Elastomère tèmoplastik (TPE), pafwa refere yo kòm Thermoplastic Rubbers (TPR), se yon klas copolymers oswa melanj fizik polymères—tipikman yon plastik ak yon kawotchou—ki konbine pwopriyete tèrmoplastik ak elastomè.. Konbinezon inik sa a pèmèt TPE yo trete tankou tèrmoplastik (atravè ekstrizyon, bòdi piki, kònen bòdi, elatriye.) pandan y ap kenbe Elastisite a ak fleksibilite nan kawotchou. Kontrèman ak kawotchou vulkanize tradisyonèl yo, TPE yo ka fonn epi trete plizyè fwa san pèt enpòtan nan pèfòmans, fè yo plis zanmitay anviwònman an ak pri-la efikas. Kòm demann lan pou lejè, fleksib, ak materyèl resikle ap grandi atravè endistri tankou otomobil, elektrik, konstriksyon, ak byen pou konsomatè, TPE yo te vin de pli zan pli popilè, driving the development of specialized masterbatch and extrusion technologies tailored to their unique processing requirements.
Masterbatch, as a key material for coloring and functional modification of TPEs, plays a crucial role in enhancing the performance and expanding the application scope of TPE products. The processing of TPE masterbatch requires precise control of mixing, dispersing, and temperature parameters, as TPEs have specific viscosity, rezistans chalè, and elasticity characteristics that differ from traditional plastics. Twin-screw extruders, with their superior mixing and dispersing capabilities, kontwòl tanperati egzak, and adaptability to diverse materials, have become the core processing equipment for TPE masterbatch. Zhuoyue, a professional manufacturer of twin-screw extruders, offers a full range of advanced extrusion solutions specifically designed for TPE compounding and masterbatch processing, covering TPE/SBS/TPU/TPR/TPV and other major TPE categories, to meet the diverse needs of manufacturers in different industries.
1. Overview of Thermoplastic Elastomers (TPE): Categories, Properties and Key Characteristics
TPEs are a diverse family of materials, classified into six general commercial categories based on their chemical composition and structure. Each category has unique properties, processing characteristics, and application fields, which directly determine the requirements for masterbatch formulation and extrusion equipment. Understanding the classification and properties of TPEs is the foundation for optimizing masterbatch processing and selecting suitable twin-screw extruders.
1.1 Sis Kategori Komèsyal Jeneral nan TPEs
1.1.1 Styrenic Blòk Copolymers (TPS, TPE-s).
TPS se kategori ki pi lajman itilize nan TPE yo, kontablite pou yon gwo pati nan mache TPE mondyal la. Li konpoze de blòk styrenic (tankou polystyrène, PS) ak blòk elastomerik (tankou polybutadien, PB; polyisoprene, PI; oswa etilèn-butilèn, EB), konekte pa lyezon kovalan. Kalite TPS ki pi komen yo enkli SBS (Styrenes-Butadienes-Styrenes), SIS (Styrene-Isoprene-Styrène), SEBS (Styrene-Ethylene-Butylene-Styrene), ak SEPS (Styrene-Ethylene-Propylene-Styrène).
Pwopriyete kle nan TPS gen ladan fleksibilite ekselan, elastisite, ak processability. SEBS ak SEPS, ki se vèsyon idwojene SBS ak SIS, te amelyore rezistans chalè, rezistans move tan, ak rezistans aje, fè yo apwopriye pou aplikasyon pou deyò ak wo-tanperati. Materyèl TPS yo fasil koulè ak modifye ak masterbatch, ak tanperati pwosesis yo varye ant 150 ℃ ak 220 ℃, ki se konpatib ak pifò extruders jimo-vis. Aplikasyon komen nan TPS gen ladan eleman otomobil, fil ak câbles, byen pou konsomatè, ak aparèy medikal.
1.1.2 Thermoplastic Polyolefin Elastomères (TPO, TPE-o).
TPO se yon melanj fizik polyolefin (tankou polypropylène, PP; oswa polyethylene, PE) ak elastomè (tankou monomère ethylene-propylene-diene, EPDM). Li konbine frigidité nan polyolefins ak elastisite nan elastomèr, epi li gen ekselan rezistans chimik, rezistans move tan, ak fleksibilite tanperati ki ba. TPO yo pa toksik, san odè, ak resikle, fè yo ideyal pou aplikasyon ki mande zanmitay anviwònman an.
Tanperati pwosesis TPO varye ant 160 ℃ ak 230 ℃, epi li gen bon konpatibilite ak divès kalite masterbatch (masterbatch koulè, masterbatch ignifuge, elatriye.). TPO yo lajman itilize nan pati eksteryè otomobil (tankou kouvèti eksepsyonèl, revètman fender), materyo pou konstriksyon (tankou fok, garnitur), ak konpozan elektrik. Akòz kontni segondè polyolefin yo, Pwosesis TPO masterbatch mande pou extruders ak bon kapasite melanje asire dispèsyon inifòm nan pigman ak aditif..
1.1.3 Vulkanizat tèmoplastik (VAT, TPE v).
TPV se yon melanj dinamik vulkanize nan polyolefin (anjeneral PP) ak elastomè (anjeneral EPDM). Pandan pwosesis la, se faz elastomèr la vulkanize nan ti patikil ak inifòm gaye nan matris la polyolefin, sa ki lakòz elastisite ekselan, konpresyon mete rezistans, ak rezistans chalè. TPV yo gen pi bon pwopriyete mekanik ak estabilite dimansyon pase TPE tradisyonèl yo, epi li ka kenbe tèt ak alontèm ekspoze wo-tanperati (jiska 150 ℃).
TPV processing requires precise temperature control and strong shear force to ensure uniform vulcanization and dispersion. The processing temperature ranges from 170℃ to 240℃, and the material has high viscosity during processing, which places high requirements on the torque and wear resistance of twin-screw extruders. TPVs are widely used in automotive seals, hoses, garnitur, and industrial components that require high performance and durability.
1.1.4 Thermoplastic Polyurethanes (TPU).
TPU is a block copolymer composed of hard segments (diisocyanate and chain extender) and soft segments (polyol). It has excellent elasticity, abrasion resistance, oil resistance, and mechanical strength, and can be adjusted in hardness from very soft (Shore A 30) to very hard (Shore D 85) by changing the ratio of hard and soft segments.
TPU processing is sensitive to temperature and moisture. The processing temperature ranges from 180℃ to 250℃, and the material must be thoroughly dried before processing (moisture content ≤0.05%) to avoid hydrolysis and bubble formation. TPU masterbatch processing requires extruders with precise temperature control and vacuum exhaust capabilities. TPU is widely used in wires and cables, automotive hoses, footwear, medical catheters, and sports equipment.
1.1.5 Thermoplastic Copolyesters (TPC, TPE-E).
TPC is a block copolymer composed of polyester hard segments and polyether or polyester soft segments. It has excellent heat resistance, rezistans chimik, ak pwopriyete mekanik, and can withstand high temperatures up to 150℃ for long periods. TPCs also have good flexibility and elasticity, making them suitable for high-performance applications.
The processing temperature of TPC ranges from 220℃ to 280℃, which is higher than other TPE categories. It has high viscosity during processing and requires extruders with high torque and precise temperature control. TPC masterbatch processing also requires special attention to the dispersion of pigments and additives to avoid affecting the material’s mechanical properties. TPCs are widely used in automotive components (such as air intake hoses, transmission seals), aerospace parts, and industrial machinery.
1.1.6 Thermoplastic Polyamides (TPA, TPE-A).
TPA is a block copolymer composed of polyamide hard segments and polyether soft segments. It combines the high strength, wear resistance, and chemical resistance of polyamides with the flexibility and elasticity of polyethers. TPA has excellent impact resistance and low temperature performance, and can be used in harsh environments.
The processing temperature of TPA ranges from 230℃ to 290℃, and it has high water absorption, requiring thorough drying before processing. TPA masterbatch processing requires extruders with high wear resistance (due to the high hardness of polyamide) and precise temperature control to avoid material degradation. TPA is widely used in automotive components (such as gears, bearings), electrical connectors, and industrial hoses.
1.2 Key Properties of TPEs Affecting Masterbatch Processing
TPEs have unique properties that distinguish them from traditional plastics, and these properties directly affect the formulation of masterbatch and the selection of extrusion equipment. The key properties to consider in masterbatch processing are as follows:
1.2.1 Elasticity and Flexibility.
TPEs have high elasticity and flexibility, which means that the masterbatch must be compatible with the TPE matrix to avoid reducing the material’s elastic performance. The carrier of the masterbatch should have good compatibility with the TPE, and the dispersant should ensure uniform dispersion of pigments without forming agglomerates that could cause stress concentration and reduce flexibility.
1.2.2 Heat Resistance.
Different TPE categories have different heat resistance (processing temperature ranges from 150℃ to 290℃). Masterbatch pigments and additives must have heat resistance matching the TPE processing temperature to avoid decomposition, discoloration, or performance degradation during extrusion. Pou egzanp, TPC ak TPA mande pou pigman ki reziste wo-tanperati ak estabilize chalè.
1.2.3 Viskozite ak Processability.
TPE yo gen diferan viskozite pandan pwosesis la (TPV ak TPC gen pi wo viskozite, pandan ke TPS gen pi ba viskozite). Sa a afekte fòs la taye ak transmèt kondisyon nan extruder la jimo-vis. TPE ki gen gwo viskozite mande pou extruders ak gwo koupl ak gwo kapasite melanje, pandan y ap TPE ki ba-viskozite mande pou kontwòl egzak sou vitès ekstrizyon pou evite materyèl debòde.
1.2.4 Absòpsyon imidite.
Gen kèk TPEs (tankou TPU, TPA) gen gwo absòpsyon dlo, ki ka lakòz bul, idroliz, ak lòt defo nan masterbatch la. Matyè premyè yo (TPE, pigman, aditif) yo dwe byen seche anvan pwosesis la, ak extruder la ta dwe ekipe ak yon aparèy echapman vakyòm yo retire imidite ak sibstans ki sou temèt.
1.2.5 Konpatibilite ak aditif.
TPEs often require functional additives (such as antioxidants, estabilize UV, grès machin) to improve their performance. The masterbatch should be formulated to ensure that the additives are compatible with both the pigments and the TPE matrix, avoiding chemical reactions that could affect product quality.
2. Masterbatch for TPEs: Composition, Formulation and Processing Requirements
Masterbatch for TPEs is a concentrated mixture of pigments/dyes, carriers, ak aditif, designed to color TPEs and impart additional functions (such as flame retardancy, antistatik, antibacterial) while maintaining the material’s inherent elastic and processing properties. The formulation and processing of TPE masterbatch are more demanding than those for traditional plastics, due to the unique properties of TPEs. This section details the composition, formulation principles, and processing requirements of TPE masterbatch.
2.1 Core Composition of TPE Masterbatch
Like traditional masterbatch, TPE masterbatch consists of three basic components: pigments/dyes, carriers, ak aditif. The selection and proportion of each component are tailored to the type of TPE and its application requirements.
2.1.1 Pigments/Dyes.
Pigments/dyes are the core components that impart color to TPEs, accounting for 10%-70% of the masterbatch composition (depending on the color intensity and TPE type). The key requirements for pigments/dyes in TPE masterbatch are:
- – Heat Resistance: Must withstand the processing temperature of the target TPE (150℃-290℃) without decomposition or discoloration. For high-temperature TPEs (TPC, TPA), high-temperature resistant organic pigments or inorganic pigments are preferred.
- – Konpatibilite: Must be compatible with the TPE matrix to avoid migration, blooming, or reduced elasticity. Pigments with similar polarity to the TPE are more compatible (pa egzanp, polar pigments for TPU, non-polar pigments for TPS).
- – Dispersibility: Must be easily dispersed in the TPE matrix to ensure uniform coloring and avoid color spots, streaks, or reduced mechanical properties. Fine-particle pigments (20-40 mesh) with low agglomeration are preferred.
- – Environmental Friendliness: Must meet global environmental protection standards (such as REACH, RoHS) to avoid toxic or harmful substances (such as heavy metals) that could affect human health and the environment.
Common pigments used in TPE masterbatch include: inorganic pigments (titanium dioxide for white, carbon black for black, iron oxide for red/yellow), and high-temperature resistant organic pigments (phthalocyanine blue/green, quinacridone red).
2.1.2 Carriers.
Carriers are the matrix of the masterbatch, accounting for 20%-80% of the composition, and play a key role in dispersing pigments and adhering to the TPE matrix. The carrier must have excellent compatibility with both the pigments and the target TPE, as poor compatibility can lead to pigment migration, uneven coloring, and reduced TPE performance. The selection of the carrier is based on the type of TPE:
- – For TPS (SBS, SEBS): Use TPS or PP as the carrier, which has good compatibility and processing fluidity.
- – For TPO/TPE-o: Use PP or PE as the carrier, matching the polyolefin component of the TPO.
- – For TPV/TPE-v: Use PP as the carrier, which is compatible with the PP matrix of the TPV.
- – For TPU: Use TPU as the carrier, ensuring compatibility with the TPU matrix and avoiding hydrolysis.
- – For TPC/TPE-E and TPA/TPE-A: Use TPC or TPA as the carrier, respectively, to match the high-temperature processing requirements and compatibility.
The carrier should also have good processing fluidity, with a melting point and processing temperature consistent with or slightly lower than the target TPE, to ensure uniform mixing and avoid TPE degradation.
2.1.3 Additives.
Additives are auxiliary components added to improve the processing performance, dispersibility, and functional performance of TPE masterbatch, accounting for 1%-10% of the composition. The type and dosage of additives are determined by the TPE type and application requirements:
- – Dispersants: The most important additive for TPE masterbatch, used to reduce pigment surface tension, prevent agglomeration, and ensure uniform dispersion in the TPE matrix. Common dispersants include polyethylene wax, polypropylene wax, asid stearik, and maleic anhydride grafted waxes. For high-viscosity TPEs (VAT, TPC), yo pi pito dispèrsan segondè-efikasite ak konpatibilite fò.
- – Konpatibilite: Itilize pou amelyore konpatibilite ant pigman ak TPEs, ak ant masterbatch ak matris TPE. Pou egzanp, se anhydride maleik grefon PP yo itilize kòm yon konpatibilite pou TPO masterbatch, epi yo itilize sir an poliyiretàn pou masterbatch TPU.
- – Estabilizatè chalè: Itilize pou anpeche dekonpozisyon pigman ak degradasyon TPE pandan pwosesis wo-tanperati. Estabilize chalè komen yo enkli estabilize fèblan òganik (pou TPU), anpeche antioksidan fenol (pou TPS, TPO), ak antioksidan fosfit (pou TPC, TPA).
- – UV Stabilizer ak antioksidan: Itilize amelyore rezistans move tan ak rezistans aje nan pwodwi TPE ki gen koulè pal, anpeche koulè manyak ak degradasyon pèfòmans anba limyè solèy la ak oksijèn. Pou aplikasyon deyò (tankou pati eksteryè otomobil), UV absorbers and hindered amine light stabilizers (HALS) are added.
- – Lubricants: Used to reduce friction between materials and extrusion equipment (screw, barrel, mouri tèt), improve processing fluidity, and avoid material sticking to equipment. Common lubricants include stearic acid, calcium stearate, and silicone oil. For TPU and TPA, lubricants with low migration are preferred to avoid affecting product performance.
- – Functional Additives: Added to impart special functions to TPEs, such as flame retardants (for wires and cables), antistatic agents (pou konpozan elektrik), and antibacterial agents (for medical devices and consumer goods).
2.2 Formulation Principles of TPE Masterbatch
The formulation of TPE masterbatch must balance coloring effect, processing performance, and TPE inherent properties. The key principles are as follows:
2.2.1 Compatibility First.
The carrier, pigman, and additives must be compatible with the target TPE to avoid reducing the material’s elasticity, fleksibilite, ak pwopriyete mekanik. Pou egzanp, using a non-polar carrier for polar TPU will lead to poor compatibility and pigment migration.
2.2.2 Match Heat Resistance.
The pigments and additives must have heat resistance matching the TPE processing temperature. Pou egzanp, TPC masterbatch uses high-temperature resistant pigments (heat resistance ≥280℃) to avoid decomposition during processing.
2.2.3 Optimize Dispersibility.
The pigment content and dispersant dosage are adjusted to ensure uniform dispersion. High-concentration masterbatch (pigment content 50%-70%) requires more dispersants and better mixing capabilities, while low-concentration masterbatch (10%-30%) focuses on compatibility.
2.2.4 Minimize Impact on TPE Properties.
The masterbatch should not significantly affect the TPE’s elasticity, compression set, or abrasion resistance. Pou egzanp, excessive dispersants or lubricants may reduce the TPE’s mechanical strength.
2.2.5 Environmental Protection Compliance.
The formulation must meet global environmental protection standards, avoiding toxic or harmful substances (such as heavy metals, ftalat) that could restrict market access.
2.3 Processing Requirements of TPE Masterbatch
TPE masterbatch processing is mainly carried out using twin-screw extrusion technology, which requires strict control of raw material pretreatment, premixing, extrusion parameters, and post-processing to ensure product quality. The key processing requirements are as follows:
2.3.1 Raw Material Pretreatment.
TPEs (especially TPU, TPA) gen gwo absòpsyon dlo, so all raw materials (TPE carrier, pigman, aditif) yo dwe byen seche anvan pwosesis la. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 èdtan, TPS/TPO is dried at 80-100℃ for 3-5 èdtan, ak pigman yo seche nan 60-80 ℃ pou 2-4 èdtan. Kontni imidite nan matyè premyè sèk yo ta dwe kontwole anba a 0.1% (0.05% pou TPU/TPA).
Anplis de sa, pigman ak gwosè patikil gwo oswa agglomere yo ta dwe kraze ak tamize (20-40 mesh) pou amelyore dispersibilité, ak enpurte (patikil metal yo, pousyè) yo ta dwe retire pou evite mete sou ekipman extrusion ak domaj nan masterbatch.
2.3.2 Premixing.
Matyè premyè sèk yo (pigman, konpayi asirans, aditif) yo melanje nan yon mixer gwo vitès dapre rapò fòmil la pou fòme yon melanj inifòm preliminè. Paramèt premixing yo ajiste ki baze sou kalite TPE: vitès melanje 800-1200 rpm, tan melanje 5-10 minit, tanperati melanje 40-60 ℃. Pou mètr ki gen gwo konsantrasyon oswa transpòtè TPE ki gen gwo viskozite, se tan an premix pwolonje, ak dispersant yo ajoute premye nan rad pigman yo, amelyore dispèsibilite.
2.3.3 Kontwòl paramèt extrusion.
Twin-screw extrusion is the core step of TPE masterbatch processing, and the key parameters (tanperati, vitès vis, extrusion pressure, feeding speed) must be precisely controlled to match the TPE type:
- – Kontwòl Tanperati: The barrel is divided into 4-6 temperature control sections (feeding section, melting section, mixing section, homogenizing section, die head section). The temperature of each section is adjusted according to the TPE processing temperature. Pou egzanp, TPS masterbatch: feeding section 100-120℃, melting section 160-180℃, mixing section 170-190℃, homogenizing section 160-180℃, die head section 150-170℃; TPC masterbatch: feeding section 150-170℃, melting section 230-250℃, mixing section 240-260℃, homogenizing section 230-250℃, die head section 220-240℃. The temperature control precision should reach ±1℃ to avoid TPE degradation and pigment decomposition.
- – Screw Speed: The screw speed ranges from 200-800 rpm, adjusted based on TPE viscosity. High-viscosity TPEs (VAT, TPC) require higher screw speed (500-800 rpm) to generate sufficient shear force for pigment dispersion; low-viscosity TPEs (TPS) use moderate speed (300-500 rpm) to avoid material overflow.
- – Extrusion Pressure: The pressure ranges from 5-12MPa, kept stable (fluctuation ≤±0.5MPa) to ensure uniform mixing and shaping. High-viscosity TPEs require higher pressure, while low-viscosity TPEs use moderate pressure.
- – Feeding Speed: Adjusted to match the screw speed and extrusion speed, ensuring stable and uniform feeding. For high-viscosity TPEs, a forced feeding device is used to avoid material accumulation.
2.3.4 Post-Processing.
After extrusion, the strip-shaped masterbatch is cooled (water tank cooling, 20-30℃), granulated (gwosè patikil 2-5mm), tès depistaj (pou retire patikil ki pa kalifye), ak pake (anbalaj sele ak imidite-prèv). Pou imidite-sansib TPE masterbatch (TPU, TPA), se pwodwi a fini cheche ankò anvan anbalaj yo anpeche absòpsyon imidite.
3. Jaden aplikasyon TPE Masterbatch ak Matching Zhuoyue Extruder Solutions
TPE yo lajman itilize nan otomobil, elektrik, konstriksyon, byen pou konsomatè, ak lòt endistri yo, ak diferan jaden aplikasyon yo gen diferan kondisyon pou pèfòmans TPE masterbatch (koulè, dispersibility, fonksyonalite) ak efikasite pwodiksyon an. Seri konplè Zhuoyue nan extruders jimo-vis (HTS BASIC/PLUS/SUPER, ZTE, HTE) yo espesyalman optimize pou pwosesis TPE masterbatch, bay solisyon vize pou diferan kategori TPE ak jaden aplikasyon yo. Anba la a se yon entwodiksyon detaye nan domèn aplikasyon prensipal TPE masterbatch ak seri Zhuoyue extruder matche..
3.1 Endistri otomobil: Pi gwo jaden aplikasyon TPE Masterbatch
Endistri otomobil la se pi gwo konsomatè TPE yo, kontablite pou plis pase 40% nan mache mondyal TPE a. TPE yo itilize nan yon pakèt eleman otomobil akòz lejè yo, fleksib, ak pwopriyete resikle, ak TPE masterbatch jwe yon wòl kle nan koloran ak modifikasyon fonksyonèl nan eleman sa yo. Prensipal aplikasyon otomobil TPE masterbatch genyen ladan yo:
3.1.1 Otomobil sele ak Joints.
TPEs (sitou TPV, TPO) yo itilize pou pwodwi sele pòt otomobil, sele fenèt yo, sele kapo, ak garnitur, ki mande bon elastisite, rezistans move tan, ak fleksibilite tanperati ki ba. Masterbatch la pou eleman sa yo mande pou koloran inifòm, bon rezistans move tan (UV rezistans, rezistans aje), ak konpatibilite ak matris TPV/TPO.
Matche extruders: Seri HTS PLUS ak seri HTE. The HTS PLUS series has high torque and wear resistance, suitable for TPV masterbatch processing (high viscosity, high shear force required); the HTE series integrates high performance and cost-effectiveness, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPEs (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, door panels, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (non-toxic, san odè). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Matche extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small and medium-sized manufacturers producing TPS interior masterbatch; the HTE series has good mixing dispersibility and low energy consumption, suitable for large-scale production of TPU/TPS interior masterbatch.
3.1.3 Automotive Hoses and Tubing.
TPEs (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, rezistans chalè, and mechanical strength. The masterbatch requires high-temperature resistance, oil resistance, and uniform dispersibility to avoid affecting the hose’s performance.
Matche extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has ultra-high torque, kontwòl tanperati egzak, and high wear resistance, suitable for TPC/TPA masterbatch processing (high temperature, high viscosity); the HTS PLUS series has good heat resistance and mixing capabilities, suitable for TPU masterbatch processing.
3.1.4 Other Automotive Components.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, ki mande pwopriyete diferan (tankou rezistans pousyè, transparans, rezistans enpak). Se masterbatch la formul selon kondisyon espesifik, ak extruders matche yo chwazi ki baze sou kalite TPE ak echèl pwodiksyon an.
3.2 Endistri elektrik ak elektwonik: Fonksyonèl TPE Masterbatch Aplikasyon
Endistri elektrik ak elektwonik se yon lòt aplikasyon enpòtan nan TPEs, kote TPE yo itilize pou pwodwi fil ak câbles, konektè, ak lòt konpozan, mande masterbatch fonksyonèl (antistatik, ignifuge flanm dife, segondè-tanperati rezistan) pou satisfè kondisyon sekirite ak pèfòmans.
3.2.1 Fil ak Câbles.
TPEs (mainly TPU, TPS, TPO) yo itilize kòm materyèl izolasyon ak djenn pou fil ak câbles (câbles pouvwa, fil ignisyon, fil ekoutè, ploge konektè), ki mande bon izolasyon elektrik, reta flanm dife, ak rezistans abrasion. Masterbatch la mande pou ignifuge flanm dife (satisfè UL94 V-0 estanda), pwopriyete antistatik, and uniform coloring.
Matche extruders: HTS PLUS series, HTE series, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, suitable for small and medium-sized production; the HTS SUPER series is suitable for high-end, high-concentration flame-retardant masterbatch processing.
3.2.2 Electrical Connectors and Plugs.
TPEs (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, ki mande bon izolasyon elektrik, rezistans enpak, and environmental friendliness. The masterbatch requires uniform coloring, high-temperature resistance, and no migration.
Matche extruders: HTS PLUS series and HTS SUPER series. The HTS PLUS series has good compatibility with TPU/TPA, ensuring uniform dispersion; the HTS SUPER series has precise temperature control, avoiding TPA degradation during processing.
3.3 Construction and Transportation Industry: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, expansion joints, subway mats, ak lòt konpozan, requiring good weather resistance, rezistans aje, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPEs (sitou TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, UV rezistans, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Matche extruders: Seri HTS PLUS ak seri HTE. The HTS PLUS series has good weather-resistant additive mixing capabilities, suitable for TPV masterbatch processing; the HTE series is energy-saving and efficient, suitable for large-scale production of TPO masterbatch.
3.3.2 Transportation Components.
TPEs are used to produce subway mats, road noise reduction mats, and transportation vehicle seals, ki mande pou bon absòpsyon chòk, rediksyon bri, ak mete rezistans. Masterbatch la mande pou dispèsibilite inifòm ak bon konpatibilite ak matris TPE pou kenbe pèfòmans absòpsyon chòk.
Matche extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, apwopriye pou pwodiksyon ti pakèt; seri a HTE gen bon kapasite melanje, asire dispèsyon inifòm nan aditif absòbe chòk.
3.4 Byen Konsomatè ak lòt endistri yo: Divès TPE Masterbatch Aplikasyon
TPE yo lajman itilize nan machandiz konsomatè yo ak lòt endistri yo, ak divès senaryo aplikasyon ak diferan kondisyon masterbatch, konsantre sou koulè, soft touch, and environmental friendliness.
3.4.1 Endistri soulye.
TPEs (mainly TPU, TPS) yo itilize pou pwodwi plant soulye, anwo soulye, ak Pwodwi pou Telefòn soulye, which require good flexibility, abrasion resistance, ak manyen mou. The masterbatch requires bright colors, uniform dispersibility, and no migration (pou evite tach chosèt).
Matche extruders: Seri HTS BASIC ak seri ZTE. Seri ZTE a gen pèfòmans pri ekselan, apwopriye pou manifaktirè soulye ti ak mwayen gwosè; seri a HTS BASIC gen bon dispersibility melanje, asire koloran inifòm nan mètr sèl soulye.
3.4.2 Nesesite nan kay la ak chak jou.
TPE yo itilize pou pwodwi manch, rus, tapi pye, jwèt, ak lòt bagay nan kay la, ki mande ki pa toksik, san odè, soft touch, ak koulè klere. Masterbatch la mande pou zanmitay anviwònman an (satisfè estanda kontak manje pou rus / manch) and uniform coloring.
Matche extruders: Seri ZTE ak seri HTS BASIC. Seri ZTE a senp pou opere, ba nan pri antretyen, apwopriye pou ti-pakèt, pwodiksyon milti-varyete; seri HTS BASIC la gen bon konpatibilite masterbatch pwoteksyon anviwònman an, satisfè estanda kontak manje.
3.4.3 Aparèy Medikal.
TPEs (mainly TPU, TPS) yo itilize pou pwodui katetè medikal, sereng, ak mask medikal, ki mande ki pa toksik, esteril, ak biokonpatib. Masterbatch la mande pwoteksyon anviwònman medikal klas (reyinyon ISO 10993 estanda), segondè transparans (pou katetè), ak dispèsibilite inifòm.
Matche extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, kontwòl tanperati egzak, avoiding material pollution; the HTS PLUS series has good compatibility with medical grade TPEs, ensuring product sterility and biocompatibility.
3.4.4 Other Industrial Applications.
TPEs are also used to produce drain pipes, industrial gaskets, and mechanical components, which require good chemical resistance, wear resistance, and mechanical strength. The masterbatch is formulated according to specific industrial requirements, ak extruders matche yo chwazi ki baze sou kalite TPE ak echèl pwodiksyon an.
4. Zhuoyue’s Full Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue has long been engaged in the research, development, and production of high-performance twin-screw extruders, and has accumulated rich experience in TPE masterbatch processing. Based on the unique processing characteristics of TPEs (high viscosity, temperature sensitivity, moisture absorption) and the diverse needs of manufacturers (different TPE categories, production scales, application fields), Zhuoyue has launched a full series of extruders suitable for TPE masterbatch processing, including HTS BASIC, HTS PLUS, HTS SUPER, ZTE, and HTE series. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Excellent Mixing and Dispersing Effect.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, with a reasonable screw pitch, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, carriers, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Anplis de sa, the screws adopt a modular design, which can freely combine different screw elements (conveying, melanje, shearing) according to the TPE type. Pou egzanp, high-viscosity TPV/TPC masterbatch requires more mixing and shearing elements to enhance dispersion; low-viscosity TPS masterbatch uses more conveying elements to improve production efficiency.
4.1.2 Precise Temperature Control, Avoiding TPE Degradation.
TPEs are sensitive to temperature, and excessive temperature or temperature fluctuation can lead to material degradation (such as TPU hydrolysis, TPC chain scission). All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, avèk 4-6 independent temperature control sections, temperature control precision of ±1℃, and real-time temperature monitoring and alarm functions. The barrel adopts a double-layer jacket design, realizing rapid heating and cooling, and improving temperature response speed. The die head is equipped with an independent temperature control device, ensuring stable shaping of the masterbatch strip.
4.1.3 High Wear Resistance and Corrosion Resistance.
Some TPE masterbatches (such as TPA, TPC) contain high-hardness pigments or additives, which can wear the screw and barrel. Zhuoyue’s extruders use high-quality wear-resistant materials and advanced manufacturing technologies: HTS PLUS/SUPER/HTE series screws and barrels are made of imported wear-resistant alloy steel, undergoing bimetallic composite or laser cladding treatment, surface hardness ≥65 HRC (HTS SUPER series ≥70 HRC), service life 2-3 times that of ordinary extruders; HTS BASIC/ZTE series screws and barrels are nitrided, surface hardness ≥60 HRC, meeting the needs of ordinary TPE masterbatch processing.
4.1.4 Vacuum Exhaust and Moisture Removal Capabilities.
TPEs such as TPU and TPA have high water absorption, and moisture can cause bubbles and defects in the masterbatch. All Zhuoyue’s mid-to-high-end extruders (HTS PLUS/SUPER/HTE) are equipped with a vacuum exhaust device, which can effectively remove moisture, sibstans ki temèt, ak lè nan materyèl la, asire dansite ak bon jan kalite masterbatch la. Degre nan vakyòm se reglabl (0.06-0.09MPa), adapte a diferan kondisyon kontni imidite.
4.1.5 Segondè efikasite pwodiksyon ak ekonomize enèji.
Èkstrudeurs Zhuoyue yo adopte bwat gwo koupl ak estrikti vis optimize, ak gwo kapasite transmèt ak efikasite pwodiksyon segondè. Konpare ak extruders òdinè, efikasite pwodiksyon ogmante pa 20%-50%, ak konsomasyon enèji redwi pa 15%-25%. Pou egzanp, HTS SUPER seri kapasite pwodiksyon rive nan 1000-3000kg / h, apwopriye pou pwodiksyon an mas gwo echèl; ZTE seri kapasite pwodiksyon se 50-400kg / h, apwopriye pou pwodiksyon ti pakèt.
4.1.6 Entelijan kontwòl ak operasyon fasil.
Tout extruders adopte yon sistèm kontwòl entèlijan PLC ak koòdone operasyon manyen ekran, ki ka estoke jiska 100 ansanm fòmil ak paramèt pwosesis. When switching between different TPE masterbatches, only the corresponding parameters need to be called, avoiding repeated debugging. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, production data monitoring, and predictive maintenance, realizing intelligent production management.
4.1.7 Wide Adaptability.
Zhuoyue’s full series of extruders can adapt to the processing of all TPE categories (TPS/SBS/TPU/TPR/TPV/TPC/TPA) and masterbatch types (masterbatch koulè, masterbatch ignifuge, antistatic masterbatch), with pigment content ranging from 10% pou 70%. They can also be matched with auxiliary equipment (high-speed mixers, dryers, coolers, granulators) to form a complete automatic production line.
4.2 Detailed Introduction of Zhuoyue’s Extruder Series for TPE Masterbatch Processing
Each series of Zhuoyue’s extruders has unique performance characteristics and targeted adaptation scenarios, and manufacturers can select the appropriate series according to their TPE type, production scale, and application requirements.
4.2.1 HTS BASIC Series: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, kontwòl otomatik tanperati, ak manje, senp pou opere. Konsepsyon vis modilè a pèmèt konfigirasyon fleksib selon kondisyon masterbatch TPS/TPO. Seri HTS BASIC la se yon chwa ideyal pou manifaktirè ti ak mwayen gwosè ak bidjè limite, konsantre sou pwodiksyon òdinè TPE masterbatch (tankou byen nan kay la, fil òdinè ak câbles).
4.2.2 Seri HTS PLUS: High-Torque pou Jeni TPE ak High-Konsantrasyon Masterbatch.
Seri a HTS PLUS pozisyone kòm yon pwodwi mitan-wo-fen, ki fèt espesyalman pou gwo demann TPE masterbatch pwosesis (VAT, TPU, segondè-konsantrasyon TPE mètr, masterbatch ignifuge). Li adopte bwat segondè-koupl poukont devlope pa Zhuoyue, koupl espesifik 13-16Nm / cm³, vis dyamèt 40-75mm, kapasite pwodiksyon 300-1200kg / h.
Seri a sèvi ak vis konpoze bimetalik ak barik (surface hardness ≥65 HRC), ak ekselan rezistans mete ak rezistans korozyon, apwopriye pou pwosesis TPV/TPC masterbatch (high viscosity, pigman ki wo dite). Li ekipe ak yon 5-6 seksyon egzak sistèm kontwòl tanperati ak aparèy echapman vakyòm, evite idroliz TPU ak degradasyon TPC. Eleman melanje amelyore asire dispèsyon inifòm nan pigman ki wo konsantrasyon (50%-70%) ak aditif fonksyonèl (ignifuge flanm dife, antistatic agents). Seri HTS PLUS la apwopriye pou manifaktirè gwosè mwayen ak gwo echèl ki pwodui bon jan kalite masterbatch TPE. (tankou sele otomobil, fil segondè ak câbles, aparèy medikal).
4.2.3 HTS SUPER Seri: Ultra-segondè pèfòmans pou High-End TPE Masterbatch.
Seri HTS SUPER se seri extruder ki pi wo Zhuoyue a, ki reprezante nivo avanse extruders jimo-vis Lachin nan, fèt pou-wo fen, gwo demann TPE masterbatch pwosesis (TPA, TPC, masterbatch ultra-wo konsantrasyon, masterbatch for new energy vehicles/aerospace).
It adopts Zhuoyue’s latest ultra-high torque transmission device, specific torque 17-20Nm/cm³, screw diameter 50-95mm, production capacity 1000-3000kg/h. The screws are made of new wear-resistant alloy steel, undergoing laser cladding treatment (surface hardness ≥70 HRC), service life 3-4 times that of ordinary extruders. The barrel adopts a double-layer jacket + forced cooling structure, temperature control precision ±1℃, suitable for high-temperature TPE processing (220-290℃). The multi-stage mixing screw combination ensures ultra-high mixing uniformity (≥98%), suitable for ultra-high-concentration masterbatch (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, and predictive maintenance. It is suitable for large-scale, high-standard manufacturers producing high-end TPE masterbatch (such as automotive high-temperature hoses, precision electrical connectors, aerospace components).
4.2.4 ZTE Series: Cost-Effective for Universal TPE Masterbatch.
The ZTE series is positioned as a cost-effective product, designed for manufacturers balancing processing quality and cost, producing universal ordinary TPE masterbatch (low-concentration TPS/TPO/TPU masterbatch). It adopts a twin-screw parallel co-rotating structure, specific torque 8-11Nm/cm³, screw diameter 25-65mm, production capacity 50-400kg/h.
The series uses nitrided screws and barrels (surface hardness ≥60 HRC), meeting the needs of ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a 4-section temperature control system, simple touch screen operation, easy to learn and master. The ZTE series has a simple structure, low energy consumption, and low maintenance cost, suitable for small manufacturers, small workshops, and enterprises producing small-batch, multi-variety TPE masterbatch (such as small toys, local household goods).
4.2.5 HTE Series: High Performance and Cost-Effective Integrated Solution.
The HTE series integrates high performance and cost-effectiveness, designed for medium-sized manufacturers upgrading product quality and expanding production scale. Li adopte bwat segondè-koupl poukont devlope pa Zhuoyue, specific torque 12-14Nm/cm³, screw diameter 35-70mm, production capacity 200-800kg/h.
Seri a sèvi ak vis konpoze bimetalik ak barik (surface hardness ≥65 HRC), with good wear resistance, suitable for TPU/TPO masterbatch processing. It adopts an optimized screw structure and high-efficiency energy-saving motor, energy consumption reduced by 18%-25% compared with ordinary extruders. The 5-section precise temperature control system and vacuum exhaust device ensure product quality, and the enhanced mixing elements ensure uniform dispersion. The HTE series balances performance and cost, suitable for medium-sized manufacturers producing medium-grade TPE masterbatch (such as automotive interior components, ordinary medical devices, mid-grade wires and cables).
5. Common Problems and Solutions in TPE Masterbatch Twin-Screw Extrusion Processing
In TPE masterbatch processing, due to the unique properties of TPEs (temperature sensitivity, moisture absorption, high viscosity), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Problem 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Causes: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Premixing: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) Equipment: Worn screw mixing elements; blocked die head.
Solutions: (1) Optimize raw materials: Select fine-particle pigments (20-40 mesh), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 rpm, extend mixing time to 5-10 minit. (3) Adjust extrusion parameters: Increase screw speed (500-800 rpm for high-viscosity TPEs); increase extrusion temperature to ensure complete melting of TPE. (4) Maintain equipment: Replace worn screw elements; clean die head regularly.
5.2 Problem 2: TPE Degradation and Masterbatch Discoloration
Manifestation: Masterbatch discolors (yellowing, darkening), generates peculiar smell; TPE products have reduced elasticity and mechanical strength, even brittle fracture.
Causes: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (more than 3 minit) in the extruder. (3) Poor equipment cooling, local overheating of the barrel. (4) Raw materials: TPE has poor heat resistance; moisture content is too high (causing TPU hydrolysis).
Solutions: (1) Adjust temperature: Reduce mixing/homogenizing section temperature, control within TPE processing range; check temperature sensor accuracy. (2) Shorten residence time: Increase screw speed, reduce screw compression ratio. (3) Maintain cooling system: Clean cooling pipes, replace faulty cooling elements. (4) Optimize raw materials: Select high-temperature resistant TPE; dry raw materials thoroughly (moisture content ≤0.05% for TPU/TPA); add heat stabilizers.
5.3 Problem 3: High Wear of Screw and Barrel
Manifestation: Rapid wear of screw and barrel, reduced shear force and mixing capacity; masterbatch dispersibility decreases, equipment maintenance cost increases.
Causes: (1) Raw materials: High-hardness pigments/additives (tankou nwa kabòn, diyoksid Titàn); gwo gwosè patikil. (2) Extrusion parameters: Gwo vitès vis, fòs taye twòp; presyon ekstrizyon segondè. (3) Equipment: Vis/materyèl barik gen move rezistans mete.
Solutions: (1) Optimize raw materials: Chwazi ti patikil, pigman ki ba dite; kraze ak vannen matyè premyè; ajoute grès machin pou diminye friksyon. (2) Ajiste paramèt yo: Diminye vitès vis ak presyon ekstrizyon kòmsadwa. (3) Chwazi ekipman ki reziste ki wo: Chwazi seri HTS PLUS/SUPER/HTE Zhuoyue ak konpoze bimetalik oswa vis/barik lazè-rekouvèr..
5.4 Problem 4: Ti boul nan Masterbatch
Manifestation: Ti boul nan patikil masterbatch, afekte dansite pwodwi ak pwopriyete mekanik; Pwodwi TPE yo gen porositë ak domaj.
Causes: (1) Raw materials: Segondè kontni imidite (espesyalman TPU/TPA); sibstans temèt nan pigman / aditif. (2) Extrusion parameters: Ba tanperati extrusion, fonn enkonplè; ensifizan echapman vakyòm. (3) Premixing: Lè melanje nan melanj la pandan premelang.
Solutions: (1) Siye matyè premyè byen: Extend drying time, increase drying temperature. (2) Adjust extrusion parameters: Increase extrusion temperature; improve vacuum exhaust (vacuum degree ≥0.08MPa). (3) Optimize premixing: Reduce mixing speed appropriately to avoid air mixing; use a closed mixer.
5.5 Problem 5: Poor Processing Fluidity, Equipment Blockage
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); high pigment content (more than 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, fonn enkonplè; low screw speed, insufficient conveying capacity. (3) Equipment: Worn conveying elements; blocked die head.
Solutions: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Ajiste paramèt yo: Increase extrusion temperature; increase screw speed; replace die head with larger holes. (3) Maintain equipment: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Practical Application Cases of Zhuoyue Extruders in TPE Masterbatch Processing
Pou verifye avantaj pèfòmans extruders Zhuoyue nan pwosesis TPE masterbatch, seksyon sa a prezante plizyè ka pratik, ki kouvri diferan kategori TPE, production scales, and application fields, demontre solisyon yo vize bay Zhuoyue.
6.1 Ka 1: HTS SUPER Seri nan TPC Masterbatch Processing pou kawotchou otomobil
Background Kliyan: Yon gwo manifakti eleman otomobil nan Shanghai, Lachin, pwodui kawotchou TPC ki reziste wo-tanperati pou machin enèji nouvo. Kliyan an bezwen pwodwi TPC masterbatch (pigment content 60%, segondè-tanperati rezistan) ak kondisyon nan dispèsibilite ultra-segondè (pa gen okenn tach koulè), rezistans chalè (260℃), ak estabilite pakèt. Ekipman orijinal la te gen pwoblèm koupl ensifizan, kontwòl tanperati enstab, ak pòv dispèsibilite, ki pa t 'kapab satisfè kondisyon yo.
Solisyon: Zhuoyue rekòmande extruders seri HTS SUPER (vis dyamèt 75mm, koupl espesifik 18Nm / cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Premye, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Dezyèmman, the barrel is equipped with a double-layer jacket + forced cooling structure, avèk 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Third, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Anplis de sa, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect: Apre 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 mwa, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.
6.1 Ka 1: HTS SUPER Seri nan TPC Masterbatch Processing pou kawotchou otomobil
Background Kliyan:
Yon gwo manifakti eleman otomobil nan Shanghai, Lachin, pwodui kawotchou TPC ki reziste wo-tanperati pou machin enèji nouvo. Kliyan an bezwen pwodwi TPC masterbatch (pigment content 60%, segondè-tanperati rezistan) ak kondisyon nan dispèsibilite ultra-segondè (pa gen okenn tach koulè), rezistans chalè (260℃), ak estabilite pakèt. Ekipman orijinal la te gen pwoblèm koupl ensifizan, kontwòl tanperati enstab, ak pòv dispèsibilite, ki pa t 'kapab satisfè kondisyon yo.
Solisyon:
Zhuoyue rekòmande extruders seri HTS SUPER (vis dyamèt 75mm, koupl espesifik 18Nm / cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Premye, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Dezyèmman, the barrel is equipped with a double-layer jacket + forced cooling structure, avèk 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Third, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Anplis de sa, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect:
Apre 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 mwa, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.