extruders are positioned as mid-to-high-end products, specially developed for masterbatch processing scenarios with higher requirements, such as engineering plastic masterbatch and filler masterbatch. Different from the HTS BASIC series, this series adopts high-torque gearboxes independently developed and manufactured by Zhuoyue, with a specific torque of 13-16Nm/cm³, which can provide stronger shear force and kneading force, effectively solving the processing difficulties of high-viscosity, high-hardness masterbatch materials.

In terms of core components, the screws and barrels of the HTS PLUS series are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment. The surface hardness reaches ≥65 HRC, koji ima odličnu otpornost na habanje i koroziju, i može se lako nositi s habanjem uzrokovanim masterbatch punilom (kao što je kalcijum karbonat, Masterbatch punjen talkom) i inženjering plastične masterbatch (such as PA, PC masterbatch). Vijak ima modularni dizajn, i opremljen je poboljšanim elementima za miješanje i elementima za smicanje, koji može u potpunosti dispergirati punila i pigmente u nosaču, osiguravaju ujednačenost i stabilnost masterbatcha. The barrel is divided into 5-6 sekcije za kontrolu temperature, sa preciznošću kontrole temperature od ±1℃, koji može precizno kontrolirati temperaturu obrade inženjerske plastike (200-280℃) i izbjeći raspadanje materijala.

Kapacitet proizvodnje ekstrudera serije HTS PLUS kreće se od 300 kg/h do 1200 kg/h, koji je pogodan za srednje i velike proizvođače masterbatcha koji proizvode inženjersku plastičnu masterbatch, punilo masterbatch, masterbatch boje visoke koncentracije (pigment content 50%-70%) i druge proizvode. Na primjer, u preradi PA inženjerske plastične masterbatch, HTS PLUS serija može se osloniti na svoj visoki obrtni moment i preciznu kontrolu temperature kako bi osigurala da je PA nosač potpuno otopljen, a pigmenti i funkcionalni aditivi su jednolično dispergovani, izbjegavanje problema s mrljama u boji, pruge i loša mehanička svojstva matične smjese. U preradi masterbatch punila, njegova snažna sila smicanja može u potpunosti raspršiti čestice punila (koji se lako aglomeriraju) u nosaču, poboljšanje kompatibilnosti između punila i nosača, i osiguravanje performansi obrade masterbatch-a kada se pomiješa sa plastičnim sirovinama koje se nalaze u nastavku.

Osim toga, ekstruderi serije HTS PLUS opremljeni su nadograđenim PLC inteligentnim kontrolnim sistemom, koji može ostvariti precizniju kontrolu parametara i praćenje podataka. Sistem može automatski podesiti brzinu zavrtnja, brzina dodavanja i pritisak ekstruzije prema viskoznosti materijala i efektu obrade, osiguravanje stabilnosti kvaliteta proizvoda između serija. Ekstruder je također opremljen sa uređajem za prisilno hranjenje i uređajem za vakuumsko ispuštanje: uređaj za prisilno hranjenje može osigurati nesmetano hranjenje visoko viskoznih materijala; Vakuumski ispušni uređaj može efikasno ukloniti vlagu, isparljivih tvari i zraka u materijalima, izbjegavanje mjehurića i pora u masterbatchu, i poboljšanje gustine i kvaliteta masterbatcha. Ova serija ekstrudera balansira performanse i troškove, i pogodan je za proizvođače koji trebaju poboljšati kvalitetu proizvoda i proširiti proizvodni opseg.

3.2.3 Ekstruderi serije HTS SUPER: The Pinnacle of Zhuoyue’s Technology for High-End Masterbatch

As Zhuoyue’s highest-end extruder series, the HTS SUPER series represents the advanced level of China’s twin-screw extruder development, specially designed for high-end, high-demand masterbatch processing scenarios, such as high-concentration functional masterbatch, special engineering plastic masterbatch (such as PBT, POM, LCP), and masterbatch for high-end downstream fields (new energy vehicles, medicinskih uređaja, high-end electronics).

The core highlight of the HTS SUPER series is the adoption of Zhuoyue’s latest independently developed ultra-high torque transmission device, with a specific torque of 17-20Nm/cm³, which is far higher than that of the HTS PLUS series. This ultra-high torque design enables the extruder to cope with the processing of ultra-high viscosity, ultra-high hardness masterbatch materials, such as masterbatch with high filler content (filler content above 60%) and special engineering plastic masterbatch with high melting point and high viscosity. U isto vreme, aiming at the high torque and high speed characteristics of this series, Zhuoyue has carried out a comprehensive optimization of the structural design of all key components of the extruder: the screw adopts a new type of wear-resistant alloy steel and undergoes laser cladding treatment, with a surface hardness of ≥70 HRC, which has extremely strong wear resistance and service life (3-4 puta više od običnih ekstrudera); the barrel adopts a double-layer jacket + forced cooling structure, which can realize rapid temperature adjustment and precise control, avoiding local overheating of materials during high-speed, high-torque processing; the gearbox adopts a precision planetary gear structure, with low noise, high efficiency and stable operation, which can withstand long-term high-load work.

In terms of mixing and dispersing effect, the HTS SUPER series is equipped with a new type of multi-stage mixing screw combination, including high-shear mixing elements, kneading blocks and dispersing elements, which can generate multi-directional shear force and kneading force, fully breaking the agglomerates of pigments and fillers (even agglomerates below 50μm), and making the pigments, fillers and carriers uniformly mixed. The mixing uniformity of the masterbatch can reach more than 98%, which is suitable for the processing of high-concentration, high-dispersibility masterbatch (pigment content 70%-80%). Osim toga, this series of extruders adopts a variable frequency speed regulation system with high precision, a brzina zavrtnja se može podesiti u rasponu od 300-1000 rpm, koji se može fleksibilno prilagoditi prema vrsti masterbatcha i zahtjevima obrade, osiguravajući najbolji efekat obrade.

Kapacitet proizvodnje ekstrudera serije HTS SUPER kreće se od 1000 kg/h do 3000 kg/h, koji je pogodan za velike, visokostandardni proizvođači masterbatcha koji se fokusiraju na vrhunska tržišta. Na primjer, u preradi masterbatcha za nove energetske dijelove vozila (kao što su dijelovi unutrašnjosti i eksterijera automobila, masterbatch kućišta baterije), HTS SUPER serija može osigurati da masterbatch ima odličnu otpornost na vremenske uvjete, otpornost na visoke temperature i disperzibilnost, ispunjavanje strogih zahtjeva kvaliteta proizvođača automobila; u obradi masterbatch medicinskog kvaliteta (kao što je masterbatch za medicinske katetere, medicinski kontejneri), može ostvariti čistu proizvodnju, izbegavajte materijalno zagađenje, and ensure that the masterbatch meets the medical grade environmental protection standards. This series of extruders is also equipped with an intelligent cloud control system, koji može realizovati daljinsko podešavanje parametara, production data monitoring, fault early warning and predictive maintenance. Manufacturers can monitor the production status of the equipment in real time through mobile phones or computers, realize intelligent production management, and greatly improve production efficiency and management level.

3.2.4 Ekstruderi serije ZTE: Cost-Effective Choice for Universal Masterbatch Processing

The ZTE series extruders are positioned as cost-effective products, specially designed for manufacturers that need to balance processing quality and cost, and mainly produce universal ordinary masterbatch. This series of extruders has excellent cost performance, and its designed parameters can meet the processing needs of most common masterbatch materials (PE, PP, PVC masterbatch, low-concentration color masterbatch, black masterbatch and white masterbatch with pigment content ≤50%).

U pogledu konstrukcijskog dizajna, the ZTE series adopts a twin-screw parallel co-rotating structure, with a screw diameter ranging from 25mm to 65mm, and a specific torque of 8-11Nm/cm³, which can provide sufficient shear force and conveying capacity for ordinary masterbatch processing. The screws and barrels are made of high-quality wear-resistant alloy steel with nitriding treatment, and the surface hardness reaches ≥60 HRC, which can meet the wear requirements of ordinary pigments (such as organic pigments, low-hardness inorganic pigments) and has a long service life. The barrel is divided into 4 sekcije za kontrolu temperature, with a temperature control precision of ±2℃, koji može precizno kontrolirati temperaturu obrade obične masterbatch (150-220℃), izbjegavanje razgradnje pigmenta i degradacije nosača.

Proizvodni kapacitet ZTE serije ekstrudera kreće se od 50kg/h do 400kg/h, koji je pogodan za male i srednje proizvođače masterbatcha, male radionice i preduzeća koja treba da proizvode male serije više varijanti masterbatcha. Ova serija ekstrudera ima prednosti jednostavne strukture, jednostavan rad, niska potrošnja energije i niski troškovi održavanja. Operativni interfejs ima jednostavan dizajn ekrana osetljivog na dodir, koje je lako naučiti i savladati, i pogodan je za operatere sa malo iskustva. Osim toga, ZTE serija se takođe može fleksibilno konfigurisati prema potrebama kupaca, kao što je dodavanje uređaja za prisilno hranjenje, vakuumski ispušni uređaj ili specijalna glava matrice, to meet the personalized processing needs of different customers. Although the ZTE series is cost-effective, its core performance indicators (such as mixing uniformity, temperature control precision) are far higher than those of ordinary extruders on the market, which can ensure that the produced masterbatch has uniform coloring, stable performance and meets the basic use requirements of downstream customers. It is an ideal choice for enterprises with limited budget and mainly producing ordinary masterbatch.

3.2.5 HTE Series Extruders: High-Performance and Cost-Effective Integrated Solution

The HTE series extruders integrate the advantages of high performance and cost-effectiveness, aiming at medium-sized masterbatch manufacturers that need to improve production efficiency and product quality while controlling costs. This series of extruders is designed to balance performance, efficiency and cost, and is suitable for a variety of masterbatch processing scenarios, including high-concentration color masterbatch (pigment content 50%-60%), ordinary functional masterbatch (vatrootporna masterbatch, antistatic masterbatch) and masterbatch for films, blow molding and injection molding products.

In terms of core performance, the HTE series adopts a high-torque gearbox independently developed by Zhuoyue, with a specific torque of 12-14Nm/cm³, which is higher than that of the HTS BASIC and ZTE series, and can provide stronger shear force and kneading force, ensuring the uniform dispersion of pigments and additives. The screws adopt a modular design, and are equipped with a combination of conveying elements, mixing elements and shearing elements, which can be flexibly adjusted according to the type of masterbatch, improving the adaptability of the extruder. The screws and barrels are made of imported wear-resistant alloy steel with bimetallic composite treatment, and the surface hardness reaches ≥65 HRC, which has excellent wear resistance and can cope with the processing of high-hardness pigments (such as titanium dioxide, carbon black) and low-content filler masterbatch.

The biggest advantage of the HTE series is that it can reduce energy consumption while improving production efficiency. This series of extruders adopts an optimized screw structure and a high-efficiency energy-saving motor, što može smanjiti potrošnju energije 18%-25% compared with ordinary extruders of the same type. U isto vreme, its production capacity ranges from 200kg/h to 800kg/h, which is 15%-20% higher than that of the HTS BASIC series of the same specification. The barrel is divided into 5 sekcije za kontrolu temperature, sa preciznošću kontrole temperature od ±1℃, koji može precizno kontrolisati temperaturu obrade, izbjegavajte materijalni otpad uzrokovan pregrijavanjem ili nedovoljnim topljenjem, i dodatno smanjiti troškove proizvodnje. Osim toga, HTE serija je opremljena PLC inteligentnim kontrolnim sistemom, koji može realizovati automatsku kontrolu parametara, praćenje podataka i skladištenje formula, osiguravanje stabilnosti kvaliteta proizvoda između serija. Ekstruder je također opremljen vakuumskim ispušnim uređajem i uređajem za prisilno hranjenje, što može poboljšati kvalitet masterbatcha i osigurati nesmetan napredak proizvodnje.

HTE serija je pogodna za srednje proizvođače masterbatcha koji su u fazi širenja proizvodnog opsega i unapređenja kvaliteta proizvoda. Ne samo da može zadovoljiti potrebe obrade visokokvalitetnog masterbatcha, ali i efektivnu kontrolu troškova proizvodnje, pomaže preduzećima da poboljšaju svoju tržišnu konkurentnost. U poređenju sa HTS PLUS serijom, HTE serija ima razumniju cijenu; u poređenju sa ZTE serijom, ima bolje performanse i veću efikasnost proizvodnje, što je isplativ izbor između proizvoda srednjeg i visokog kvaliteta.

4. Široka polja primjene Masterbatch i odgovarajućih Zhuoyue ekstruderskih rješenja

Kao nezamjenjiv osnovni materijal u industriji plastike, masterbatch se široko koristi u vlaknima, filmovi, puhanje, ekstruziono oblikovanje, brizganje i druga polja. Različita polja primjene imaju različite zahtjeve za performanse masterbatcha (kao što je disperzibilnost, temperaturna otpornost, postojanost boje) i efikasnost proizvodnje, što takođe određuje izbor dvopužnih ekstrudera. Zhuoyue puna serija ekstrudera može pružiti ciljana rješenja za različita područja primjene, ensuring that the produced masterbatch meets the specific requirements of downstream products. The following is a detailed introduction to the application fields of masterbatch and the matching Zhuoyue extruder series.

4.1 Fiber Field: High-Dispersibility and Color Fastness Requirements

Masterbatch in the fiber field is mainly used for coloring chemical fibers, kao što su poliesterska vlakna, najlonsko vlakno, polypropylene fiber, itd., and the final products include carpets, tekstil, cushions, non-woven fabrics, itd. This field has extremely high requirements on masterbatch: prvo, high dispersibility. The fiber diameter is very small (usually a few microns to dozens of microns), and if the pigments in the masterbatch are not uniformly dispersed, it will cause color spots, streaks and uneven fineness of the fiber, affecting the appearance and quality of the fiber product; drugo, high color fastness. The fiber products need to go through spinning, weaving, dyeing and finishing and other processes, and the masterbatch must have good washing fastness, light fastness and friction fastness, avoiding color fading and discoloration; treće, low impurity content. Impurities in the masterbatch will cause breakage of the fiber during spinning, reducing the yield of the fiber.

According to the requirements of the fiber field, the suitable Zhuoyue extruder series are HTS PLUS series, HTS SUPER series and HTE series. For high-end fiber masterbatch (such as high-grade textile fiber, carpet fiber), the HTS SUPER series is recommended. Its ultra-high mixing uniformity (≥98%) can ensure that the pigments are uniformly dispersed in the carrier, avoiding color spots and streaks of the fiber; the high-torque and precise temperature control can ensure the stability of the masterbatch performance, improving the color fastness of the fiber. For medium-grade fiber masterbatch (such as ordinary textile fiber, non-woven fabric), the HTS PLUS series and HTE series are recommended. Their high mixing and dispersing effect can meet the basic requirements of fiber masterbatch, and the cost performance is higher. For small-batch, low-cost fiber masterbatch, the HTS BASIC series can also be selected, which can ensure the basic dispersibility and color fastness.

4.2 Film Field: High Transparency and Uniform Coloring Requirements

Masterbatch in the film field is mainly used for coloring plastic films, kao što su torbe za kupovinu, casting filmova, višeslojnih filmova, folije za pakovanje, agricultural films, itd. The key requirements of this field for masterbatch are: prvo, high transparency. For transparent or translucent films (kao što su folije za pakovanje hrane, poljoprivredne malč folije), masterbatch mora imati dobru transparentnost, izbjegavanje utjecaja na izgled i vidljivost upakovanih proizvoda; drugo, ujednačeno bojenje. Površina filma mora biti ujednačene boje, bez mrlja u boji, pruge u boji i razlika u boji, osiguravanje estetskih svojstava filma; treće, dobra fluidnost obrade. Brzina ekstruzije filma je velika, a masterbatch mora imati dobru fluidnost, što pogoduje ujednačenom miješanju masterbatch-a i osnovnog materijala filma, i izbjegavanje utjecaja na efikasnost formiranja filma.

Za filmsko polje, odgovarajuća serija ekstrudera Zhuoyue je HTS BASIC serija, HTE serija i HTS PLUS serija. Za obični filmski masterbatch (kao što su torbe za kupovinu, obične folije za pakovanje), preporučuju se HTS BASIC serije i HTE serije. Njihovo dobro mešanje i efekat dispergovanja može obezbediti ujednačeno obojenje filma, and the good processing fluidity can match the high-speed extrusion of the film. For high-end film masterbatch (kao što su folije za pakovanje hrane, multi-layer composite films), the HTS PLUS series is recommended. Its precise temperature control can avoid the decomposition of pigments and carriers, ensuring the transparency and safety of the film; the enhanced mixing elements can further improve the dispersibility of the masterbatch, making the film surface more smooth and uniform. For ultra-high transparent film masterbatch (such as PET packaging films), the HTS SUPER series can be selected, which can achieve ultra-high dispersibility of pigments, ensuring the transparency and clarity of the film.

4.3 Blow Molding Field: Good Fluidity and Dimensional Stability Requirements

Masterbatch in the blow molding field is mainly used for coloring blow molding products, kao što su medicinski i kozmetički kontejneri, posude za ulje i boju za podmazivanje, beverage bottles, plastične bačve, itd. The requirements of this field for masterbatch are: prvo, dobra fluidnost obrade. Blow molding products need to be formed by high-temperature blow molding, a masterbatch mora imati dobru fluidnost, which is conducive to the uniform distribution of the masterbatch in the parison, avoiding uneven wall thickness and color difference of the product; drugo, good dimensional stability. The blow molding products have strict requirements on dimensional accuracy, and the masterbatch must have stable performance, avoiding the deformation of the product due to uneven shrinkage; treće, zaštita životne sredine. Especially for medical and cosmetic containers, the masterbatch must meet environmental protection standards, non-toxic and harmless, without volatile substances.

For the blow molding field, the suitable Zhuoyue extruder series are ZTE series, HTS BASIC series and HTE series. For ordinary blow molding masterbatch (kao što su posude za ulje za podmazivanje, plastične bačve), preporučuje se serija ZTE i HTS BASIC serija. Njihova razumna struktura vijaka i sistem kontrole temperature mogu osigurati dobru fluidnost i stabilnost masterbatcha, ispunjavanje osnovnih zahtjeva za proizvode za puhanje. Za masterbatch za oblikovanje puhanjem srednjeg kvaliteta (kao što su kozmetičke posude, beverage bottles), preporučuje se serija HTE. Njegova visoka proizvodna efikasnost i prednosti uštede energije mogu smanjiti troškove proizvodnje, a dobar efekat miješanja i dispergiranja može osigurati ujednačenu boju i stabilnost dimenzija proizvoda. Za vrhunsku masterbatch kalupa za puhanje (kao što su medicinski kontejneri), preporučuju se serije HTS PLUS i HTS SUPER. Njihova precizna kontrola temperature i čist proizvodni dizajn mogu osigurati da masterbatch ispunjava standarde medicinske kvalitete, and the stable performance can ensure the dimensional accuracy and safety of the product.

4.4 Extrusion Molding Field: High Dimensional Stability and Wear Resistance Requirements

Masterbatch in the extrusion molding field is mainly used for coloring extrusion products, kao što su listovi, cijevi, žice i kablovi, profili, itd. The key requirements of this field for masterbatch are: prvo, high dimensional stability. Extrusion products (such as pipes, profili) have strict requirements on dimensional accuracy, and the masterbatch must have stable performance, avoiding the deformation and color difference of the product due to uneven shrinkage; drugo, good wear resistance. For products such as pipes and wires and cables that need to withstand friction and extrusion, the masterbatch must have good wear resistance, ensuring the service life of the product; treće, good weather resistance. For outdoor extrusion products (such as building profiles, outdoor pipes), the masterbatch must have good weather resistance, avoiding color fading and performance degradation under sunlight and rain.

For the extrusion molding field, the suitable Zhuoyue extruder series are HTS PLUS series, HTE series and HTS SUPER series. For ordinary extrusion masterbatch (such as indoor sheets, ordinary pipes), the HTE series and HTS BASIC series are recommended. Their good mixing and dispersing effect can ensure uniform coloring of the product, and the stable performance can ensure the dimensional accuracy of the product. For medium-grade extrusion masterbatch (such as wires and cables, building profiles), the HTS PLUS series is recommended. Its high-torque gearbox and wear-resistant screw/barrel can cope with the processing of high-hardness, high-viscosity masterbatch, ensuring the wear resistance and weather resistance of the product. For high-end extrusion masterbatch (such as high-temperature resistant pipes, outdoor high-grade profiles), the HTS SUPER series is recommended. Njegov ultra-visok obrtni moment i precizna kontrola temperature mogu osigurati stabilne performanse masterbatcha, a poboljšana otpornost na habanje može dodatno produžiti vijek trajanja proizvoda.

4.5 Polje brizganja: Visoki zahtjevi za disperzibilnost i stabilnost serije

Masterbatch u oblasti brizganja je najčešće korišten, uglavnom se koristi za bojenje proizvoda za brizganje, kao što su automobilski dijelovi, elektronski proizvodi, građevinski materijali, kućni aparati, namještaj, igračke, itd. Zahtjevi ovog polja za masterbatch su različiti, ali osnovni zahtjevi su: prvo, high dispersibility. Proizvodi za brizganje imaju složene oblike i male veličine, a masterbatch mora imati visoku disperzibilnost, izbjegavanje mrlja u boji, pruge u boji i neujednačeno obojenje proizvoda; drugo, dobra stabilnost serije. Proizvodi za brizganje obično se proizvode u velikim serijama, and the masterbatch must have stable performance, osiguravajući da nema razlike u boji između serija proizvoda; treće, ciljane funkcionalne zahtjeve. Na primjer, automobilski dijelovi zahtijevaju masterbatch otporan na visoke temperature i otpornost na vatru, elektronski proizvodi zahtevaju masterbatch sa antistatičkim performansama, a igračke zahtijevaju masterbatch sa netoksičnim i ekološkim performansama.

Za polje brizganja, Zhuoyue puna serija ekstrudera može pružiti odgovarajuća rješenja prema različitim nivoima proizvoda. Za obične masterbatch za brizganje (kao što su igračke, obicnih kucnih aparata), preporučuje se serija ZTE i HTS BASIC serija. Njihove isplative prednosti mogu smanjiti troškove proizvodnje, a osnovni efekat miješanja i dispergiranja može zadovoljiti zahtjeve običnih proizvoda. Za brizganje srednjeg kvaliteta masterbatch (kao što su elektronski proizvodi, obicnih auto delova), preporučuju se serije HTE i HTS PLUS. Njihovo visoko djelovanje miješanja i dispergiranja i stabilnost serije mogu osigurati kvalitetu proizvoda, a ciljani funkcionalni kapacitet obrade masterbatch može zadovoljiti posebne zahtjeve proizvoda. Za vrhunsku masterbatch za brizganje (kao što su visokokvalitetni automobilski dijelovi, precizni elektronski proizvodi), the HTS SUPER series is recommended. Njegova ultra-visoka disperzibilnost, Stabilnost serije i otpornost na visoke temperature mogu zadovoljiti stroge zahtjeve kvalitete vrhunskih proizvoda, a inteligentni kontrolni sistem može osigurati efikasnost i stabilnost proizvodnje velikih razmjera.

5. Uobičajeni problemi i rješenja u Masterbatch ekstruziji s dva vijka

U stvarnom procesu proizvodnje masterbatcha, zbog uticaja sirovina, formula, parametri obrade i performanse opreme, često se javljaju razni problemi, which affect the quality of masterbatch and production efficiency. Based on years of industry experience, Zhuoyue summarizes the common problems in masterbatch twin-screw extrusion processing, analyzes the causes in detail, and provides corresponding solutions, which can help manufacturers quickly solve production problems and improve production efficiency and product quality.

5.1 Common Problem 1: Poor Dispersibility of Masterbatch, Color Spots and Streaks in Products

This is the most common problem in masterbatch processing, which is mainly manifested in uneven coloring of the masterbatch, obvious pigment agglomerates, and color spots and streaks in the colored plastic products. The main causes and solutions are as follows:

5.1.1 Main Causes:

• (1) Raw material problems: The pigment particle size is too large, the agglomeration degree is high, a sušenje je nedovoljno; kompatibilnost između pigmenta i nosača je loša; doza disperzanta je nedovoljna ili je vrsta neodgovarajuća.
• (2) Problemi sa premiksanjem: Brzina miješanja je preniska, vrijeme miješanja je prekratko, temperatura mešanja nije odgovarajuća, što dovodi do neravnomjernog prethodnog miješanja sirovina.
• (3) Problemi sa parametrima ekstruzije: Brzina zavrtnja je preniska, sila smicanja je nedovoljna, a aglomerati pigmenta se ne mogu u potpunosti razbiti; temperatura ekstruzije je preniska, nosač nije potpuno otopljen, and the pigment cannot be uniformly dispersed.
• (4) Problemi sa opremom: Elementi za vijčano mešanje su nedovoljni ili su istrošeni; cijev i vijak su istrošeni, što rezultira smanjenom silom smicanja; glava matrice je blokirana, utičući na ujednačenu ekstruziju materijala.

5.1.2 Rješenja:

• (1) Optimizirajte sirovine: Odaberite pigmente male veličine čestica i niskog stepena aglomeracije, i dobro ih osušite (sadržaj vlage ≤0,1%); odaberite nosače kompatibilne s pigmentima; zamijenite odgovarajuće disperzante i na odgovarajući način povećajte dozu (unutar 1%-5% of the pigment dosage).
• (2) Poboljšajte efekat prethodnog mešanja: Povećajte brzinu miješanja do 800-1200 rpm, produžite vrijeme miješanja do 5-10 minuta, i kontrolirajte temperaturu miješanja na 40-60℃; za masterbatch visoke koncentracije, prvo dodajte disperzant i pomiješajte s pigmentom, zatim pomiješati s nosačem i drugim aditivima.
• (3) Podesite parametre ekstruzije: Povećajte brzinu zavrtnja na odgovarajući način (500-800 rpm za masterbatch visoke koncentracije), poboljšati silu smicanja; povećajte temperaturu ekstruzije na odgovarajući način kako biste osigurali da je nosač potpuno otopljen (prilagodite prema vrsti nosača).
• (4) Održavajte opremu: Zamijenite istrošene vijčane elemente za miješanje, cijev i vijak; redovno čistite glavu matrice kako biste izbjegli blokadu; redovito provjeravajte opremu kako biste bili sigurni da su vijak i cijev pravilno usklađeni.

5.2 Common Problem 2: Razgradnja pigmenta i promjena boje masterbatcha

Ovaj problem se uglavnom manifestira u promjeni boje matične smjese (kao što je žutilo, zamračenje), boja nije u skladu sa standardnim uzorkom, čak se stvara i neobičan miris. Uglavnom je uzrokovano pregrijavanjem materijala tokom ekstruzijske obrade, što je uobičajeno u organskoj pigmentnoj masterbatch i inženjerskoj plastičnoj masterbatch. The main causes and solutions are as follows:

5.2.1 Main Causes:

• (1) Temperatura ekstruzije je previsoka: Temperatura sekcije za miješanje, homogenizacijski dio ili glava kalupa je previsoka, prekoračenje granice otpornosti na toplotu pigmenta ili nosača.
• (2) Vrijeme zadržavanja materijala je predugo: Brzina zavrtnja je preniska, omjer kompresije je prevelik, resulting in the material staying in the extrusion cavity for too long (more than 3 minuta), and thermal decomposition occurs.
• (3) Poor heat dissipation of the equipment: The cooling system of the barrel fails, resulting in local overheating of the barrel.
• (4) Raw material problems: The heat resistance of the pigment is poor, or the carrier is easy to degrade at high temperature.

5.2.2 Rješenja:

• (1) Adjust extrusion temperature: Reduce the temperature of the mixing section, homogenizing section and die head appropriately, and control it within the heat resistance range of the pigment and carrier (150-220℃ for ordinary masterbatch, 200-280℃ za inženjering plastične masterbatch); check the temperature sensor regularly to ensure accurate temperature control.
• (2) Shorten the residence time: Povećajte brzinu zavrtnja na odgovarajući način, reduce the compression ratio of the screw, and ensure that the residence time of the material in the extrusion cavity is 1-3 minuta.
• (3) Maintain the cooling system: Redovno proveravajte sistem cirkulacije rashladne vode, očistite rashladnu cijev, i osigurajte da cijev može normalno rasipati toplinu; zamijenite neispravan rashladni element na vrijeme.
• (4) Optimizirajte sirovine: Odaberite pigmente sa dobrom otpornošću na toplotu (kao što su anorganski pigmenti za obradu na visokim temperaturama); odaberite nosače sa stabilnim performansama i koje nije lako degradirati; dodati odgovarajuće stabilizatore toplote (0.5%-3%) kako bi se spriječilo raspadanje pigmenta i degradacija nosača.

5.3 Common Problem 3: Visoko trošenje zavrtnja i cijevi, Kratak vijek trajanja

Ovaj problem je uobičajen kod obrade bijelog masterbatcha, crna masterbatch i masterbatch punila, što se uglavnom očituje u brzom trošenju vijka i cijevi, smanjena sila smicanja i kapacitet miješanja ekstrudera, i povećani troškovi održavanja. The main causes and solutions are as follows:

5.3.1 Main Causes:

• (1) Raw material problems: Pigment ili punilo ima visoku tvrdoću (such as titanium dioxide, carbon black, kalcijum karbonat), a veličina čestica je prevelika, which causes severe wear to the screw and barrel.
• (2) Problemi sa parametrima ekstruzije: The screw speed is too high, the shear force is too large, and the friction between the material and the screw/barrel is increased; the extrusion pressure is too high, which increases the wear of the screw and barrel.
• (3) Problemi sa opremom: The screw and barrel are made of materials with poor wear resistance, or the processing technology is improper; the screw and barrel are not properly matched, resulting in uneven stress and increased wear.

5.3.2 Rješenja:

• (1) Optimizirajte sirovine: Select pigments or fillers with small particle size (20-40 mesh) and low hardness; crush and sieve the raw materials to remove large particles; add appropriate lubricants (0.5%-2%) to reduce the friction between the material and the screw/barrel.
• (2) Podesite parametre ekstruzije: Reduce the screw speed and extrusion pressure appropriately, and control the shear force within a reasonable range; avoid long-term high-speed and high-pressure operation of the equipment.
• (3) Select high-wear-resistant equipment: Select extruders with high-wear-resistant screws and barrels, such as Zhuoyue’s HTS PLUS, HTS SUPER and HTE series, whose screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite or laser cladding treatment, which can greatly improve the service life; regularly check the wear of the screw and barrel, and replace them in time when the wear is serious.

5.4 Common Problem 4: Instability of Product Quality Between Batches, Color Difference

This problem is mainly manifested in the inconsistency of masterbatch quality (such as concentration, dispersibility, boja) between different batches, resulting in color difference of downstream products, which affects the reputation of the manufacturer. The main causes and solutions are as follows:

5.4.1 Main Causes:

• (1) Formula problem: The formula ratio is not strictly controlled, and the dosage of pigment, disperzanti i drugi aditivi variraju (greška prelazi ±1%).
• (2) Problem sa sirovinama: Performanse sirovina (kao što je jačina nijansiranja pigmenta, tačka topljenja nosača) različitih serija je nedosljedan.
• (3) Problem parametara obrade: Temperatura ekstruzije, brzina zavrtnja, brzina hranjenja i drugi parametri variraju između različitih serija, što rezultira nedosljednim efektom obrade.
• (4) Problem sa opremom: Oprema ima slabu stabilnost, i parametri (kao što je temperatura, pritisak) ne može se dugo održavati stabilnim.

5.4.2 Rješenja:

• (1) Strogo kontrolirajte omjer formule: Koristite opremu za vaganje visoke preciznosti za vaganje sirovina, a greška se kontroliše unutar ±1%; uspostaviti sistem upravljanja formulama, i detaljno zabilježite dozu svake sirovine.
• (2) Standardizirati nabavku sirovina i inspekciju: Odaberite dobavljače sirovina sa stabilnim kvalitetom, i inspekciju performansi sirovina (kao što je jačina nijansiranja, veličina čestica, moisture content) prije upotrebe; za sirovine različitih serija, prvo izvršite probnu proizvodnju kako biste osigurali dosljedan učinak.
• (3) Standardizirati parametre obrade: Koristite inteligentni sistem upravljanja (kao što je Zhuoyueov PLC kontrolni sistem) za pohranjivanje parametara obrade različitih masterbatcha, i pozvati odgovarajuće parametre prilikom proizvodnje različitih serija, izbjegavanje ponovnog otklanjanja grešaka; redovno provjeravajte parametre opreme kako biste osigurali stabilan rad.
• (4) Uspostaviti sistem kontrole kvaliteta: Provedite strogu inspekciju kvaliteta svake serije masterbatcha, uključujući boju, dispersibility, koncentracija i drugi pokazatelji, i isporučuju samo proizvode koji zadovoljavaju standarde.

5.5 Common Problem 5: Loša tečnost obrade masterbatcha, Difficult Extrusion, Blokada opreme

Ovaj problem se uglavnom očituje u teškoćama transporta i ekstruzije materijala, low production efficiency, nestabilan pritisak ekstruzije, pa čak i blokada glave matrice i ekstruzione šupljine, što utiče na normalnu proizvodnju. The main causes and solutions are as follows:

5.5.1 Main Causes:

• (1) Problem sa sirovinama: Nosač ima slabu tečnost, ili je sadržaj pigmenta previsok (more than 80%), što rezultira lošom fluidnošću smjese; sirovina ima visok sadržaj vlage, što uzrokuje aglomeraciju materijala i blokiranje ulaznog otvora.
• (2) Problem premiksanja: Prethodno miješanje je neravnomjerno, a disperzant nije u potpunosti izmiješan, što rezultira slabom fluidnošću materijala.
• (3) Problem parametara ekstruzije: Temperatura ekstruzije je preniska, nosač nije potpuno otopljen, a tečnost je slaba; brzina zavrtnja je preniska, kapacitet transporta je nedovoljan; otvor glave matrice je premali, a otpor ekstruziji je prevelik.
• (4) Problem sa opremom: Elementi pužnog transporta su istrošeni, the conveying capacity is reduced; the feeding device fails, resulting in uneven feeding.

5.5.2 Rješenja:

• (1) Optimizirajte sirovine: Select carriers with good fluidity; reduce the pigment content appropriately (control within 80%); dry the raw materials thoroughly to control the moisture content below 0.1%.
• (2) Poboljšajte efekat prethodnog mešanja: Extend the premixing time, increase the mixing speed, ensure that the dispersant is fully mixed with the pigment and carrier, and improve the fluidity of the mixture.
• (3) Podesite parametre ekstruzije: Increase the extrusion temperature appropriately to ensure that the carrier is fully melted; increase the screw speed to improve the conveying capacity; replace the die head with larger die holes to reduce extrusion resistance.
• (4) Održavajte opremu: Replace worn screw conveying elements; check the feeding device regularly, and repair or replace the faulty parts in time; clean the feeding port and extrusion cavity regularly to avoid material accumulation and blockage.

6. Practical Application Cases of Zhuoyue Extruders in Masterbatch Processing

To further verify the performance advantages and application effects of Zhuoyue’s full series of extruders in masterbatch processing, this section will introduce several practical application cases, covering different masterbatch types, production scales and application fields. These cases fully demonstrate that Zhuoyue’s extruders can provide targeted and efficient processing solutions for different manufacturers, helping manufacturers improve production efficiency, product quality and market competitiveness.

6.1 Slučaj 1: Application of HTS SUPER Series in High-Concentration Black Masterbatch Processing for New Energy Vehicles

Customer Background: Veliki proizvođač masterbatcha u Jiangsuu, Kina, uglavnom proizvodi vrhunski funkcionalni masterbatch, fokusirajući se na polje novih energetskih vozila. Kupac treba da proizvede crni masterbatch visoke koncentracije (sadržaj čađe 70%) za dijelove kućišta automobilskih akumulatora. Masterbatch zahtijeva ultra-visoku disperzibilnost (nema crnih mrlja i pruga na proizvodu), otpornost na visoke temperature (može izdržati visoku temperaturu od 200℃ bez promjene boje), i dobra stabilnost serije. Originalna oprema kupca ima probleme kao što je nedovoljan efekat mešanja i disperzije, nestabilna kontrola temperature, i niska efikasnost proizvodnje, koji ne mogu zadovoljiti proizvodne zahtjeve.

Rješenje: Zhuoyue preporučuje dvopužne ekstrudere serije HTS SUPER (prečnik šrafa 75mm) za kupca. Ova serija usvaja mjenjače ultra-visokog obrtnog momenta i laserski obložene vijke/cijevnice otporne na habanje, which can provide strong shear force and wear resistance, effectively solving the problem of carbon black agglomeration; the 6-section precise temperature control system (temperature control precision ±1℃) can accurately control the extrusion temperature, avoiding carbon black decomposition; the multi-stage mixing screw combination ensures that the carbon black is uniformly dispersed in the PE carrier; the intelligent cloud control system can realize remote parameter adjustment and data monitoring, ensuring batch stability.

Application Effect: After using the HTS SUPER series extruders, the customer’s high-concentration black masterbatch has achieved ultra-high dispersibility, and the colored battery shell parts have no black spots and streaks, which meets the strict requirements of new energy vehicle manufacturers; the high temperature resistance of the masterbatch has been significantly improved, and no discoloration occurs at 200℃; the production efficiency has increased from 500kg/h to 1200kg/h, and the energy consumption has decreased by 22%; the batch stability of the masterbatch has been greatly improved, and the color difference between batches is less than 0.5, which has won high recognition from downstream customers. The customer has successively purchased 8 sets of HTS SUPER series extruders, forming a large-scale production line.

6.2 Slučaj 2: Application of HTS PLUS Series in Engineering Plastic PA Masterbatch Processing

Customer Background: A medium-sized masterbatch manufacturer in Guangdong, Kina, mainly produces engineering plastic masterbatch, focusing on the automotive and electronic fields. The customer needs to produce PA66 masterbatch (pigment content 50%) for automotive connector parts. Masterbatch zahtijeva dobru disperzibilnost, otpornost na visoke temperature (260℃), i dobra kompatibilnost sa PA66 sirovinama. Originalna oprema kupca ima probleme kao što je slaba otpornost na habanje vijka/cijev, nedovoljan obrtni moment, i laka dekompozicija PA66 nosača, što utiče na kvalitet proizvoda.

Rješenje: Zhuoyue preporučuje ekstrudere s dva puža HTS PLUS serije (prečnik šrafa 65mm) za kupca. Ova serija usvaja menjače visokog obrtnog momenta koje je nezavisno razvio Zhuoyue, koji može pružiti dovoljan obrtni moment za PA66 masterbatch obradu; bimetalni kompozitni vijak/cijev ima odličnu otpornost na habanje i koroziju, koji može da se nosi sa habanjem pigmenata visoke tvrdoće; Precizni sistem kontrole temperature od 5 dijelova i vakuumski ispušni uređaj mogu izbjeći raspadanje PA66 nosača i ukloniti vlagu i isparljive tvari, ensuring the quality of the masterbatch; the modular screw design can be flexibly configured according to the PA66 masterbatch processing characteristics, improving the mixing and dispersing effect.

Application Effect: After using the HTS PLUS series extruders, the customer’s PA66 masterbatch has good dispersibility, and the automotive connector parts have uniform coloring and no color spots; the masterbatch can withstand 260℃ high temperature without decomposition and discoloration, and has good compatibility with PA66 raw materials; the service life of the screw/barrel has increased from 6 mjeseci do 18 mjeseci, reducing the maintenance cost by 60%; the production efficiency has increased from 300kg/h to 800kg/h, and the product qualification rate has increased from 92% to 99%. The customer’s PA66 masterbatch has successfully entered the supply chain of a well-known automotive parts manufacturer.

6.3 Slučaj 3: Application of HTE Series in Cost-Effective Film Masterbatch Processing

Customer Background: A small and medium-sized masterbatch manufacturer in Zhejiang, Kina, mainly produces film masterbatch, focusing on the packaging film field. The customer needs to produce PE film masterbatch (pigment content 40%) for food packaging films. The masterbatch requires good transparency, ujednačeno bojenje, and low production cost. The customer’s original equipment has problems such as high energy consumption, unstable product quality, i niska efikasnost proizvodnje, which cannot meet the market competition needs.

Rješenje: Zhuoyue recommends the HTE series twin-screw extruders (screw diameter 50mm) za kupca. This series integrates high performance and cost-effectiveness, adopts high-efficiency energy-saving motors and optimized screw structures, što može smanjiti potrošnju energije 18%-25%; the precise temperature control system ensures that the PE carrier is fully melted, avoiding affecting the transparency of the masterbatch; the enhanced mixing elements ensure uniform coloring of the masterbatch, and the stable performance ensures batch consistency; the reasonable price and low maintenance cost can help the customer reduce production costs.

Application Effect: After using the HTE series extruders, the customer’s PE film masterbatch has good transparency and uniform coloring, and the food packaging films produced have smooth surface and no color spots, which meets the food packaging standards; the energy consumption per ton of masterbatch has decreased by 20%, and the production efficiency has increased from 150kg/h to 400kg/h; the product qualification rate has increased from 90% to 98%, and the production cost has decreased by 15%. The customer’s market competitiveness has been significantly improved, and the order volume has increased by 40% within half a year. The customer has purchased 4 sets of HTE series extruders to expand production scale.

6.4 Slučaj 4: Application of ZTE Series in Small-Batch Multi-Variety Ordinary Masterbatch Processing

Customer Background: A small masterbatch manufacturer in Shandong, Kina, mainly produces small-batch multi-variety ordinary masterbatch (PE/PP color masterbatch, black masterbatch, white masterbatch), focusing on the local plastic product processing market. The customer has limited budget, small production scale, and needs to produce multiple types of masterbatch with small batches (50-100kg per batch). The customer’s requirements for the equipment are simple operation, niski troškovi održavanja, and strong adaptability.

Rješenje: Zhuoyue recommends the ZTE series twin-screw extruders (screw diameter 35mm) za kupca. This series has excellent cost performance, simple structure and easy operation, which is suitable for operators with little experience; the modular screw design can be flexibly adjusted according to different types of masterbatch, with strong adaptability; the wear-resistant screw/barrel and stable temperature control system can meet the basic processing requirements of ordinary masterbatch; the low energy consumption and low maintenance cost can help the customer reduce the initial investment and daily operation costs.

Application Effect: After using the ZTE series extruders, the customer can flexibly produce multiple types of ordinary masterbatch, and the product quality meets the basic requirements of local plastic product manufacturers; the equipment operation is simple, and the operator can master it quickly; the maintenance cost is low, and the annual maintenance cost is less than 5000 yuan; the production efficiency can meet the small-batch production needs (50-200kg/h). The ZTE series extruders have helped the customer stabilize the local market and lay a foundation for future expansion.

7. Future Development Trend of Masterbatch and Twin-Screw Extrusion Technology

With the continuous development of the global plastics industry, the upgrading of environmental protection policies and the diversification of downstream market demand, the masterbatch industry and twin-screw extrusion technology are facing new development opportunities and challenges. The future development trend will focus on environmental protection, funkcionalizacija, intelligence and high efficiency, and Zhuoyue will continue to focus on technological innovation, keep up with the industry trend, and provide more advanced and efficient processing solutions for masterbatch manufacturers.

7.1 Development Trend of Masterbatch Industry

7.1.1 In-depth Development of Environmental Protection and Low Toxicity.

With the strengthening of global environmental protection awareness and the strictness of environmental protection policies (such as the European Union’s REACH directive, China’s “double carbon” goal), environmental protection masterbatch will become the mainstream of the market. The future environmental protection masterbatch will focus on non-toxic, harmless, low-volatile, degradable and recyclable, and toxic and harmful pigments (such as heavy metal pigments) and additives will be completely eliminated. Na primjer, water-based masterbatch, bio-based masterbatch and recyclable masterbatch will have broad market prospects. U isto vreme, the recycling of masterbatch waste will also become an important development direction, which can reduce resource waste and environmental pollution.

7.1.2 Functional Integration and High Performance.

With the diversification of downstream product requirements, masterbatch will develop towards functional integration, that is, integrating multiple functions (such as coloring, usporivač plamena, antistatik, antibacterial, UV-resistant) into one masterbatch, which can reduce the addition amount of masterbatch, simplify the processing process, and reduce production costs. Na primjer, new energy vehicle masterbatch will integrate high temperature resistance, usporivač plamena, antistatic and other functions; medical masterbatch will integrate non-toxic, antibacterial, high transparency and other functions. Osim toga, high-performance masterbatch (such as high-concentration, high-dispersibility, high-temperature resistant, corrosion-resistant masterbatch) will be more widely used in high-end fields such as aerospace, precision electronics and new energy.

7.1.3 Customization and Personalization.

With the upgrading of downstream market demand, the customization and personalization of masterbatch will become more and more prominent. Different downstream manufacturers have different requirements on masterbatch (kao što je boja, concentration, funkcija, carrier type), and masterbatch manufacturers need to provide personalized customization solutions according to the specific needs of customers. Na primjer, according to the color sample provided by the customer, customize the masterbatch with matching color; according to the special use environment of the product, customize the masterbatch with targeted functions. This requires masterbatch manufacturers to have strong R&D capabilities and flexible production capacity.

7.2 Development Trend of Twin-Screw Extrusion Technology

7.2.1 Intelligence and Automation Upgrading.

The future twin-screw extruders will develop towards higher intelligence and automation. The intelligent control system will integrate AI, big data, Internet of Things and other technologies, which can realize real-time monitoring, automatic parameter adjustment, fault early warning, predictive maintenance and production data analysis of the extrusion process. Na primjer, the AI system can automatically adjust the screw speed, extrusion temperature and feeding speed according to the raw material performance and processing effect, ensuring the stability of product quality; the Internet of Things technology can realize the interconnection of multiple extruders, realizing centralized management and intelligent scheduling of the production line; the big data system can analyze the production data, optimize the processing parameters and formula, and improve production efficiency and product quality.

7.2.2 Visoka efikasnost, Ušteda energije i zaštita životne sredine.

High efficiency, energy saving and environmental protection will continue to be the key development direction of twin-screw extrusion technology. The future extruders will adopt more advanced screw structures, high-efficiency energy-saving motors and heating/cooling systems, which can further reduce energy consumption and improve production efficiency. Na primjer, the optimized screw structure can reduce the shear loss and improve the conveying efficiency; the high-efficiency energy-saving motor can reduce the energy consumption by 25%以上 compared with the traditional motor; the closed structure and waste gas treatment system can reduce the emission of dust and volatile substances, meeting the higher environmental protection requirements.

7.2.3 High Performance and Wear Resistance.

With the development of high-concentration, high-hardness masterbatch (such as filler masterbatch, engineering plastic masterbatch), the requirements for the performance and wear resistance of twin-screw extruders will be higher. The future extruders will adopt more high-performance wear-resistant materials (such as new alloy steel, ceramic materials) and advanced manufacturing technologies (such as laser cladding, bimetallic composite), which can greatly improve the wear resistance and corrosion resistance of the screw and barrel, extend the service life of the equipment. U isto vreme, the extruders will be equipped with higher torque gearboxes and more advanced mixing elements, which can provide stronger shear force and kneading force, meeting the processing needs of high-performance masterbatch.

7.2.4 Modularization and Flexibility.

Modularization and flexibility will become an important development trend of twin-screw extruders. The future extruders will adopt a more perfect modular design, and the screw, bure, die head and other components can be freely combined and replaced according to the type of masterbatch and processing requirements, which can improve the adaptability of the equipment and reduce the investment cost of the customer. Na primjer, when producing different types of masterbatch, only the corresponding screw elements and die head need to be replaced, without replacing the entire extruder. Osim toga, the small and medium-sized modular extruders will be more popular, which can meet the small-batch and multi-variety production needs of small and medium-sized manufacturers.

7.3 Zhuoyue’s Layout in the Future Development Trend

Facing the future development trend of the masterbatch industry and twin-screw extrusion technology, Zhuoyue will focus on technological innovation and product upgrading, and make layout in the following aspects: prvo, strengthen the R&D of intelligent extrusion technology, integrate AI, big data and Internet of Things technologies into the extruder design, launch more intelligent and automatic extruders, and help customers realize intelligent production; drugo, increase the R&D investment in high-performance wear-resistant materials and energy-saving technologies, develop more efficient, energy-saving and wear-resistant extruders, reduce the production cost and environmental impact of customers; treće, strengthen the R&D of customized solutions, according to the personalized needs of different customers, provide targeted extruder configuration and processing solutions, and improve customer satisfaction; četvrto, expand the R&D of environmental protection masterbatch processing technology, launch extruders suitable for water-based masterbatch, bio-based masterbatch and recyclable masterbatch processing, and help the masterbatch industry achieve green development.

8. Zaključak

Masterbatch, as the core material of plastic coloring and functional modification, plays an indispensable role in the global plastics industry. Twin-screw extrusion technology, as the key processing technology of masterbatch, directly determines the quality, production efficiency and market competitiveness of masterbatch products. With the continuous development of the masterbatch industry towards environmental protection, funkcionalizacija, high concentration and intelligence, the requirements for twin-screw extruders are becoming higher and higher.

Zhuoyue, as a professional manufacturer of twin-screw extruders, has launched a full series of extruders (HTS BASIC/PLUS/SUPER, ZTE, HTE) specially designed for masterbatch processing, each series has its own unique performance characteristics and targeted adaptation scenarios, which can provide personalized and efficient processing solutions for masterbatch manufacturers of different scales and fields. These extruders have the advantages of excellent mixing and dispersing effect, precizna kontrola temperature, high wear resistance, high production efficiency, energy saving and environmental protection, intelligent control and wide application range, which have been fully verified in many practical application cases.

This article comprehensively elaborates on the core knowledge of masterbatch, the principle and process of twin-screw extrusion technology, the performance advantages of Zhuoyue’s full series of extruders, the application fields of masterbatch, common problems and solutions in processing, practical application cases, and the future development trend. It is hoped that this article can provide comprehensive and professional reference for masterbatch manufacturers, processing technicians, industry practitioners and relevant researchers.

In the future, Zhuoyue will continue to adhere to the concept of technological innovation and customer-oriented, keep up with the development trend of the industry, continuously upgrade products and technologies, provide more advanced, efficient and environmentally friendly twin-screw extrusion solutions, and work together with masterbatch manufacturers around the world to promote the high-quality development of the masterbatch industry.