Iarrtasan Teicneòlas Eas-tharraing Twin-Screw Adhartach Masterbatch agus fuasglaidhean giullachd coileanta

1. Sealladh farsaing air Gnìomhachas Masterbatch agus Prìomh Eòlas

1.1 Suidheachadh làithreach agus Claonadh Leasachaidh Gnìomhachas Masterbatch

Masterbatch, ris an canar cuideachd masterbatch dath no dùmhlachd dath, na sheòrsa ùr de stuth dathte plastaig le dùmhlachd àrd, àrd dispersibility agus goireasach cleachdadh. Tha e air a dhèanamh le bhith a’ sgapadh pigmentan no dathan gu co-ionnan, luchd-giùlan agus stuthan cur-ris ann an cuibhreann sònraichte tro mheasgachadh proifeasanta agus teicneòlas granulation eas-tharraing. An coimeas ris an dòigh dathte dìreach traidiseanta (cuir pigmentan gu dìreach ri stuthan amh plastaig), Tha buannachdan aig masterbatch airson cleachdadh goireasach, dath èideadh, coileanadh seasmhach, dìon na h-àrainneachd agus sàbhaladh lùtha, a tha air a dhol an àite an dòigh dathaidh traidiseanta mean air mhean agus a thàinig gu bhith na phrìomh fhuasgladh dathaidh ann an gnìomhachas plastaig.

Anns na bliadhnachan mu dheireadh, air a stiùireadh le leasachadh luath de ghnìomhachasan sìos an abhainn leithid pacadh, càraichean, aodaich, eileagtronaigeach, innealan togail agus dachaigh, tha margaidh masterbatch na cruinne air gluasad seasmhach agus luath a nochdadh. A rèir dàta gnìomhachais buntainneach, tha meud margaidh masterbatch na cruinne air a dhol thairis air 30 billean dolar na SA, agus thathar an dùil ìre fàis bliadhnail iom-fhillte de 6%-8% anns na còig bliadhna ri teachd. Nam measg, Is e Asia-Pacific am margaidh cinneasachaidh is caitheamh masterbatch as motha san t-saoghal, cunntas a thoirt air barrachd na 60% de roinn margaidh na cruinne, sa mhòr-chuid air sgàth leasachadh luath ann an gnìomhachas plastaig ann an Sìona, Na h-Innseachan agus dùthchannan eile, leasachadh leantainneach air comas taic gnìomhachais, agus iarrtas a tha a’ sìor fhàs airson càileachd àrd, toraidhean masterbatch gnìomh agus càirdeil don àrainneachd.

Sìona, mar an riochdaire agus neach-cleachdaidh masterbatch as motha san t-saoghal, tha iarrtas mòr sa mhargaidh agus sèine gnìomhachais iomlan. Tha toradh bliadhnail agus caitheamh masterbatch a’ fàs aig ìre dà-fhigearach, gu sònraichte ann an raointean carbadan lùtha ùra, pacadh glas, aodach àrd-deireadh agus innealan meidigeach, iarrtas airson masterbatch àrd-choileanadh (leithid masterbatch àrd-teòthachd, masterbatch lasair-retardant, Masterbatch dìon na h-àrainneachd) a’ nochdadh gluasad fàis spreadhaidh. Le leasachadh leantainneach air poileasaidhean dìon àrainneachd na cruinne (leithid casg air pigmentan puinnseanta agus cronail) agus àrdachadh iarrtas luchd-cleachdaidh airson stuthan plastaig àrd-inbhe, tha gnìomhachas masterbatch a’ leasachadh mean air mhean a dh’ ionnsaigh dùmhlachd àrd, sgaoileadh àrd, comas-gnìomh, dìon na h-àrainneachd agus fiosrachadh.

Tha na prìomh ghluasadan leasachaidh ann an gnìomhachas masterbatch air an nochdadh ann an ceithir taobhan: a’ chiad, dìon na h-àrainneachd agus ìosal toxicity. Le neartachadh mothachadh dìon na h-àrainneachd agus teann poileasaidhean dìon na h-àrainneachd, neo-phuinnseanta, gun chron, Bidh masterbatch dìon àrainneachd ìosal luaineach agus truaillidh gu bhith na phrìomh shruth den mhargaidh, agus pigmentan puinnseanta agus cronail (leithid pigmentan meatailt trom) thèid a chuir air falbh mean air mhean; an dàrna, comas-gnìomh. A bharrachd air dathadh, Tha masterbatch cuideachd a’ leasachadh a dh’ ionnsaigh amalachadh gnìomh, leithid masterbatch lasair-retardant, masterbatch antistatic, masterbatch antibacterial, Masterbatch a tha an aghaidh UV, a choinnicheas ri riatanasan cleachdadh sònraichte de thoraidhean sìos an abhainn; an treas, dùmhlachd àrd agus dispersibility àrd. Faodaidh masterbatch dùmhlachd àrd an ìre a bharrachd a lughdachadh, cosgaisean toraidh a lùghdachadh, agus faodaidh àrd-sgaoilidh dèanamh cinnteach à dath èideadh de thoraidhean plastaig, seachain spotan dath agus eadar-dhealachadh dath, a tha na phrìomh dhòigh air càileachd toraidh a leasachadh; an ceathramh, fiosrachadh agus fèin-ghluasad giollachd. Feumaidh giollachd masterbatch smachd teann air èideadh measgachadh, teòthachd agus crìochan eile. Inntinneach, bidh loidhnichean toraidh fèin-ghluasadach dà-sgriubha gu bhith mar phrìomh shruth, a’ coileanadh sgrùdadh fìor-ùine, atharrachadh paramadair fèin-ghluasadach agus mòr-chinneasachadh, ag adhartachadh èifeachdas toraidh agus cunbhalachd toraidh.

Mar phrìomh uidheamachd giollachd masterbatch, Tha àite deatamach aig extruders dà-sgriubha ann an leasachadh gnìomhachas masterbatch. Tha riatanasan teann aig measgachadh Masterbatch a thaobh buaidh measgachadh is sgapadh, smachd teothachd agus èifeachdas cinneasachaidh extruders. Sreath slàn de extruders Zhuoyue (HTS BASIC / PLUS / SUPER, ZTE, HTE) air an dealbhadh gu sònraichte airson giollachd masterbatch, le buannachdan coileanaidh cuimsichte, as urrainn coinneachadh gu h-èifeachdach ri feumalachdan giollachd diofar sheòrsaichean masterbatch agus luchd-saothrachaidh a chuideachadh gus càileachd toraidh agus èifeachdas toraidh adhartachadh.

1.2 Bun-sgrìobhadh agus Prionnsapal Obrach Masterbatch

Tha Masterbatch air a dhèanamh suas de thrì eileamaidean bunaiteach: pigmentan no dathan, luchd-giùlain agus stuthan cur-ris. Bidh co-roinn agus coileanadh gach eileamaid gu dìreach a’ dearbhadh càileachd agus buaidh cleachdaidh masterbatch. Tha a bhith a’ tuigsinn prìomh cho-dhèanamh agus prionnsapal obrach masterbatch na bhunait airson a bhith a’ maighstireachd an teicneòlas giullachd agus a’ taghadh uidheamachd eas-tharraing iomchaidh.

1.2.1 Dathan no dathan: Am prìomh phàirt dathte

Is e pigmentan no dathan na prìomh phàirtean a bheir coileanadh dathadh masterbatch, cunntasachd airson 10%-80% den sgrìobhadh masterbatch (tha an tomhas sònraichte an urra ris an t-seòrsa pigment, riatanasan dathaidh agus dùmhlachd masterbatch). Tha pigmentan air an roinn ann am pigmentan organach agus pigmentan neo-organach: tha dathan soilleir aig pigmentan organach, neart clò-bhualaidh àrd, follaiseachd math, ach droch sheasamh teas agus strì an aghaidh na h-aimsire, air a chleachdadh sa mhòr-chuid ann am plastaic giollachd aig teòthachd ìosal (leithid PE, PP) agus toraidhean le riatanasan dath àrd (leithid aodach, filmichean pacaidh); tha deagh sheasamh teas aig pigmentan neo-organach, strì an aghaidh sìde agus seasmhachd ceimigeach, ach neart clò ìosal agus droch fhollaiseachd, sa mhòr-chuid air a chleachdadh ann an àrd-teòthachd giollachd plastaic (leithid plastaig innleadaireachd) agus bathar a-muigh (leithid stuthan togail, pàirtean taobh a-muigh chàraichean).

Tha dathan eadar-dhealaichte bho pigmentan. Tha fuasgladh math aig dathan ann an stuthan amh plastaig, dathan soilleir agus follaiseachd àrd, ach tha droch sheasamh teas agus solas an aghaidh, air a chleachdadh sa mhòr-chuid ann am bathar plastaig follaiseach (leithid botail PET, Duilleagan PC). Bu chòir an taghadh de dhath no dathan a bhith stèidhichte air an t-seòrsa de stuthan amh plastaig (teòthachd giollachd), àrainneachd cleachdadh toraidh (a-staigh/a-muigh), riatanasan dathte (soilleireachd dath, follaiseachd) agus riatanasan dìon na h-àrainneachd, gus dèanamh cinnteach gu bheil coileanadh dathaidh seasmhach aig a’ masterbatch agus a’ coinneachadh ri riatanasan cleachdaidh thoraidhean sìos an abhainn.

1.2.2 Luchd-giùlain: An Co-phàirt Sgaoileadh agus Adhesion

Is e luchd-giùlan am matrix de masterbatch, cunntasachd airson 10%-80% den sgrìobhadh masterbatch, sa mhòr-chuid a’ cluich pàirt a bhith a’ sgapadh pigmentan/dathan agus a’ cumail ri stuthan amh plastaig. Feumaidh co-chòrdalachd math a bhith aig an neach-giùlan leis an dà chuid pigmentan / dathan agus na stuthan amh plastaig targaid (na stuthan amh plastaig a bhith air an dath), air neo bheir e buaidh air sgapadh pigmentan agus buaidh dathaidh thoraidhean. Am measg stuthan giùlain cumanta tha polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyamide (PA), terephthalate polyethylene (Peata), etc., a tha air an taghadh a rèir an t-seòrsa de stuthan amh plastaig targaid: Mar eisimpleir, Tha giùlan PE air a chleachdadh airson dathadh plastaig PE, Tha giùlan PP air a chleachdadh airson dathadh plastaig PP, agus tha giùlan PA air a chleachdadh airson dathadh PA plastaig innleadaireachd.

Bu chòir gum biodh fileantachd giullachd math aig an neach-giùlain cuideachd, a tha cuideachail airson sgaoileadh èideadh de pigmentan aig àm giollachd eas-tharraing agus measgachadh masterbatch le stuthan amh plastaig targaid. A bharrachd air, bu chòir puing leaghaidh agus teòthachd giollachd an neach-giùlain a bhith co-chòrdail ri no beagan nas ìsle na an stuth amh plastaig targaid, gus lobhadh an neach-giùlain no am plastag targaid a sheachnadh rè giollachd.

1.2.3 Cur-ris: An Co-phàirt Gnìomhach Cuideachail

Tha cur-ris nam pàirtean taice air an cur ris gus coileanadh giollachd a leasachadh, dispersibility agus cleachdadh coileanadh masterbatch, cunntasachd airson 1%-10% den sgrìobhadh masterbatch. Tha an seòrsa agus an dòs de chur-ris air a dhearbhadh a rèir an seòrsa masterbatch agus riatanasan giullachd. Tha cur-ris cumanta a’ toirt a-steach:

• Luchd-sgaoilidh: An rud as cudromaiche ann an masterbatch, a dh’ fhaodadh teannachadh uachdar pigmentan a lughdachadh, casg a chur air cruinneachadh pigment, agus dèan pigmentan air an sgapadh gu cothromach anns a’ ghiùlan. Am measg an luchd-sgaoilidh cumanta tha cèir polyethylene, cèir polypropylene, searbhag stearic, stearate calcium, etc. Faodaidh cur-ris luchd-sgaoilidh leasachadh mòr a thoirt air sgapadh masterbatch, dèanamh cinnteach à dath èideadh de thoraidhean, agus lughdaich caitheamh uidheamachd eas-tharraing.
• Co-fhreagarrachd: Air a chleachdadh gus an co-chòrdalachd eadar pigmentan agus luchd-giùlan a leasachadh, agus eadar masterbatch agus targaid stuthan amh plastaig. Mar eisimpleir, nuair a tha droch cho-chòrdalachd aig an neach-giùlain agus am plastaig targaid (leithid giùlan PE agus plastaig PA), luchd-coimhid (leithid polyethylene grafted anhydride maleic) faodar a chur ris gus neart ceangail a neartachadh eatorra, seachain sgaradh masterbatch agus targaid plastaig rè giollachd, agus a’ leasachadh feartan meacanaigeach thoraidhean.
• Stabilizers teas: Air a chleachdadh gus casg a chuir air lobhadh pigmentan, luchd-giùlan agus plastaic targaid aig àm giollachd eas-tharraing àrd-teòthachd. Tha stabilizers teas cumanta a’ toirt a-steach salainn luaidhe, stabilizers calcium-sinc, stabilizers staoin organach, etc., a tha air an taghadh a rèir teòthachd giollachd agus riatanasan dìon na h-àrainneachd.
• Stabilizers aotrom agus antioxidants: Air a chleachdadh gus strì an aghaidh na h-aimsire agus an aghaidh a bhith a’ fàs nas sine ann am prìomh bhaidse agus toraidhean plastaig dathte, cuir casg air crìonadh dath agus truailleadh dèanadais de thoraidhean fo sholas na grèine agus ocsaidean, agus a 'leudachadh beatha seirbheis nan stuthan.
• Bealaidh: Air a chleachdadh gus an suathadh eadar stuthan agus uidheamachd eas-tharraing a lughdachadh (sgread, baraille, ceann bàs), leasachadh fluidity giollachd, lùghdachadh caitheamh lùtha, agus seachain stuth a’ cumail ri uidheamachd, a tha cuideachail airson adhartas rèidh ann an giullachd eas-tharraing.

1.2.4 Prionnsabal obrach masterbatch

Tha prionnsapal obrach masterbatch stèidhichte air an sgaoileadh èideadh de pigmentan dùmhlachd àrd anns a’ ghiùlan. Aig àm giollachd stuthan plastaig, àireamh bheag de masterbatch (mar as trice 1%-5%) air a mheasgachadh le stuthan amh plastaig gun dath. Fo ghnìomhachd teòthachd àrd agus feachd rùsgaidh aig àm eas-tharraing no cumadh stealladh, bidh giùlan an masterbatch a 'leaghadh agus a' measgachadh leis na stuthan amh plastaig targaid, agus tha na pigmentan a tha sgapte gu cothromach air an leigeil ma sgaoil agus air an sgaoileadh gu co-ionnan anns a’ mhaitrix plastaig targaid, mar sin a’ coileanadh adhbhar dathadh stuthan plastaig. Is e prìomh adhbhar a’ phròiseis seo gum feum na pigmentan anns an masterbatch a bhith air an sgapadh gu co-ionnan gun a bhith a’ cruinneachadh, air neo bidh e ag adhbhrachadh spotan dath, eadar-dhealachadh dath agus uireasbhaidhean eile anns na toraidhean dathte.

1.3 Seòrsachadh cumanta de Masterbatch

Faodar Masterbatch a roinn ann an diofar sheòrsaichean a rèir diofar inbhean seòrsachaidh, leithid seòrsa dath, seòrsa neach-giùlain, raon tagraidh, seòrsa gnìomh, etc. Tha an seòrsachadh ceart a’ cuideachadh le tuigse nas fheàrr fhaighinn air feartan coileanaidh agus riatanasan giullachd masterbatch, agus tagh uidheamachd eas-tharraing iomchaidh agus dòighean giullachd.

1.3.1 Seòrsachadh a rèir seòrsa dath

A rèir an t-seòrsa de cho-phàirt dathte, faodar masterbatch a roinn ann an dath masterbatch, masterbatch geal agus masterbatch dubh.

• Masterbatch dath: An seòrsa masterbatch as cumanta, a bhios a’ cleachdadh pigmentan organach no neo-organach de dhiofar dhathan (leithid dearg, buidhe, gorm, uaine, orains) mar phàirtean dathte, agus tha e air a chleachdadh airson dathadh stuthan plastaig de dhiofar dhathan. An neart clò-bhualaidh, Is e soilleireachd dath agus dispersibility dath masterbatch na prìomh chomharran airson a chàileachd a thomhas.
• Masterbatch geal: A 'cleachdadh titanium dà-ogsaid (TiO2) mar am prìomh phàirt dathte, 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, etc.

• PE Masterbatch: Using PE as the carrier, it is suitable for coloring PE plastic products (such as PE films, PE pipes, 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, Duilleagan PP). 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 (leithid pìoban PVC, Pròifilean PVC, PVC films). It needs to be matched with PVC heat stabilizers to avoid PVC decomposition during processing.
• Engineering Plastic Masterbatch: Using engineering plastics (PA, PC, PBT, etc.) as carriers, tha e freagarrach airson dathadh bathar plastaig innleadaireachd (leithid pàirtean càr, co-phàirtean dealain). Tha deagh sheasamh teas aige agus co-chòrdalachd le plastaic innleadaireachd, agus tha riatanasan àrd aige air uidheamachd giollachd eas-tharraing.

1.3.3 Seòrsachadh a rèir raon tagraidh

A rèir raon tagraidh masterbatch, faodar a roinn ann an fiber masterbatch, masterbatch film, masterbatch cumadh buille, masterbatch eas-tharraing, masterbatch cumadh stealladh, etc., a tha a rèir nan còig prìomh raointean tagraidh de masterbatch.

• Fiber Masterbatch: Air a chleachdadh airson dathadh snàithleach ceimigeach (leithid snàithleach polyester, freumhag nylon), a tha air a chleachdadh ann am bratan-ùrlair, aodaich, cuiseanan agus bathar eile. Feumaidh e dispersibility àrd agus luaths dath, agus chan eil dath sam bith a’ seargadh aig àm snìomh agus fighe.
• Film masterbatch: Air a chleachdadh airson dathadh filmichean plastaig (leithid pocannan ceannach, filmichean tilgeadh, filmichean ioma-fhillte), a dh’ fheumas soilleireachd àrd agus dath èideadh, agus gun spotan dath no sreathan air uachdar an fhilm.
• Masterbatch Moulding Sèididh: Air a chleachdadh airson dath a dhèanamh air toraidhean cumadh buille (leithid soithichean meidigeach agus cosmaigeach, soithichean ola lubaidh agus peant), a dh’ fheumas fileantachd giollachd math agus dathadh èideadh, agus gun deformachadh no eadar-dhealachadh dath air a’ ghobhar.
• Masterbatch eas-tharraing: Air a chleachdadh airson dath a dhèanamh air toraidhean eas-tharraing (leithid duilleagan, pìoban, uèirichean agus càbaill), a dh ’fheumas seasmhachd meud math agus dath èideadh, agus gun eadar-dhealachadh dath air uachdar an toraidh.
• Masterbatch molltair stealladh: Air a chleachdadh airson dath a dhèanamh air toraidhean cumadh stealladh (leithid pàirtean càr, bathar eileagtronaigeach, stuthan togail, innealan taighe, àirneis, dèideagan), a dh’ fheumas dispersibility àrd agus coileanadh seasmhach, agus chan eil eadar-dhealachadh dath ann eadar batches de thoraidhean.

1.3.4 Seòrsachadh a rèir seòrsa gnìomh

A rèir gnìomhan a bharrachd masterbatch, it can be divided into ordinary masterbatch (only coloring function) agus masterbatch gnìomh (dathadh + gnìomhan a bharrachd). Is e masterbatch gnìomh an gluasad leasachaidh sa ghnìomhachas, agus tha seòrsachan cumanta a’ toirt a-steach masterbatch lasair-retardant, masterbatch antistatic, masterbatch antibacterial, Masterbatch a tha an aghaidh UV, masterbatch cruaidh, etc. Feumaidh masterbatch gnìomh cuir-ris gnìomh co-fhreagarrach a bharrachd air bunait masterbatch àbhaisteach, aig a bheil riatanasan nas àirde a thaobh buaidh measgachadh agus sgapadh uidheamachd eas-tharraing.

2. Teicneòlas giollachd bunaiteach de Masterbatch: Teicneòlas eas-tharraing Twin-Screw

Tha giollachd Masterbatch sa mhòr-chuid a’ toirt a-steach measgachadh, eas-tharraing, fuarachadh, granulation agus pròiseasan eile, am measg sin tha teicneòlas eas-tharraing dà-sgriubha mar phrìomh theicneòlas measgachadh masterbatch agus granulation. An coimeas ri teicneòlas eas-tharraing aon-sgriubha, Tha buannachdan aig teicneòlas eas-tharraing dà-sgriubha airson comas measgachadh làidir agus sgaoilidh, smachd teòthachd mionaideach, ùine còmhnaidh goirid, èifeachdas toraidh àrd agus sùbailteachd làidir gu stuthan amh, a dh'fhaodas fuasgladh èifeachdach a dhèanamh air na prìomh dhuilgheadasan a thaobh giollachd masterbatch (leithid cruinneachadh pigment, measgachadh neo-chothromach, èifeachdas toraidh ìosal) agus dèanamh cinnteach à càileachd bathar masterbatch.

Is e measgachadh masterbatch aon de na prìomh thagraidhean aig extruders dà-sgriubha. Tha càileachd masterbatch air a dhearbhadh gu dìreach le coileanadh an extruder dà-sgriubha agus reusantachd a ’phròiseas giullachd. Is e na prìomh riatanasan airson giollachd masterbatch airson extruders dà-sgriubha: measgachadh làidir agus buaidh sgaoilidh (gus dèanamh cinnteach à sgapadh aon-dath de pigmentan), smachd teòthachd mionaideach (gus lobhadh pigment agus truailleadh luchd-giùlain a sheachnadh), feachd gearraidh iomchaidh (gus cruinneachaidhean pigment a bhriseadh gun a bhith a’ dèanamh cron air mìrean pigment), èifeachdas toraidh àrd (gus coinneachadh ri feumalachdan cinneasachaidh mòr) agus deagh sheasamh an aghaidh caitheamh (gus gabhail ri caitheamh pigmentan àrd-chruaidh leithid titanium dioxide agus carbon dubh).

2.1 Duilgheadasan giullachd Masterbatch agus riatanasan airson uidheamachd eas-tharraing

Ged a tha teicneòlas eas-tharraing dà-sgriubha freagarrach airson giollachd masterbatch, air sgàth cho sònraichte ‘s a tha sgrìobhadh masterbatch (susbaint àrd pigment, cruinneachadh furasta de pigmentan) agus riatanasan giullachd (sgaoileadh èideadh, coileanadh seasmhach), tha mòran dhuilgheadasan ann fhathast ann an giullachd fìor. Tha na prìomh dhuilgheadasan giullachd agus riatanasan co-fhreagarrach airson uidheamachd eas-tharraing mar a leanas:

2.1.1 Agglomeration Pigment agus Droch Sgapadh

Dathan (gu sònraichte pigmentan neo-organach leithid titanium dioxide agus carbon dubh) tha polarity làidir agus farsaingeachd uachdar sònraichte mòr aca, a tha furasta an cruinneachadh ann am mìrean mòra rè stòradh agus measgachadh. Mura h-urrainnear na agglomerates a bhriseadh gu h-iomlan agus an sgapadh rè giollachd eas-tharraing, bidh droch sgapadh aig a’ masterbatch, agus bidh spotan dath air na toraidhean plastaig dathte, sreathan dath agus dath neo-chothromach, a bheir buaidh mhòr air càileachd toraidh. Is e seo an duilgheadas as cumanta agus as cudromaiche ann an giullachd masterbatch.

Feumaidh seo gum bi comas làidir measgachadh is sgaoilidh aig an uidheamachd eas-tharraing agus feachd rùsgaidh iomchaidh. Bu chòir don extruder dà-sgriubha gabhail ri structar co-chuairteachaidh eadar-mheadhanach, agus bu chòir gum biodh an sgriubha air a uidheamachadh le eileamaidean measgachadh gu leòr agus eileamaidean rùsgaidh gus feachd rùsgaidh làidir agus feachd glùineachaidh a ghineadh rè cuairteachadh, a dh’ fhaodas na cruinneachaidhean pigment a bhriseadh gu tur agus na pigmentan a sgaoileadh gu cothromach anns a’ ghiùlan. A bharrachd air, the screw speed and extrusion pressure should be adjustable to adapt to different types of pigments and masterbatch concentrations.

2.1.2 Pigment Decomposition and Carrier Degradation Caused by Overheating

Most pigments (especially organic pigments) have poor heat resistance, and the carrier (leithid PE, PP) also has a certain temperature resistance limit. If the extrusion temperature is too high or the residence time of the material in the extruder is too long, the pigment will decompose (resulting in color fading, discoloration), and the carrier will degrade (resulting in reduced mechanical properties of the masterbatch). This is another key difficulty in masterbatch processing.

This requires the extrusion equipment to have precise temperature control capacity and short residence time. The barrel of the extruder should be divided into multiple temperature control sections, and the temperature of each section should be precisely controlled within the optimal range (usually 150-220℃ for ordinary masterbatch, 200-280℃ for engineering plastic masterbatch), with a temperature control precision of ±1℃. The screw structure should be optimized to shorten the residence time of the material in the extruder (mar as trice 1-3 mionaidean), avoiding long-term contact between the material and high temperature.

2.1.3 Wear of Screw and Barrel Caused by High-Hardness Pigments

Inorganic pigments such as titanium dioxide and carbon black have high hardness (Mohs hardness 5-7), which will cause serious wear to the screw and barrel of the extruder during extrusion processing. Ma tha droch sheasamh aig an sgriubha agus am baraille, bidh iad air an caitheamh gu sgiobalta, resulting in reduced shear force and mixing capacity of the extruder, affecting the dispersibility of the masterbatch and reducing the service life of the equipment.

This requires the screw and barrel of the extruder to be made of high-quality wear-resistant materials and processed by advanced manufacturing technology. Mar eisimpleir, the screw and barrel can be made of imported wear-resistant alloy steel, and undergo bimetallic composite treatment or laser cladding treatment, 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, measgachadh ùine, extrusion temperature, astar sgriubha, astar beathachaidh). If the parameters fluctuate, the quality of the masterbatch (such as concentration, sgapadh, 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, astar sgriubha, extrusion temperature and other parameters, and store multiple sets of formula parameters. When producing different batches of masterbatch, chan fheumar ach na paramadairean co-fhreagarrach a ghairm, a’ seachnadh ath-dhebugging, ensuring the stability of product quality between batches.

2.1.5 High Requirements on Processing Fluidity

Masterbatch has high pigment content, which will reduce the processing fluidity of the material. If the processing fluidity is too poor, bidh an stuth duilich a ghiùlan agus a thoirt a-mach, mar thoradh air èifeachdas toraidh ìosal, cuideam eas-tharraing neo-sheasmhach agus eadhon bacadh uidheamachd.

Feumaidh seo gum bi comas giùlain làidir agus feachd rùsgaidh a ghabhas atharrachadh aig an uidheamachd eas-tharraing. Bu chòir don extruder dà-sgriubha gabhail ri raon sgriubha reusanta, dealbhadh co-mheas luaidhe agus teannachaidh, agus bu chòir an sgriubha a bhith uidheamaichte le eileamaidean giùlain gu leòr gus dèanamh cinnteach gun tèid stuthan a ghiùlan gu rèidh. A bharrachd air, faodar an teòthachd eas-tharraing atharrachadh gu h-iomchaidh gus fluidity giollachd an stuth a leasachadh, agus faodar bealaidh a chuir ris gus an suathadh eadar stuthan a lughdachadh.

2.2 Prionnsabal Obrach agus Sruth Pròiseas de Extrusion Twin-Screw Masterbatch

Tha am pròiseas eas-tharraing dà-sgriubha de masterbatch na phròiseas measgachadh corporra iom-fhillte, a tha sa mhòr-chuid a’ toirt a-steach pretreatment stuthan amh, premixing, a 'biathadh, leaghadh, measgachadh agus rùsgadh, eas-tharraing, fuarachadh, gràinealachd, sgrìonadh agus pacadh. Is e am prìomh adhbhar pigmentan a sgaoileadh gu cothromach, luchd-giùlan agus stuthan cur-ris gus gràinneagan masterbatch àrd-inbhe a chruthachadh. Tha am prionnsapal obrach sònraichte agus sruth pròiseas mar a leanas:

2.2.1 Pretreatment Stuth Raw

Is e pretreatment stuthan amh bunait giollachd eas-tharraing masterbatch, a bheir buaidh dhìreach air buaidh measgachadh agus càileachd toraidh. Tha stuthan amh masterbatch sa mhòr-chuid a’ toirt a-steach pigmentan / dathan, luchd-giùlain, stuthan cur-ris (luchd-sgaoilidh, luchd-coimhid, stabilizers teas, etc.). Tha na ceumannan pretreatment mar a leanas:

• Làimhseachadh a 'tiormachadh: Cuid de pigmentan (leithid pigmentan organach) agus luchd-siubhail (leithid PA, Peata) tha sùghadh uisge àrd aca. Ma tha an taiseachd ro àrd, bheir e builgeanan, cruinneachadh agus uireasbhaidhean eile anns an masterbatch aig àm giollachd eas-tharraing, agus eadhon ag adhbhrachadh truailleadh hydrolytic den neach-giùlain. Uime sin, feumaidh na stuthan amh a bhith air an tiormachadh mus tèid an giullachd. Tha an teòthachd agus an ùine tiormachaidh air an co-dhùnadh a rèir an seòrsa stuth amh: Mar eisimpleir, tha pigmentan organach air an tiormachadh aig 60-80 ℃ airson 2-4 uairean, Tha luchd-giùlan PE / PP air an tiormachadh aig 80-100 ℃ airson 3-5 uairean, agus PA luchd-còmhdhail air an tiormachadh aig 100-120 ℃ airson 6-8 uairean. Bu chòir smachd a chumail air susbaint taiseachd nan stuthan amh tiormaichte gu h-ìosal 0.1%.
• A 'bruthadh agus a' sgoltadh: For pigments with large particle size (such as titanium dioxide agglomerates) and carriers with uneven particle size, crushing and sieving treatment should be carried out to ensure the uniformity of raw materials. Bu chòir smachd a chumail air meud nan stuthan amh a tha air am pronnadh aig 20-40 mogal, which is conducive to the uniform mixing of raw materials and the breaking of pigment agglomerates during extrusion.
• Impurity Removal: The raw materials may contain impurities (such as metal particles, clachan, duslach) during production and transportation. Impurities not only affect the quality of the masterbatch, ach cuideachd caith sgriubha agus baraille an extruder, agus eadhon bacadh uidheamachd adhbhrachadh. Uime sin, the raw materials must be filtered and removed before use, using a filter screen with appropriate mesh size to remove impurities.

2.2.2 Premixing

Premixing is the key step to improve the mixing and dispersing effect of masterbatch. A rèir a 'cho-mheas foirmle, the dried, crushed and impurity-removed pigments, bidh luchd-giùlan agus stuthan cur-ris air an cur ann am measgadair aig astar luath airson premixing. Is e adhbhar premixing toirt air na pigmentan agus na stuthan cur-ris cumail gu co-ionnan ri uachdar nam mìrean giùlain, cruthaich measgachadh tòiseachaidh, agus cuir bunait airson an sgapadh èideadh rè eas-tharraing.

Is e prìomh pharaimearan premixing astar measgachadh, measgachadh ùine agus teòthachd measgachadh. Tha an astar measgachadh san fharsaingeachd 800-1200 rpm, tha an ùine measgachadh 5-10 mionaidean, agus tha an teòthachd measgachadh air a smachdachadh aig 40-60 ℃. Faodaidh an teòthachd measgachadh iomchaidh feabhas a thoirt air gèilleadh cur-ris (leithid luchd-sgaoilidh) don neach-giùlain agus pigmentan, brosnachadh measgachadh èideadh. Airson masterbatch le susbaint àrd de pigment (Leithid 50% gu h-àrd), faodar an ùine premixing a leudachadh gu h-iomchaidh, agus faodar beagan inneal-sgaoilidh a chuir ris an toiseach gus sgapadh pigmentan a leasachadh. An dèidh premixing, bu chòir don mheasgachadh a bhith èideadh ann an dath, às aonais cruinneachaidhean pigment follaiseach agus mìrean cur-ris.

2.2.3 A 'biadhadh agus a' giùlan

The premixed mixture is sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. The feeding device of the extruder is usually equipped with a frequency conversion speed regulation function, which can adjust the feeding speed according to the screw speed and extrusion speed to ensure that the materials enter the extrusion cavity stably and uniformly, avoiding material accumulation or insufficient feeding.

The feeding hopper is also equipped with a drying device (such as an electric heating jacket) to prevent the raw materials from absorbing moisture again during feeding. For masterbatch with high pigment content and poor fluidity, a forced feeding device can be selected to ensure the smooth feeding of materials. A bharrachd air, the feeding port of the extruder should be smooth, without dead corners, to avoid material sticking and accumulation.

2.2.4 A' leaghadh, A 'measgachadh agus a' rùsgadh

Tha na stuthan a tha a’ dol a-steach do chuas eas-tharraing an extruder dà-sgriubha air am putadh air adhart gu leantainneach leis na sgriothan rothlach. Tha an cuas eas-tharraing air a dhèanamh suas de sgriubha agus baraille, agus bidh meud a’ chuas eas-tharraing a ’dol sìos mean air mhean air taobh an axis. Nuair a thionndaidheas na sgriothan, tha na stuthan air an teannachadh mean air mhean fo ghnìomhachd nan sgriothan agus a’ bharaille, agus bidh an cuideam anns a’ chuas eas-tharraing ag àrdachadh mean air mhean (generally 5-12MPa).

Aig an aon àm, tha na stuthan fo smachd feachd rùsgaidh làidir agus feachd brisidh air a chruthachadh leis a’ ghluasad dàimheach eadar na sgriothan agus am baraille, a bharrachd air eadar na tursan-adhair sgriubha. 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. Faodaidh an fheachd brisidh cuideachd beagan teas a ghineadh, a tha air a chur còmhla ri teasachadh taobh a-muigh a 'bharaille (teasachadh dealain no teasachadh smùid) to make the carrier gradually melt and plasticize.

Mar as trice tha baraille an extruder air a roinn ann 4-6 earrannan smachd teothachd (roinn beathachaidh, earrann leaghaidh, earrann measgachadh, roinn homogenizing, roinn ceann bàs), and the temperature of each section is precisely controlled according to the type of masterbatch (seòrsa neach-giùlain, pigment type). Mar eisimpleir, 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℃. Faodaidh an smachd teothachd mionaideach dèanamh cinnteach gu bheil an neach-giùlain air a leaghadh gu tur gun lobhadh teirmeach, agus chan eil na pigmentan air an lobhadh no air an dath.

Bidh sgriubha an extruder dà-sgriubha a’ gabhail ri dealbhadh modular, a dh’ fhaodas diofar eileamaidean sgriubha a chur còmhla gu saor (leithid eileamaidean giùlan, measgachadh eileamaidean, eileamaidean rùsgaidh) a rèir an t-seòrsa masterbatch. Mar eisimpleir, nuair a bhios tu a’ giullachd masterbatch le susbaint àrd de pigment agus cruinneachadh furasta, faodar barrachd eileamaidean measgachaidh agus eileamaidean rùsgaidh a rèiteachadh gus a’ bhuaidh measgachaidh is sgapadh a neartachadh; nuair a bhios tu a’ giullachd masterbatch le deagh fhileantachd, faodar barrachd eileamaidean giùlain a rèiteachadh gus èifeachdas cinneasachaidh a leasachadh.

2.2.5 Extrusion agus cumadh

An làn leaghadh, tha stuth measgaichte agus sgapte air a phutadh gu ceann die an extruder leis na sgriothan. Mar as trice bidh ceann die an extruder masterbatch air a uidheamachadh le grunn thuill bàis cruinn (tha àireamh agus meud nan tuill-bàis air an co-dhùnadh a rèir meud nam pàirtean den masterbatch). 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, a ghabhas atharrachadh a rèir feumalachdan luchd-cleachdaidh).

The temperature of the die head is slightly lower than that of the homogenizing section, 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 Cooling and Solidification

Bithear a’ cur na toraidhean leth-chrìochnaichte cumadh stiallach gu inneal fuarachaidh airson fuarachadh luath agus solidification. Mar as trice is e fuarachadh tanca uisge an dòigh fuarachaidh airson masterbatch, agus tha teòthachd an uisge fuarachaidh air a smachdachadh aig 20-30 ℃. Tha fad an tanca uisge fuarachaidh 3-5 meatairean, agus tha an ùine fuarachaidh 2-4 mionaidean. Faodaidh fuarachadh luath toirt air an stiall daingneachadh gu sgiobalta, cumail suas cumadh agus meud an stiall, agus seachain deformation agus adhesion.

Bu chòir a thoirt fa-near gum bu chòir an astar fuarachaidh a bhith co-ionnan. Ma tha an astar fuarachaidh ro luath, bidh cuideam a-staigh an stiall ro mhòr, agus bidh an stiall brisg agus furasta a bhriseadh aig àm granulation; ma tha an astar fuarachaidh ro shlaodach, bidh an stiall bog agus furasta a chumail, toirt buaidh air buaidh granulation. An dèidh fuarachadh, bu chòir uachdar na stiall a bhith tioram, rèidh agus saor bho builgeanan agus sgàinidhean.

2.2.7 Buain agus Granaidh

An dèidh fuarachadh agus solidification, the strip is sent to a granulator for cutting to form granular masterbatch products. The granulator is equipped with a rotary knife and a fixed knife, and the cutting speed is adjustable (san fharsaingeachd 500-1000 rpm). The particle size of the masterbatch is controlled by adjusting the cutting speed and the speed of the strip conveying. The common particle size of masterbatch is 2-5mm (length and diameter are basically the same), which is convenient for mixing with plastic raw materials during later use.

The granulator should be equipped with a screening device to remove unqualified particles (leithid ro mhòr, too small, agglomerated or broken particles). The qualified particles enter the next process, and the unqualified particles are crushed and recycled (after drying and premixing, they are re-extruded and granulated).

2.2.8 Sgrionadh, Inspection and Packaging

Bithear a’ cur an masterbatch gràinealaichte gu scrion crathaidh airson sgrìonadh gus tuilleadh gràineanan agus neo-chunbhalachd a thoirt air falbh. Tha an scrion crathaidh air a uidheamachadh le scrion ioma-fhilleadh (diofar mheudan mogaill), as urrainn sgrìonadh a-mach mìrean masterbatch de dhiofar shònrachaidhean a rèir feumalachdan teachdaiche.

Às deidh sgrìonadh, feumaidh an masterbatch a dhol tro sgrùdadh càileachd. Tha na nithean sgrùdaidh sa mhòr-chuid a’ toirt a-steach: dath (èideadh, cunbhalachd leis an sampall àbhaisteach), sgapadh (air fhaicinn le miocroscop no dathadh pìos deuchainn), dùmhlachd (deuchainn neart teannachaidh), susbaint taiseachd, cuairteachadh meud gràin, etc. Is e dìreach an masterbatch a choinnicheas ri inbhean càileachd a dh’ fhaodar a phacaigeadh.

Bidh pacadh masterbatch a’ gabhail ri pacadh seulaichte agus dìon-taise (leithid pocannan plastaig fighte le film plastaig a-staigh, pocannan foil aluminium), agus mar as trice tha cuideam pacaidh 25kg/bag no 50kg/bag. The packaging bag is marked with the product name, modail, dath, dùmhlachd, seòrsa neach-giùlain, production date, shelf life, manufacturer and other information. The packaged masterbatch should be stored in a dry, taigh-bathair fionnar is fionnaraichte, a’ seachnadh solas dìreach agus taiseachd, agus tha beatha sgeilp san fharsaingeachd 6-12 mìosan.

2.3 Prìomh fhactaran a bheir buaidh air buaidh eas-tharraing dà-sgriubha Masterbatch

Bidh buaidh eas-tharraing dà-sgriubha a’ toirt buaidh dhìreach air càileachd masterbatch (sgapadh, tinting strength, seasmhachd). Tha grunn nithean ann a tha a’ toirt buaidh air a’ bhuaidh eas-tharraing, sa mhòr-chuid a’ toirt a-steach feartan stuthan amh, co-mheas foirmle, buaidh premixing, crìochan eas-tharraing agus coileanadh uidheamachd. Le bhith a’ maighstireachd nam prìomh nithean sin agus a’ dèanamh atharrachaidhean saidheansail faodaidh sin dèanamh cinnteach à seasmhachd a’ bhuaidh eas-tharraing agus cunbhalachd càileachd toraidh.

2.3.1 Feartan stuthan amh

An seòrsa, meud gràin, tha susbaint taiseachd agus purrachd stuthan amh a’ toirt buaidh mhòr air a ’bhuaidh eas-tharraing. Airson pigmentan, bu chòir meud na gràin a bhith èideadh agus ceart (20-40 mogal), agus bu chòir an ìre cruinneachaidh a bhith ìosal; tha droch sheasamh teas aig pigmentan organach, mar sin bu chòir smachd teann a chumail air an teòthachd eas-tharraing; tha cruas àrd aig pigmentan neo-organach, mar sin bu chòir gum biodh deagh sheasamh caitheamh aig an extruder. Airson luchd-siubhail, bu chòir an ìre leaghaidh agus an teòthachd giollachd a bhith co-chòrdail ris na stuthan amh plastaig targaid, agus bu chòir an co-chòrdalachd le pigmentan a bhith math. Airson stuthan cur-ris, bu chòir an seòrsa agus an dòs a bhith reusanta, and the compatibility with carriers and pigments should be good.

A bharrachd air, the moisture content of raw materials must be strictly controlled below 0.1%; ma tha an taiseachd ro àrd, it will cause bubbles and agglomeration in the masterbatch. Tha purrachd stuthan amh cuideachd glè chudromach; impurities in raw materials will not only affect the product quality, ach cuideachd caith sgriubha agus baraille an extruder.

2.3.2 Co-mheas foirmle

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 (susbaint pigment 50%-80%) can reduce the addition amount and production cost, but requires better dispersibility; low-concentration masterbatch (susbaint pigment 10%-30%) has better dispersibility, ach tha an t-suim a bharrachd mòr agus tha a’ chosgais toraidh àrd.

Tha dosage de dispersants san fharsaingeachd 1%-5% den dosachadh pigment; bidh cus sgaoilidh a’ leantainn gu droch sgapadh pigmentan, agus bheir cus sgaoilidh buaidh air feartan meacanaigeach an masterbatch agus na toraidhean dathte. Dosage de stuthan cur-ris eile (luchd-coimhid, stabilizers teas, bealaidh) tha san fharsaingeachd 0.5%-3%, a bu chòir a bhith air atharrachadh a rèir an t-seòrsa masterbatch agus giollachd riatanasan. Bu chòir smachd teann a chumail air co-mheas na foirmle, agus bu chòir don mhearachd a bhith taobh a-staigh ± 1%, gus dèanamh cinnteach à cunbhalachd càileachd toraidh eadar batches.

2.3.3 Buaidh Premixing

Is e premixing bunait giollachd eas-tharraing. Bidh èideadh premixing a’ toirt buaidh dhìreach air buaidh measgachadh agus sgapadh pigmentan aig àm eas-tharraing. Ma tha an premixing neo-chothromach, chan urrainnear na pigmentan a chumail gu co-ionnan ri uachdar an neach-giùlain, mar thoradh air cruinneachadh ionadail de pigmentan, measgachadh neo-chòmhnard de stuthan rè eas-tharraing, and reduced product dispersibility.

Gus dèanamh cinnteach à buaidh premixing, tha e riatanach smachd a chumail air astar measgachadh (800-1200 rpm), measgachadh ùine (5-10 mionaidean) and mixing temperature (40-60℃). Airson masterbatch le susbaint àrd de pigment, faodar an ùine premixing a leudachadh gu h-iomchaidh, and the dispersant can be added first and mixed with the pigment, then mixed with the carrier and other additives. A bharrachd air, the premixed mixture should be inspected; if there are obvious pigment agglomerates, it should be crushed and remixed.

2.3.4 Paramadairean eas-tharraing

Is e paramadairean eas-tharraing na factaran as cudromaiche a bheir buaidh air a’ bhuaidh eas-tharraing, sa mhòr-chuid a’ toirt a-steach astar sgriubha, teòthachd eas-tharraing agus cuideam eas-tharraing.

• Luas sgriubha: The screw speed of twin-screw extruders for masterbatch processing generally ranges from 200 gu 800 rpm. Mar as àirde an astar sgriubha, mar as motha am feachd rùsgaidh agus an fheachd brisidh a gheibh na stuthan, the better the mixing and dispersing effect of pigments, agus mar as àirde an èifeachdas toraidh. Ge-tà, ma tha astar an sgriubha ro àrd, tha ùine còmhnaidh nan stuthan anns a’ chuas eas-tharraing ro ghoirid, resulting in incomplete melting of the carrier, measgachadh gu leòr de stuthan, and uneven dispersibility; ma tha astar an sgriubha ro ìosal, chan eil an fheachd rùsgaidh agus an fheachd brisidh gu leòr, the pigment agglomerates cannot be fully broken, agus tha an èifeachdas toraidh ìosal.
• 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.
• Teòthachd extrusion: 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 (seòrsa neach-giùlain, pigment type). Tha teòthachd an earrann beathachaidh nas ìsle (beagan nas àirde na an teòthachd tiormachaidh de na stuthan amh), a tha sa mhòr-chuid airson casg a chuir air na stuthan bho bhith a’ còcaireachd agus dèanamh cinnteach à biadhadh rèidh; tha teòthachd na h-earrainn leaghaidh meadhanach, which is mainly to promote the melting and plasticization of the carrier; tha teòthachd na h-earrainn measgachadh nas àirde, a tha sa mhòr-chuid airson a’ bhuaidh rùsgaidh is measgachaidh a neartachadh, and promote the uniform dispersion of pigments; tha teòthachd na h-earrainn homogenizing beagan nas ìsle na an roinn measgachadh, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, which is to ensure the shaping effect of the strip.
• The temperature control precision should reach ±1℃. Mar eisimpleir, nuair a bhios tu a’ làimhseachadh masterbatch PP le pigmentan organach, tha teòthachd gach earrann: earrann beathachaidh 110-130 ℃, earrann leaghadh 170-190 ℃, earrann measgachadh 180-200 ℃, homogenizing earrann 170-190 ℃, roinn ceann bàsachadh 160-180 ℃. Ma tha an teòthachd ro àrd, bidh am pigment a’ lobhadh agus bidh an neach-giùlain a’ dol sìos; ma tha an teòthachd ro ìosal, cha bhith an neach-giùlain air a leaghadh gu tur, agus chan urrainn am pigment a bhith air a sgaoileadh gu co-ionnan.
• Extrusion Brùthadh: Mar as trice tha an cuideam eas-tharraing de eas-tharraing dà-sgriubha masterbatch a’ dol bho 5 gu 12MPa. Tha an cuideam anns a’ chuas eas-tharraing air a dhearbhadh sa mhòr-chuid le co-mheas teannachaidh an sgriubha, meud an toll-bàis agus astar an sgriubha. Mar as àirde an cuideam eas-tharraing, 's ann as fheàrr a bhios buaidh measgachadh agus sgapadh stuthan, agus mar is dùmhail an stiall. Ge-tà, ma tha an cuideam ro àrd, àrdaichidh e caitheamh lùtha agus caitheamh an uidheim, agus eadhon a 'toirt air a' cheann bàs bacadh; ma tha an cuideam ro ìosal, chan urrainn na stuthan a bhith làn dhlùthadh agus measgachadh, tha an stiall sgaoilte, agus tha an sgapadh truagh.
• Bu chòir an cuideam eas-tharraing atharrachadh a rèir an seòrsa masterbatch agus meud ceann die: airson masterbatch le susbaint àrd de pigment agus droch fhileantachd, tha feum air cuideam eas-tharraing nas àirde; airson masterbatch le deagh fluidity, tha cuideam meadhanach eas-tharraing gu leòr. The extrusion pressure should be kept stable, agus bu chòir an atharrachadh a bhith taobh a-staigh ± 0.5MPa, gus dèanamh cinnteach à trast-thomhas èideadh an stiall agus cunbhalachd càileachd masterbatch.

2.3.5 Coileanadh Uidheam

Bidh coileanadh an extruder dà-sgriubha a’ dearbhadh gu dìreach a ’bhuaidh eas-tharraing. Tha prìomh chomharran coileanaidh an extruder gabhail a-steach measgachadh agus sgapadh comas, mionaideachd smachd teothachd, strì an aghaidh caitheamh, comas giùlain agus comas smachd tuigseach. Sreath slàn de extruders Zhuoyue (HTS BASIC / PLUS / SUPER, ZTE, HTE) air an dealbhadh gu sònraichte airson giollachd masterbatch, le coileanadh sàr-mhath anns na taobhan sin, as urrainn coinneachadh gu h-èifeachdach ri feumalachdan giollachd diofar sheòrsaichean masterbatch.

3. Sreath slàn Zhuoyue Extruders: Fuasglaidhean proifeasanta airson pròiseasadh Masterbatch

Tha Zhuoyue air a bhith an sàs anns an rannsachadh o chionn fhada, leasachadh agus cinneasachadh àrd-choileanadh dà-sgriubha extruders, agus tha e air eòlas beairteach a chruinneachadh ann an raon giollachd masterbatch. A rèir feartan giollachd masterbatch (susbaint àrd pigment, cruinneachadh furasta de pigmentan, riatanasan smachd teothachd teann, riatanasan àrd caitheamh caitheamh) agus feumalachdan eadar-dhealaichte luchd-saothrachaidh (diofar ìrean toraidh, diofar sheòrsaichean de masterbatch, different application fields), Zhuoyue has launched a full series of extruders suitable for masterbatch processing, gabhail a-steach sreath HTS BASIC, HTS PLUS series, HTS SUPER series, ZTE series and HTE series. Each series has its own performance characteristics and targeted adaptation scenarios, which can provide personalized and efficient processing solutions for masterbatch manufacturers of different scales.

3.1 Core Advantages of Zhuoyue’s Extruders for Masterbatch Processing

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, cinneasachadh èifeachdach agus seasmhach:

3.1.1 Buaidh measgachadh is sgapadh sàr-mhath

The core requirement of masterbatch processing is the uniform dispersion of pigments. Bidh a h-uile inneal-sgaoilidh dà-sgriubha Zhuoyue a’ gabhail ri structar co-chuairteachaidh eadar-mheadhanach, le pitch sgriubha reusanta, dealbhadh co-mheas luaidhe agus teannachaidh. Faodaidh eadar-fhilleadh agus cuairteachadh nan sgriubhaichean càraid feachd rùsgaidh làidir agus feachd glùineachaidh a ghineadh, which can fully break the agglomerates of pigments (eadhon cruinneachaidhean beaga de 100 μm gu h-àrd), agus dèan na pigmentan air an sgapadh gu cothromach anns a’ ghiùlan. Faodaidh èideadh measgachadh an extruders ruighinn barrachd air 95%, a tha mòran nas àirde na an fheadhainn àbhaisteach le dà sgriubha extruders (85%-90%).

A bharrachd air, bidh na sgriothan de gach sreath de extruders a’ gabhail ri dealbhadh modular, a tha comasach air diofar sheòrsaichean de eileamaidean sgriubha a chur còmhla gu saor (a' giùlan eileamaidean, measgachadh eileamaidean, eileamaidean rùsgaidh) a rèir an t-seòrsa masterbatch (leithid masterbatch dath, white masterbatch, maighstir dubh) agus feartan pigment. Mar eisimpleir, nuair a bhios tu a’ làimhseachadh masterbatch dubh le carbon dubh (cruinneachadh furasta), faodar barrachd eileamaidean measgachaidh agus eileamaidean rùsgaidh a rèiteachadh gus a’ bhuaidh measgachaidh is sgapadh a neartachadh; nuair a bhios tu a’ làimhseachadh masterbatch dath le pigmentan organach (poor heat resistance), faodar barrachd eileamaidean giùlain agus nas lugha de eileamaidean rùsgaidh a rèiteachadh gus an ùine còmhnaidh a ghiorrachadh agus lobhadh pigment a sheachnadh.

3.1.2 Smachd teòthachd mionaideach, A 'seachnadh lobhadh pig

Tha riatanasan teann aig giollachd Masterbatch a thaobh smachd teothachd, 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. Tha am baraille air a roinn na 4-6 independent temperature control sections, and the temperature of each section can be precisely adjusted and controlled in real time.

Tha an siostam smachd teothachd uidheamaichte le gnìomh sgrùdaidh is rabhaidh fìor-ùine: ma tha teòthachd earrann sam bith nas àirde na an raon stèidhichte, cuiridh an siostam a-mach inneal-rabhaidh ann an ùine, and automatically adjust the heating power or start the cooling system to return the temperature to the set range. A bharrachd air, the barrel of the extruder adopts a double-layer jacket design, a dh'fhaodas teasachadh agus fuarachadh luath a thoirt gu buil, agus ag adhartachadh astar freagairt smachd teothachd. Tha an ceann die cuideachd uidheamaichte le inneal smachd teothachd neo-eisimeileach, which ensures the uniform temperature of the die head and the stable shaping of the strip.

3.1.3 Frith-aghaidh caitheamh àrd, Beatha seirbheis fhada

Inorganic pigments such as titanium dioxide and carbon black have high hardness, which will cause serious wear to the screw and barrel of the extruder during processing. Bidh extruders Zhuoyue a’ gabhail ri stuthan caitheamh caitheamh àrd-inbhe agus teicneòlas saothrachaidh adhartach gus dèanamh cinnteach gu bheil na prìomh phàirtean an aghaidh caitheamh.

Na sgriothan agus na baraillean de shreath HTS PLUS, Tha sreath HTS SUPER agus sreath HTE air an dèanamh de stàilinn alloy dìon-caitheamh a chaidh a thoirt a-steach (leithid 38CrMoAlA), and undergo bimetallic composite treatment or laser cladding treatment. Faodaidh cruas uachdar nan sgriothan agus na baraillean ruighinn ≥65 HRC (HTS PLUS series, Sreath HTE) agus ≥70 HRC (HTS SUPER series), aig a bheil neart caitheamh làidir agus strì an aghaidh creimeadh, agus is urrainn dha gu h-èifeachdach seasamh an aghaidh a’ chaitheamh a tha air adhbhrachadh le pigmentan àrd-chruaidh. Is e beatha seirbheis nan sgriothan agus na baraillean 2-3 amannan nas motha na extruders àbhaisteach, lùghdachadh tricead ath-chur phàirtean agus cosgais cumail suas an uidheim.

Tha na sgriothan agus na baraillean de shreath HTS BASIC agus sreath ZTE air an dèanamh de stàilinn alloy àrd-inbhe a tha an aghaidh caitheamh le làimhseachadh nitriding, agus faodaidh cruas an uachdar ruighinn ≥60 HRC, a choinnicheas ri feumalachdan giollachd àbhaisteach masterbatch (susbaint pigment ≤50%) agus tha coileanadh cosgais reusanta aige.

3.1.4 Àrd Èifeachdas Riochdachaidh, Energy Saving and Environmental Protection

Zhuoyue’s extruders adopt a high-torque gearbox and an optimized screw structure, which have strong conveying capacity and high production efficiency. Compared with ordinary twin-screw extruders, the production efficiency of Zhuoyue’s extruders can be increased by 20%-50%. Mar eisimpleir, the production capacity of HTS SUPER series extruders can reach 1000-3000kg/h, which is suitable for large-scale mass production; the production capacity of ZTE series extruders is 100-500kg/h, which is suitable for small and medium-sized batch production.

A bharrachd air, all Zhuoyue’s extruders adopt high-efficiency motors and energy-saving heating elements, which can reduce energy consumption by 15%-20% an coimeas ri extruders àbhaisteach. The extruders are equipped with a closed structure, which can reduce the emission of dust and volatile substances during processing, meeting the environmental protection requirements of the masterbatch industry.

3.1.5 Intelligent Control, Obrachadh agus cumail suas furasta

All Zhuoyue’s extruders adopt a PLC intelligent control system and a touch screen operation interface, a tha sìmplidh agus intuitive, furasta obrachadh. The system can store multiple sets of product formulas and processing parameters (Suas gu 100 sets), and when producing different types of masterbatch, only the corresponding formula and parameters need to be called, gun debugging a-rithist, which saves time and improves production efficiency.

Tha an siostam cuideachd uidheamaichte le gnìomh sgrùdaidh fìor-ùine, as urrainn sùil a chumail air prìomh pharamadairean a’ phròiseas eas-tharraing (leithid teòthachd, cuideam, astar sgriubha, astar beathachaidh) ann an àm fìor, agus clàraich an dàta toraidh (leithid toradh, ùine giollachd) airson ceist agus mion-sgrùdadh nas fhaide air adhart. Airson an t-sreath HTS SUPER extruders, bidh sinn cuideachd a’ toirt seachad gnìomh smachd sgòthan, a dh'fhaodas atharrachadh paramadair iomallach a thoirt gu buil, sgrùdadh dàta toraidh agus cumail suas ro-innse air uidheamachd, a’ toirt gu buil riaghladh cinneasachaidh tuigseach.

A bharrachd air, the extruders adopt a reasonable structural design, a nì an cumail suas nas goireasaiche. Na sgriothan, barrels and die heads can be disassembled and assembled quickly, a lughdaicheas an ùine cumail suas agus dian saothair. Zhuoyue’s after-sales service team will provide professional installation, coimiseanadh agus seirbheisean trèanaidh do luchd-ceannach, dèanamh cinnteach gun urrainn do luchd-ceannach an uidheamachd a chleachdadh gu rèidh.

3.1.6 Raon tagraidh farsaing, Strong Adaptability

Zhuoyue’s full series of extruders have a wide application range, as urrainn atharrachadh a rèir feumalachdan giullachd diofar sheòrsaichean de masterbatch, gabhail a-steach masterbatch dath, white masterbatch, maighstir dubh, masterbatch àbhaisteach, masterbatch gnìomh (masterbatch lasair-retardant, masterbatch antistatic), agus masterbatch le diofar luchd-giùlan (PE, PP, PVC, PA, Peata, etc.). Faodaidh an extruders cuideachd atharrachadh gu bhith a’ giullachd masterbatch le diofar stuthan pigment (10%-80%), agus is urrainn dhaibh coinneachadh ri feumalachdan giollachd diofar raointean tagraidh (snàithleach, filmichean, cumadh buille, eas-tharraing, cumadh stealladh).

Ge bith an e neach-saothrachaidh beag is meadhanach a th ’ann a’ toirt a-mach masterbatch àbhaisteach, no neach-saothrachaidh mòr-sgèile a’ toirt a-mach masterbatch gnìomh àrd, Faodaidh Zhuoyue fuasglaidhean extruder iomchaidh a thoirt seachad. A bharrachd air, faodar an extruders a mhaidseadh le diofar uidheamachd taice (leithid measgairean aig astar luath, tiormairean, fuaradairean, granairean, innealan sgrìonaidh, innealan pacaidh) gus loidhne toraidh fèin-ghluasadach iomlan a chruthachadh, a’ toirt gu buil cinneasachadh leantainneach bho pretreatment stuthan amh gu pacadh toraidh.

3.2 Ro-ràdh mionaideach air Sreath Extruder Zhuoyue agus an atharrachadh gu pròiseasadh Masterbatch

Tha sreath extruder Zhuoyue airson giollachd masterbatch a’ toirt a-steach HTS BASIC, HTS PLUS, HTS Super, ZTE agus HTE, tha na feartan coileanaidh sònraichte fhèin aig gach sreath agus suidheachaidhean atharrachaidh cuimsichte. Faodaidh luchd-saothrachaidh an t-sreath extruder iomchaidh a thaghadh a rèir an sgèile toraidh aca fhèin, seòrsa toraidh, dùmhlachd masterbatch, raon tagraidh agus buidseat.

3.2.1 HTS BASIC Series Extruders: Roghainn sùbailte agus cosg-èifeachdach airson Masterbatch àbhaisteach

Is e sreath toraidh cosg-èifeachdach a th’ ann an extruders sreath HTS BASIC a chaidh a dhealbhadh airson luchd-saothrachaidh no luchd-saothrachaidh masterbatch beag is meadhanach a bhios gu ìre mhòr a ’toirt a-mach masterbatch àbhaisteach.. Bidh an t-sreath de extruders seo a’ cleachdadh bogsaichean gèar torque meadhanach bho phrìomh luchd-saothrachaidh Eòrpach, aig a bheil na buannachdan bho choileanadh seasmhach, fuaim ìosal, àrd-èifeachdais agus seirbheis fhada beatha. Is e torque sònraichte an extruders 10-12Nm / cm³, a choinnicheas ri feumalachdan giollachd àbhaisteach masterbatch (susbaint pigment ≤50%), leithid masterbatch dath PE / PP, masterbatch geal le dùmhlachd ìosal agus masterbatch dubh.

A thaobh dealbhadh structarail, bidh an t-sreath extruders sreath HTS BASIC a’ gabhail ri structar co-chuairteachaidh co-shìnte dà-sgriubha, le trast-thomhas sgriubha eadar 30mm agus 65mm, agus co-mheas teannachaidh de 4～8, which can be adjusted according to the type of masterbatch. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. Tha an extruder uidheamaichte le siostam smachd PLC agus eadar-aghaidh obrachaidh scrion suathaidh, a dh'fhaodas biadhadh fèin-ghluasadach a thoirt gu buil, smachd teothachd fèin-ghluasadach, smachd cuideam fèin-ghluasadach agus gearradh fèin-ghluasadach, agus tha e sìmplidh agus furasta obrachadh.

Tha comas cinneasachaidh an t-sreath HTS BASIC extruders a ’dol bho 100kg / h gu 500kg / h, which is suitable for small and medium-sized masterbatch manufacturers that mainly produce ordinary masterbatch for films, injection molding and extrusion products. Is e aon de na buannachdan as motha a tha san t-sreath seo gum faod e roghainnean sùbailte a thoirt seachad tro mheasgachadh rèiteachaidh eadar-dhealaichte. Faodaidh luchd-ceannach diofar eileamaidean sgriubha a thaghadh, bàs cinn, feeding devices and post-processing equipment according to their own product types and production needs, gus loidhne riochdachaidh a chruthachadh a tha iomchaidh airson na feumalachdan aca fhèin. Tha prìs reusanta aig extruders sreath HTS BASIC, 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. A bharrachd air, tha obrachadh sìmplidh agus cosgais cumail suas ìosal aig an t-sreath de extruders seo, agus tha an taic seirbheis às-reic aige co-chòrdail ri sreathan àrd eile, a choinnicheas gu h-iomlan ri feumalachdan cinneasachaidh làitheil luchd-saothrachaidh beaga is meadhanach.

3.2.2 Sreath HTS PLUS Extruders: Fuasgladh Àrd-Torque airson Plastaig Innleadaireachd agus Masterbatch Filler

Tha extruders sreath HTS PLUS air an suidheachadh mar thoraidhean meadhan-gu-àrd, air a leasachadh gu sònraichte airson suidheachaidhean giollachd masterbatch le riatanasan nas àirde, leithid masterbatch plastaig innleadaireachd agus masterbatch lìonaidh. Eadar-dhealaichte bhon t-sreath HTS BASIC, bidh an t-sreath seo a’ gabhail ri bogsaichean gèar àrd-torque air an leasachadh gu neo-eisimeileach agus air an dèanamh le Zhuoyue, le torque sònraichte de 13-16Nm / cm³, a bheir feachd rùsgaidh nas làidire agus feachd glùineachaidh, fuasgladh èifeachdach air duilgheadasan giullachd àrd-slaodachd, stuthan àrd-chruaidh masterbatch.

A thaobh co-phàirtean bunaiteach, tha na sgriothan agus na baraillean den t-sreath HTS PLUS air an dèanamh de stàilinn alloy dìon-caitheamh a chaidh a thoirt a-steach agus a’ faighinn làimhseachadh co-dhèanta bimetallic. Tha cruas an uachdar a’ ruighinn ≥65 HRC, aig a bheil sàr-aghaidh caitheamh agus strì an aghaidh creimeadh, agus is urrainn dhaibh dèiligeadh gu furasta ris a’ chaitheamh a tha air adhbhrachadh le lìonadh masterbatch (leithid calcium carbonate, masterbatch làn pùdar talcum) agus masterbatch plastaig innleadaireachd (leithid PA, Masterbatch airson pc). Bidh an sgriubha a’ gabhail ri dealbhadh modular, agus tha e uidheamaichte le eileamaidean measgachaidh leasaichte agus eileamaidean rùsgaidh, a tha comasach air na lìonaidhean agus na pigmentan anns a’ ghiùlan a sgaoileadh gu tur, a’ dèanamh cinnteach à aonachd agus seasmhachd an masterbatch. Tha am baraille air a roinn na 5-6 earrannan smachd teothachd, with a temperature control precision of ±1℃, a tha comasach air smachd ceart a chumail air teòthachd giollachd plastaig innleadaireachd (200-280℃) agus seachain lobhadh stuthan.

Tha comas cinneasachaidh an t-sreath HTS PLUS extruders a ’dol bho 300kg / h gu 1200kg / h, a tha freagarrach airson luchd-saothrachaidh masterbatch meadhanach mòr agus mòr a bhios a’ dèanamh masterbatch plastaig innleadaireachd, masterbatch lìonadh, masterbatch dath dùmhlachd àrd (susbaint pigment 50%-70%) agus bathar eile. Mar eisimpleir, ann an giullachd masterbatch plastaig innleadaireachd PA, faodaidh an t-sreath HTS PLUS a bhith an urra ris an torque àrd agus smachd teothachd mionaideach gus dèanamh cinnteach gu bheil an neach-giùlan PA air a leaghadh gu h-iomlan, agus tha na pigmentan agus na stuthan cur-ris gnìomhach air an sgapadh gu co-ionnan, a’ seachnadh duilgheadasan spotan dath, sruthan agus droch fheartan meacanaigeach an masterbatch. Ann an giullachd masterbatch filler, faodaidh an fheachd rùsgaidh làidir aige na gràinean lìonaidh a sgaoileadh gu tur (a tha furasta an cruinneachadh) anns a' ghiùlan, ag adhartachadh co-chòrdalachd eadar an inneal-lìonaidh agus an neach-giùlan, and ensuring the processing performance of the masterbatch when mixed with downstream plastic raw materials.

A bharrachd air, the HTS PLUS series extruders are equipped with an upgraded PLC intelligent control system, which can realize more precise parameter control and data monitoring. The system can automatically adjust the screw speed, feeding speed and extrusion pressure according to the material viscosity and processing effect, ensuring the stability of product quality between batches. The extruder is also equipped with a forced feeding device and a vacuum exhaust device: the forced feeding device can ensure the smooth feeding of high-viscosity materials; the vacuum exhaust device can effectively remove moisture, volatile substances and air in the materials, avoiding bubbles and pores in the masterbatch, and improving the density and quality of the masterbatch. This series of extruders balances performance and cost, and is suitable for manufacturers that need to improve product quality and expand production scale.

3.2.3 Sreath HTS Super Extruders: 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, innealan meidigeach, 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, a tha fada nas àirde na an t-sreath HTS PLUS. Tha an dealbhadh torque ultra-àrd seo a’ toirt comas don extruder dèiligeadh ri bhith a ’giullachd slaodachd ultra-àrd, stuthan masterbatch cruas ultra-àrd, leithid masterbatch le susbaint lìonaidh àrd (susbaint lìonaidh gu h-àrd 60%) agus masterbatch plastaig innleadaireachd sònraichte le puing leaghaidh àrd agus slaodachd àrd. Aig an aon àm, ag amas air torque àrd agus feartan astar àrd an t-sreath seo, Tha Zhuoyue air optimization coileanta a dhèanamh de dhealbhadh structarail a h-uile prìomh phàirtean den extruder: bidh an sgriubha a’ gabhail ri seòrsa ùr de stàilinn alloy a tha an aghaidh caitheamh agus a’ faighinn làimhseachadh còmhdach laser, le cruas uachdar de ≥70 HRC, aig a bheil neart caitheamh làidir agus beatha seirbheis (3-4 amannan nas motha na extruders àbhaisteach); bidh am baraille a’ gabhail ri seacaid dà-fhillte + structar fuarachadh èiginneach, 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%, a tha freagarrach airson a bhith a 'giollachd dùmhlachd àrd, masterbatch àrd-dispersibility (susbaint pigment 70%-80%). A bharrachd air, bidh an t-sreath extruders seo a’ gabhail ri siostam riaghlaidh astar tricead caochlaideach le mionaideachd àrd, agus faodar astar an sgriubha atharrachadh anns an raon de 300-1000 rpm, a ghabhas atharrachadh gu sùbailte a rèir an t-seòrsa masterbatch agus riatanasan giollachd, dèanamh cinnteach gu bheil a’ bhuaidh giollachd as fheàrr.

Tha comas cinneasachaidh an t-sreath HTS SUPER extruders a ’dol bho 1000kg / h gu 3000kg / h, a tha freagarrach airson sgèile mhòr, luchd-saothrachaidh masterbatch àrd-inbhe a bhios ag amas air margaidhean àrd-ìre. Mar eisimpleir, ann an giullachd masterbatch airson pàirtean carbaid lùth ùr (leithid pàirtean càr a-staigh agus a-muigh, masterbatch slige bataraidh), faodaidh an t-sreath HTS SUPER dèanamh cinnteach gu bheil deagh fhrith-shìde aig a’ phrìomh bhata, high temperature resistance and dispersibility, meeting the strict quality requirements of automotive manufacturers; in the processing of medical grade masterbatch (such as masterbatch for medical catheters, medical containers), it can realize clean production, avoid material pollution, 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, a dh'fhaodas atharrachadh paramadair iomallach a thoirt gu buil, sgrùdadh dàta toraidh, 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 Sreath ZTE Extruders: Cost-Effective Choice for Universal Masterbatch Processing

The ZTE series extruders are positioned as cost-effective products, air a dhealbhadh gu sònraichte airson luchd-saothrachaidh a dh’ fheumas càileachd giollachd agus cosgais a chothromachadh, agus sa mhòr-chuid a’ toirt a-mach masterbatch àbhaisteach uile-choitcheann. Tha coileanadh cosgais sàr-mhath aig an t-sreath extruders seo, agus faodaidh na paramadairean dealbhaichte aige coinneachadh ri feumalachdan giollachd nan stuthan masterbatch as cumanta (PE, PP, PVC masterbatch, masterbatch dath dùmhlachd ìosal, masterbatch dubh agus masterbatch geal le susbaint pigment ≤50%).

A thaobh dealbhadh structarail, tha an t-sreath ZTE a’ gabhail ri structar co-chuairteachaidh co-shìnte dà-sgriubha, le trast-thomhas sgriubha eadar 25mm agus 65mm, agus torque sònraichte de 8-11Nm / cm³, a bheir seachad feachd rùsgaidh gu leòr agus comas giùlain airson giollachd àbhaisteach masterbatch. Tha na sgriothan agus na baraillean air an dèanamh de stàilinn alloy àrd-inbhe a tha an aghaidh caitheamh le làimhseachadh nitriding, agus tha cruas an uachdar a’ ruighinn ≥60 HRC, which can meet the wear requirements of ordinary pigments (leithid pigmentan organach, low-hardness inorganic pigments) and has a long service life. Tha am baraille air a roinn na 4 earrannan smachd teothachd, with a temperature control precision of ±2℃, which can accurately control the processing temperature of ordinary masterbatch (150-220℃), avoiding pigment decomposition and carrier degradation.

The production capacity of the ZTE series extruders ranges from 50kg/h to 400kg/h, which is suitable for small and medium-sized masterbatch manufacturers, small workshops and enterprises that need to produce small batches of multi-variety masterbatch. This series of extruders has the advantages of simple structure, obrachadh furasta, caitheamh lùtha ìosal agus cosgais cumail suas ìosal. The operation interface adopts a simple touch screen design, which is easy to learn and master, and is suitable for operators with little experience. A bharrachd air, the ZTE series can also be flexibly configured according to customer needs, such as adding a forced feeding device, a vacuum exhaust device or a special die head, to meet the personalized processing needs of different customers. Although the ZTE series is cost-effective, its core performance indicators (such as mixing uniformity, mionaideachd smachd teothachd) 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, ag amas air luchd-saothrachaidh masterbatch meadhanach mòr a dh’ fheumas èifeachdas toraidh agus càileachd toraidh adhartachadh fhad ‘s a tha iad a’ cumail smachd air cosgaisean. Tha an t-sreath seo de extruders air a dhealbhadh gus coileanadh a chothromachadh, èifeachdas agus cosgais, agus tha e freagarrach airson grunn shuidheachaidhean giollachd masterbatch, a’ toirt a-steach masterbatch dath dùmhlachd àrd (susbaint pigment 50%-60%), masterbatch gnìomh àbhaisteach (masterbatch lasair-retardant, masterbatch antistatic) agus masterbatch airson filmichean, cumadh buille agus toraidhean cumadh stealladh.

A thaobh coileanadh bunaiteach, bidh an t-sreath HTE a’ gabhail ri bogsa gèar àrd-torque air a leasachadh gu neo-eisimeileach le Zhuoyue, le torque sònraichte de 12-14Nm / cm³, a tha nas àirde na an t-sreath HTS BASIC agus ZTE, agus is urrainn dha feachd rùsgaidh nas làidire agus feachd glùineachaidh a thoirt seachad, dèanamh cinnteach à sgapadh èideadh de pigmentan agus stuthan cur-ris. Bidh na sgriothan a’ gabhail ri dealbhadh modular, 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, which can reduce energy consumption by 18%-25% compared with ordinary extruders of the same type. Aig an aon àm, tha an comas toraidh aige a’ dol bho 200kg / h gu 800kg / h, a tha 15%-20% nas àirde na sreath HTS BASIC den aon shònrachadh. Tha am baraille air a roinn na 5 earrannan smachd teothachd, with a temperature control precision of ±1℃, a dh'fhaodas smachd ceart a chumail air teòthachd giollachd, seachain sgudal stuth air adhbhrachadh le cus teasachadh no leaghadh gu leòr, agus cosgaisean toraidh a lughdachadh tuilleadh. A bharrachd air, tha an t-sreath HTE uidheamaichte le siostam smachd tuigseach PLC, as urrainn smachd paramadair fèin-ghluasadach a thoirt gu buil, sgrùdadh dàta agus stòradh foirmle, ensuring the stability of product quality between batches. Tha an extruder cuideachd uidheamaichte le inneal fuasglaidh falamh agus inneal beathachaidh èiginneach, a dh'fhaodas càileachd masterbatch a leasachadh agus dèanamh cinnteach à adhartas rèidh ann an riochdachadh.

Tha an t-sreath HTE freagarrach airson luchd-saothrachaidh masterbatch meadhanach mòr a tha aig ìre leudachadh air sgèile toraidh agus ag ùrachadh càileachd toraidh. Chan urrainn dha a-mhàin coinneachadh ri feumalachdan giollachd masterbatch àrd-inbhe, ach cuideachd smachd a chumail air cosgais toraidh gu h-èifeachdach, a’ cuideachadh iomairtean gus am farpaiseachd sa mhargaidh a leasachadh. An coimeas ris an t-sreath HTS PLUS, tha prìs nas reusanta aig an t-sreath HTE; an coimeas ris an t-sreath ZTE, tha coileanadh nas fheàrr aige agus èifeachdas toraidh nas àirde, a tha na roghainn cosg-èifeachdach eadar toraidhean meadhan-raon agus toraidhean àrd.

4. Raointean tagraidh farsaing de Masterbatch agus a’ maidseadh Zhuoyue Extruder Solutions

Mar phrìomh stuth riatanach ann an gnìomhachas plastaig, masterbatch ga chleachdadh gu bitheanta ann an freumhag, filmichean, cumadh buille, cumadh eas-tharraing, cumadh stealladh agus raointean eile. Tha riatanasan eadar-dhealaichte aig diofar raointean tagraidh a thaobh coileanadh masterbatch (leithid dispersibility, strì an aghaidh teòthachd, luaths dath) agus èifeachdas toraidh, a bhios cuideachd a’ dearbhadh an taghadh de extruders dà-sgriubha. Zhuoyue’s full series of extruders can provide targeted solutions for different application fields, 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, leithid snàithleach polyester, freumhag nylon, polypropylene fiber, etc., and the final products include carpets, aodaich, cushions, non-woven fabrics, etc. This field has extremely high requirements on masterbatch: a’ chiad, sgaoileadh àrd. 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; an dàrna, 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; an treas, 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, a’ seachnadh spotan dathte agus sreathan den t-snàithleach; faodaidh an smachd teothachd àrd-torque agus mionaideach dèanamh cinnteach à seasmhachd coileanadh masterbatch, a 'leasachadh luaths dath an snàithle. Airson masterbatch fiber meadhanach-ìre (leithid snàithleach teacsa àbhaisteach, aodach neo-fhighte), Thathas a’ moladh sreath HTS PLUS agus sreath HTE. Faodaidh am buaidh measgachadh is sgaoilidh àrd aca coinneachadh ri riatanasan bunaiteach fiber masterbatch, agus tha coileanadh cosgais nas àirde. Airson pasgan beag, masterbatch fiber cosgais ìseal, faodar an t-sreath HTS BASIC a thaghadh cuideachd, a dh’ fhaodas dèanamh cinnteach à sgaoileadh bunaiteach agus luaths dath.

4.2 Raon film: Riatanasan àrd follaiseachd agus dath èideadh

Tha Masterbatch ann an raon film air a chleachdadh sa mhòr-chuid airson dathadh filmichean plastaig, leithid pocannan ceannach, filmichean tilgeadh, filmichean ioma-fhillte, filmichean pacaidh, filmichean àiteachais, etc. Is e prìomh riatanasan an raoin seo airson masterbatch: a’ chiad, follaiseachd àrd. Airson filmichean follaiseach no tar-shoilleir (leithid filmichean pacaidh bìdh, filmichean mulch àiteachais), feumaidh follaiseachd math a bhith aig a’ masterbatch, a’ seachnadh buaidh air coltas agus faicsinneachd thoraidhean pacaichte; an dàrna, dath èideadh. Feumaidh uachdar an fhilm a bhith èideadh ann an dath, gun spotan dath, sreathan dath agus eadar-dhealachadh dath, dèanamh cinnteach à seilbh bòidhchead an fhilm; an treas, fileantachd giollachd math. Tha astar extrusion film luath, agus feumaidh fileantachd math a bhith aig a’ phrìomh bhaidse, a tha cuideachail airson measgachadh èideadh den masterbatch agus an stuth bonn film, agus a’ seachnadh buaidh air èifeachdas cruthachadh film.

Airson an raon-cluiche film, is e an t-sreath extruder Zhuoyue iomchaidh sreath HTS BASIC, Sreath HTE agus sreath HTS PLUS. Airson masterbatch film àbhaisteach (leithid pocannan ceannach, filmichean pacaidh àbhaisteach), Thathas a’ moladh sreath HTS BASIC agus sreath HTE. Faodaidh an deagh bhuaidh measgachadh is sgaoilidh aca dèanamh cinnteach gum bi dath èideadh air an fhilm, and the good processing fluidity can match the high-speed extrusion of the film. For high-end film masterbatch (leithid filmichean pacaidh bìdh, 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, leithid soithichean meidigeach agus cosmaigeach, soithichean ola lubaidh agus peant, botail deoch, plastic barrels, etc. The requirements of this field for masterbatch are: a’ chiad, fileantachd giollachd math. Blow molding products need to be formed by high-temperature blow molding, agus feumaidh fileantachd math a bhith aig a’ phrìomh bhaidse, which is conducive to the uniform distribution of the masterbatch in the parison, avoiding uneven wall thickness and color difference of the product; an dàrna, 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; an treas, dìon na h-àrainneachd. 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, Sreath HTS BASIC agus sreath HTE. For ordinary blow molding masterbatch (such as lubricating oil containers, plastic barrels), Thathas a’ moladh sreath ZTE agus sreath HTS BASIC. Faodaidh an structar sgriubha reusanta aca agus an siostam smachd teothachd dèanamh cinnteach gu bheil deagh siùbhlachd agus seasmhachd a ’mhaighstir, a’ coinneachadh ri riatanasan bunaiteach bathar cumadh buille. Airson masterbatch cumadh buille meadhanach (leithid soithichean cosmaigeach, botail deoch), tha an t-sreath HTE air a mholadh. Faodaidh èifeachdas toraidh àrd agus buannachdan sàbhalaidh lùth cosgaisean toraidh a lughdachadh, agus faodaidh deagh bhuaidh measgachadh is sgaoilidh dèanamh cinnteach à dath èideadh agus seasmhachd meudachd an toraidh. Airson masterbatch cumadh buille àrd (leithid soithichean meidigeach), Thathas a’ moladh sreath HTS PLUS agus sreath HTS SUPER. Faodaidh an smachd teothachd àrd-chruinneas aca agus dealbhadh cinneasachaidh glan dèanamh cinnteach gu bheil am masterbatch a ’coinneachadh ri ìrean ìre meidigeach, 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, leithid duilleagan, pìoban, uèirichean agus càbaill, pròifilean, etc. Is e prìomh riatanasan an raoin seo airson masterbatch: a’ chiad, high dimensional stability. Extrusion products (leithid pìoban, pròifilean) 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; an dàrna, 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; an treas, math an aghaidh sìde. 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. Its ultra-high torque and precise temperature control can ensure the stable performance of the masterbatch, and the enhanced wear resistance can further extend the service life of the product.

4.5 Injection Molding Field: High Dispersibility and Batch Stability Requirements

Masterbatch in the injection molding field is the most widely used, mainly used for coloring injection molding products, leithid pàirtean càr, bathar eileagtronaigeach, stuthan togail, innealan taighe, àirneis, dèideagan, etc. The requirements of this field for masterbatch are diverse, but the core requirements are: a’ chiad, sgaoileadh àrd. Injection molding products have complex shapes and small sizes, and the masterbatch must have high dispersibility, avoiding color spots, color streaks and uneven coloring of the product; an dàrna, good batch stability. Injection molding products are usually produced in large batches, and the masterbatch must have stable performance, ensuring no color difference between batches of products; an treas, targeted functional requirements. Mar eisimpleir, automotive parts require masterbatch with high temperature resistance and flame retardancy, electronic products require masterbatch with antistatic performance, and toys require masterbatch with non-toxic and environmental protection performance.

For the injection molding field, Zhuoyue’s full series of extruders can provide corresponding solutions according to different product levels. For ordinary injection molding masterbatch (such as toys, ordinary home appliances), Thathas a’ moladh sreath ZTE agus sreath HTS BASIC. Their cost-effective advantages can reduce production costs, and the basic mixing and dispersing effect can meet the requirements of ordinary products. For medium-grade injection molding masterbatch (such as electronic products, ordinary automotive parts), the HTE series and HTS PLUS series are recommended. Their high mixing and dispersing effect and batch stability can ensure the quality of the product, and the targeted functional masterbatch processing capacity can meet the special requirements of the product. For high-end injection molding masterbatch (such as high-grade automotive parts, precision electronic products), the HTS SUPER series is recommended. Its ultra-high dispersibility, batch stability and high-temperature resistance can meet the strict quality requirements of high-end products, and the intelligent control system can ensure the efficiency and stability of large-scale production.

5. Common Problems and Solutions in Masterbatch Twin-Screw Extrusion Processing

In the actual production process of masterbatch, due to the influence of raw materials, formula, processing parameters and equipment performance, various problems often occur, 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, agus chan eil an tiormachadh gu leòr; tha an co-chòrdalachd eadar am pigment agus an neach-giùlan truagh; chan eil an dòs dispersant gu leòr no tha an seòrsa neo-iomchaidh.
• (2) Duilgheadasan premixing: Tha an astar measgachadh ro ìosal, tha an ùine measgachadh ro ghoirid, tha an teòthachd measgachadh neo-iomchaidh, mar thoradh air ro-mheasadh neo-chothromach de stuthan amh.
• (3) Duilgheadasan paramadair eas-tharraing: Tha astar an sgriubha ro ìosal, chan eil neart an rùsgaidh gu leòr, agus chan urrainnear na cruinneachaidhean pigment a bhriseadh gu tur; tha an teòthachd eas-tharraing ro ìosal, chan eil an neach-giùlain air a leaghadh gu tur, agus chan urrainn am pigment a bhith air a sgaoileadh gu co-ionnan.
• (4) Duilgheadasan le uidheamachd: Chan eil na h-eileamaidean measgachadh sgriubha gu leòr no air an caitheamh; tha am baraille agus an sgriubha air an caitheamh, mar thoradh air lùghdachadh ann an neart sèididh; tha an ceann marbh air a bhacadh, toirt buaidh air eas-tharraing èideadh stuthan.

5.1.2 Fuasglaidhean:

• (1) Optimize stuthan amh: Tagh pigmentan le meud mìrean beaga agus ìre cruinneachadh ìosal, and dry them thoroughly (moisture content ≤0.1%); select carriers compatible with pigments; replace appropriate dispersants and increase the dosage appropriately (a-staigh 1%-5% den dosachadh pigment).
• (2) Improve premixing effect: Increase the mixing speed to 800-1200 rpm, extend the mixing time to 5-10 mionaidean, and control the mixing temperature at 40-60℃; for high-concentration masterbatch, add dispersant first and mix with pigment, then mix with carrier and other additives.
• (3) Adjust extrusion parameters: Increase the screw speed appropriately (500-800 rpm for high-concentration masterbatch), improve the shear force; increase the extrusion temperature appropriately to ensure that the carrier is fully melted (adjust according to the carrier type).
• (4) Maintain equipment: Replace worn screw mixing elements, baraille agus sgriubha; clean the die head regularly to avoid blockage; check the equipment regularly to ensure that the screw and barrel are properly matched.

5.2 Common Problem 2: Pigment Decomposition and Discoloration of Masterbatch

This problem is mainly manifested in the discoloration of the masterbatch (such as yellowing, darkening), the color is inconsistent with the standard sample, and even peculiar smell is generated. It is mostly caused by overheating of the material during extrusion processing, which is common in organic pigment masterbatch and engineering plastic masterbatch. The main causes and solutions are as follows:

5.2.1 Main Causes:

• (1) Extrusion temperature is too high: The temperature of the mixing section, homogenizing section or die head is too high, exceeding the heat resistance limit of the pigment or carrier.
• (2) The residence time of the material is too long: Tha astar an sgriubha ro ìosal, the compression ratio is too large, resulting in the material staying in the extrusion cavity for too long (Barrachd air 3 mionaidean), 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 Fuasglaidhean:

• (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℃ for engineering plastic masterbatch); check the temperature sensor regularly to ensure accurate temperature control.
• (2) Shorten the residence time: Increase the screw speed appropriately, reduce the compression ratio of the screw, and ensure that the residence time of the material in the extrusion cavity is 1-3 mionaidean.
• (3) Maintain the cooling system: Check the cooling water circulation system regularly, clean the cooling pipe, and ensure that the barrel can dissipate heat normally; replace the faulty cooling element in time.
• (4) Optimize stuthan amh: Select pigments with good heat resistance (such as inorganic pigments for high-temperature processing); select carriers with stable performance and not easy to degrade; add appropriate heat stabilizers (0.5%-3%) to prevent pigment decomposition and carrier degradation.

5.3 Common Problem 3: High Wear of Screw and Barrel, Short Service Life

This problem is common in the processing of white masterbatch, black masterbatch and filler masterbatch, which is mainly manifested in the rapid wear of the screw and barrel, reduced shear force and mixing capacity of the extruder, and increased maintenance cost. The main causes and solutions are as follows:

5.3.1 Main Causes:

• (1) Raw material problems: The pigment or filler has high hardness (such as titanium dioxide, carbon black, calcium carbonate), and the particle size is too large, a tha ag adhbhrachadh caitheamh mòr air an sgriubha agus am baraille.
• (2) Duilgheadasan paramadair eas-tharraing: Tha astar an sgriubha ro àrd, tha feachd an rùsgaidh ro mhòr, agus tha an suathadh eadar an stuth agus an sgriubha / baraille air a mheudachadh; tha an cuideam eas-tharraing ro àrd, a tha a 'meudachadh caitheamh an sgriubha agus a' bharaille.
• (3) Duilgheadasan le uidheamachd: Tha an sgriubha agus am baraille air an dèanamh de stuthan le droch chaitheamh an aghaidh, no tha an teicneòlas giollachd neo-iomchaidh; chan eil an sgriubha agus am baraille air am maidseadh gu ceart, mar thoradh air cuideam neo-chothromach agus barrachd caitheamh.

5.3.2 Fuasglaidhean:

• (1) Optimize stuthan amh: Tagh pigmentan no lìonaichean le meud beag gràin (20-40 mogal) agus cruas ìosal; pronnadh agus criathradh na stuthan amh gus mìrean mòra a thoirt air falbh; cuir bealaidh iomchaidh ris (0.5%-2%) gus an suathadh eadar an stuth agus an sgriubha / baraille a lughdachadh.
• (2) Adjust extrusion parameters: Lùghdaich astar an sgriubha agus cuideam eas-tharraing gu h-iomchaidh, agus smachd a chumail air an fheachd rùsgaidh taobh a-staigh raon reusanta; 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, sgapadh, dath) 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, dispersant and other additives fluctuates (error exceeds ±1%).
• (2) Raw material problem: The performance of raw materials (such as pigment tinting strength, carrier melting point) of different batches is inconsistent.
• (3) Processing parameter problem: The extrusion temperature, astar sgriubha, feeding speed and other parameters fluctuate between different batches, resulting in inconsistent processing effect.
• (4) Equipment problem: The equipment has poor stability, and the parameters (leithid teòthachd, cuideam) cannot be kept stable for a long time.

5.4.2 Fuasglaidhean:

• (1) Strictly control the formula ratio: Use high-precision weighing equipment to weigh raw materials, and the error is controlled within ±1%; establish a formula management system, and record the dosage of each raw material in detail.
• (2) Standardize raw material procurement and inspection: Select raw material suppliers with stable quality, and inspect the performance of raw materials (such as tinting strength, meud gràin, susbaint taiseachd) before use; for raw materials of different batches, conduct trial production first to ensure consistent performance.
• (3) Standardize processing parameters: Use an intelligent control system (such as Zhuoyue’s PLC control system) to store the processing parameters of different masterbatch, and call the corresponding parameters when producing different batches, a’ seachnadh ath-dhebugging; regularly check the equipment parameters to ensure stable operation.
• (4) Establish quality inspection system: Conduct strict quality inspection on each batch of masterbatch, dath nam measg, sgapadh, concentration and other indicators, and only deliver the products that meet the standards.

5.5 Common Problem 5: Poor Processing Fluidity of Masterbatch, Difficult Extrusion, Equipment Blockage

This problem is mainly manifested in the difficulty of material conveying and extrusion, èifeachdas toraidh ìosal, unstable extrusion pressure, and even blockage of the die head and extrusion cavity, which affects the normal production. The main causes and solutions are as follows:

5.5.1 Main Causes:

• (1) Raw material problem: The carrier has poor fluidity, or the pigment content is too high (Barrachd air 80%), resulting in poor fluidity of the mixture; the raw material has high moisture content, which causes the material to agglomerate and block the feeding port.
• (2) Premixing problem: The premixing is uneven, and the dispersant is not fully mixed, resulting in poor fluidity of the material.
• (3) Extrusion parameter problem: The extrusion temperature is too low, chan eil an neach-giùlain air a leaghadh gu tur, and the fluidity is poor; the screw speed is too low, the conveying capacity is insufficient; the die head hole is too small, and the extrusion resistance is too large.
• (4) Equipment problem: The screw conveying elements are worn, the conveying capacity is reduced; the feeding device fails, resulting in uneven feeding.

5.5.2 Fuasglaidhean:

• (1) Optimize stuthan amh: 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) Improve premixing effect: 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) Adjust extrusion parameters: 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) Maintain equipment: 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 Cùis 1: Application of HTS SUPER Series in High-Concentration Black Masterbatch Processing for New Energy Vehicles

Customer Background: A large-scale masterbatch manufacturer in Jiangsu, Sìona, mainly produces high-end functional masterbatch, focusing on the new energy vehicle field. The customer needs to produce high-concentration black masterbatch (carbon black content 70%) for automotive battery shell parts. The masterbatch requires ultra-high dispersibility (no black spots and streaks in the product), high temperature resistance (can withstand 200℃ high temperature without discoloration), and good batch stability. The customer’s original equipment has problems such as insufficient mixing and dispersing effect, unstable temperature control, and low production efficiency, which cannot meet the production requirements.

Fuasgladh: Zhuoyue recommends the HTS SUPER series twin-screw extruders (screw diameter 75mm) for the customer. This series adopts ultra-high torque gearboxes and laser-clad wear-resistant screws/barrels, 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 Cùis 2: Application of HTS PLUS Series in Engineering Plastic PA Masterbatch Processing

Customer Background: A medium-sized masterbatch manufacturer in Guangdong, Sìona, mainly produces engineering plastic masterbatch, focusing on the automotive and electronic fields. The customer needs to produce PA66 masterbatch (susbaint pigment 50%) for automotive connector parts. The masterbatch requires good dispersibility, high temperature resistance (260℃), and good compatibility with PA66 raw materials. The customer’s original equipment has problems such as poor wear resistance of the screw/barrel, insufficient torque, and easy decomposition of PA66 carrier, which affects the product quality.

Fuasgladh: Zhuoyue recommends the HTS PLUS series twin-screw extruders (screw diameter 65mm) for the customer. This series adopts high-torque gearboxes independently developed by Zhuoyue, which can provide sufficient torque for PA66 masterbatch processing; the bimetallic composite screw/barrel has excellent wear resistance and corrosion resistance, which can cope with the wear of high-hardness pigments; the 5-section precise temperature control system and vacuum exhaust device can avoid PA66 carrier decomposition and remove moisture and volatile substances, dèanamh cinnteach à càileachd an masterbatch; faodar an dealbhadh sgriubha modular a rèiteachadh gu sùbailte a rèir feartan giollachd masterbatch PA66, a 'leasachadh buaidh measgachadh agus sgapadh.

Application Effect: An dèidh a bhith a 'cleachdadh an t-sreath HTS PLUS extruders, tha deagh sgapadh aig masterbatch PA66 an neach-ceannach, agus tha dath èideadh air na pàirtean ceangail chàraichean agus gun spotan dath; faodaidh an masterbatch seasamh ri 260 ℃ teòthachd àrd gun lobhadh agus dath dath, agus tha co-chòrdalachd math aige le stuthan amh PA66; tha beatha seirbheis an sgriubha / baraille air a dhol suas bho 6 mìosan gu 18 mìosan, lùghdachadh cosgais cumail suas le 60%; tha èifeachdas toraidh air a dhol suas bho 300kg / h gu 800kg / h, agus tha an ìre teisteanais toraidh air a dhol suas bho 92% gu 99%. Tha masterbatch PA66 an neach-ceannach air a dhol a-steach gu soirbheachail ann an sèine solair neach-dèanamh pàirtean càr ainmeil.

6.3 Cùis 3: Cur an sàs Sreath HTE ann an Giullachd Film Masterbatch a tha èifeachdach a thaobh cosgais

Customer Background: Neach-dèanamh masterbatch beag is meadhanach ann an Zhejiang, Sìona, sa mhòr-chuid a’ dèanamh film masterbatch, le fòcas air an raon film pacaidh. Feumaidh an neach-ceannach masterbatch film PE a thoirt gu buil (susbaint pigment 40%) airson filmichean pacaidh bìdh. Feumaidh an masterbatch deagh fhollaiseachd, dath èideadh, agus cosgais toraidh ìosal. Tha duilgheadasan aig uidheamachd tùsail an neach-ceannach leithid caitheamh lùth àrd, càileachd toraidh neo-sheasmhach, and low production efficiency, nach urrainn coinneachadh ri feumalachdan farpais margaidh.

Fuasgladh: Tha Zhuoyue a’ moladh an t-sreath HTE extruders dà-sgriubha (trast-thomhas sgriubha 50mm) for the customer. Tha an t-sreath seo a’ fighe a-steach àrd-choileanadh agus cosg-èifeachdas, a’ gabhail ri motaran sàbhalaidh lùth àrd-èifeachdais agus structaran sgriubha làn-leasaichte, which can reduce energy consumption by 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% gu 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 Cùis 4: Application of ZTE Series in Small-Batch Multi-Variety Ordinary Masterbatch Processing

Customer Background: A small masterbatch manufacturer in Shandong, Sìona, mainly produces small-batch multi-variety ordinary masterbatch (PE/PP color masterbatch, maighstir dubh, 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, cosgais cumail suas ìosal, and strong adaptability.

Fuasgladh: Zhuoyue recommends the ZTE series twin-screw extruders (screw diameter 35mm) for the customer. 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/u). 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, comas-gnìomh, 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, gun chron, low-volatile, degradable and recyclable, agus pigmentan puinnseanta agus cronail (leithid pigmentan meatailt trom) and additives will be completely eliminated. Mar eisimpleir, water-based masterbatch, bio-based masterbatch and recyclable masterbatch will have broad market prospects. Aig an aon àm, 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, lasair-aghaidh, antistatic, antibacterial, UV-resistant) into one masterbatch, which can reduce the addition amount of masterbatch, simplify the processing process, and reduce production costs. Mar eisimpleir, new energy vehicle masterbatch will integrate high temperature resistance, lasair-aghaidh, antistatic and other functions; medical masterbatch will integrate non-toxic, antibacterial, high transparency and other functions. A bharrachd air, 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 (leithid dath, dùmhlachd, gnìomh, seòrsa neach-giùlain), and masterbatch manufacturers need to provide personalized customization solutions according to the specific needs of customers. Mar eisimpleir, 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. Mar eisimpleir, 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 High Efficiency, Energy Saving and Environmental Protection.

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. Mar eisimpleir, 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 Àrd-choileanadh agus caitheamh an aghaidh caitheamh.

Le leasachadh dùmhlachd àrd, masterbatch àrd-chruaidh (leithid masterbatch lìonaidh, masterbatch plastaig innleadaireachd), bidh na riatanasan airson coileanadh agus caitheamh caitheamh extruders dà-sgriubha nas àirde. Bidh an extruders san àm ri teachd a’ gabhail ri barrachd stuthan dìon-caitheamh àrd-choileanadh (leithid stàilinn ùr alloy, stuthan ceirmeag) agus teicneòlasan saothrachaidh adhartach (leithid còmhdach laser, measgachadh bimetallic), which can greatly improve the wear resistance and corrosion resistance of the screw and barrel, leudachadh beatha seirbheis an uidheim. Aig an aon àm, bidh na bogsaichean gèar torque nas àirde agus eileamaidean measgachadh nas adhartaiche air an uidheamachadh, a bheir feachd rùsgaidh nas làidire agus feachd glùineachaidh, a’ coinneachadh ri feumalachdan giullachd masterbatch àrd-choileanaidh.

7.2.4 Modularization agus sùbailteachd.

Bidh modaladh agus sùbailteachd gu bhith na ghluasad leasachaidh cudromach de luchd-sgaoilidh dà-sgriubha. Gabhaidh na extruders san àm ri teachd ri dealbhadh modular nas foirfe, agus an sgriubha, baraille, 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. Mar eisimpleir, when producing different types of masterbatch, only the corresponding screw elements and die head need to be replaced, without replacing the entire extruder. A bharrachd air, 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: a’ chiad, 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; an dàrna, 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; an treas, 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; an ceathramh, 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. Co-dhùnadh

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, comas-gnìomh, high concentration and intelligence, the requirements for twin-screw extruders are becoming higher and higher.

Sùgh, 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, tha na feartan coileanaidh sònraichte fhèin aig gach sreath agus suidheachaidhean atharrachaidh cuimsichte, 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, smachd teòthachd mionaideach, strì an aghaidh caitheamh àrd, èifeachdas toraidh àrd, 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.

Anns an àm ri teachd, 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.