Jalur Produksi Granulasi Tingkat Lanjut Filler Masterbatch dan Aplikasi Teknologi Ekstrusi

Dengan pesatnya perkembangan industri plastik global, permintaan produk plastik semakin hari semakin meningkat, dan persyaratan kinerja produk, pengendalian biaya dan perlindungan lingkungan juga menjadi semakin ketat. Masterbatch pengisi, sebagai aditif fungsional utama dalam pengolahan plastik, telah banyak digunakan di berbagai bidang produksi plastik karena kelebihannya dalam menekan biaya produksi, meningkatkan kinerja produk dan mengoptimalkan efisiensi pemrosesan. Kami berkomitmen untuk menyediakan lini produksi granulasi tingkat lanjut dan ekstruder berkinerja tinggi untuk berbagai jenis masterbatch pengisi, mengandalkan pengalaman yang kaya dalam penelitian dan pengembangan teknologi ekstrusi dan manufaktur, untuk memberikan sasaran, solusi pemrosesan yang efisien dan andal untuk produsen masterbatch pengisi, membantu perusahaan meningkatkan efisiensi produksi, memastikan kualitas produk, dan mendapatkan keunggulan kompetitif dalam persaingan pasar yang ketat.

Artikel ini akan fokus pada bidang filler masterbatch, menguraikan secara mendalam konsep-konsep dasar, klasifikasi, proses produksi masterbatch pengisi, peran inti teknologi ekstrusi dalam produksi granulasinya, keunggulan seri ekstruder kami dan adaptasi yang ditargetkan pada pemrosesan masterbatch pengisi, serta bidang aplikasi spesifik, metode penggunaan dan masalah umum serta solusi dalam produksi. Ini akan melengkapi parameter teknis terperinci, detail proses dan poin kesulitan industri untuk memperkaya konten, memenuhi persyaratan jumlah kata 3000-4000 kata-kata, dan memberikan referensi yang komprehensif dan profesional untuk perusahaan dan praktisi terkait di industri masterbatch pengisi.

1. Ikhtisar Industri Filler Masterbatch dan Karakteristik Produk

1.1 Situasi Saat Ini dan Tren Perkembangan Industri Filler Masterbatch

Dalam beberapa tahun terakhir, didorong oleh pesatnya perkembangan industri hilir seperti pengemasan, konstruksi, otomotif, elektronik dan kebutuhan sehari-hari, pasar masterbatch pengisi global telah menunjukkan tren pertumbuhan yang stabil. Filler masterbatch adalah sejenis material komposit yang dibuat dengan cara pencampuran, meleleh, ekstrusi dan granulasi bahan pengisi anorganik (seperti kalsium karbonat, talek, barium sulfat, dll.) dengan pembawa polimer (misalnya polietilen, polipropilena, polivinil klorida, dll.) dan bahan tambahan yang sesuai (seperti dispersan, kompatibel, pelumas, dll.) dalam proporsi tertentu. Fungsi intinya adalah untuk mengurangi biaya produksi produk plastik sekaligus meningkatkan atau mempertahankan kinerja dasar produk plastik.

Menurut statistik data yang relevan, ukuran pasar masterbatch pengisi global telah melampaui 20 miliar dolar AS, dan diperkirakan akan mempertahankan tingkat pertumbuhan sebesar 6%-9% dalam beberapa tahun ke depan. Diantaranya, kalsium karbonat (CaCO3) masterbatch pengisi adalah jenis produk yang paling banyak digunakan, terhitung lebih dari 60% dari total pasar masterbatch pengisi, diikuti oleh masterbatch pengisi bedak, barium sulfat (BaSO4) masterbatch pengisi dan masterbatch pengisi khusus lainnya. Kawasan Asia-Pasifik merupakan pasar produksi dan konsumsi masterbatch filler terbesar di dunia, terhitung lebih dari 50% dari pangsa pasar global, Hal ini terutama disebabkan oleh pesatnya perkembangan industri pengolahan plastik di Tiongkok, India dan negara-negara lain, besarnya permintaan untuk pengurangan biaya dan peningkatan kinerja produk plastik, dan peningkatan daya dukung industri secara berkelanjutan.

Tren perkembangan industri filler masterbatch terutama tercermin dalam empat aspek: Pertama, kinerja dan fungsionalitas tinggi. Dengan peningkatan persyaratan produk plastik hilir, masterbatch pengisi tidak lagi terbatas pada pengurangan biaya, tetapi secara bertahap berkembang menuju fungsionalisasi, seperti meningkatkan kekakuan, kekerasan, tahan panas, ketahanan cuaca dan sifat penghalang produk plastik, dan mengembangkan masterbatch pengisi fungsional khusus seperti penghambat api, antistatis dan antibakteri; Kedua, jumlah pengisian tinggi dan dispersibilitas yang baik. Di bawah premis untuk memastikan kinerja produk, meningkatkan jumlah pengisian bahan pengisi anorganik dapat semakin mengurangi biaya produksi, yang memberikan persyaratan lebih tinggi pada dispersibilitas masterbatch pengisi—dispersibilitas yang sangat baik dapat memastikan bahwa pengisi didistribusikan secara merata dalam matriks plastik, menghindari munculnya bintik-bintik putih, bintik hitam atau aglomerasi pada produk akhir; ketiga, perlindungan lingkungan dan polusi rendah. Dengan penguatan kebijakan perlindungan lingkungan global dan peningkatan kesadaran perlindungan lingkungan, produsen masterbatch pengisi secara bertahap mengadopsi bahan tambahan dan proses produksi yang ramah lingkungan, mengurangi emisi zat berbahaya, dan mengembangkan masterbatch pengisi yang dapat terurai untuk beradaptasi dengan tren perkembangan plastik ramah lingkungan; keempat, kecerdasan dan efisiensi peralatan produksi. Untuk memenuhi skala besar, kebutuhan produksi masterbatch pengisi yang berkelanjutan dan berkualitas tinggi, produsen terus-menerus memperkenalkan jalur produksi granulasi canggih dan sistem kontrol cerdas, meningkatkan efisiensi produksi, mengurangi biaya tenaga kerja dan memastikan stabilitas kualitas produk.

Dengan latar belakang ini, teknologi granulasi ekstrusi, sebagai teknologi inti produksi masterbatch pengisi, telah menjadi kunci untuk menentukan kualitas masterbatch pengisi dan daya saing perusahaan. Kinerja ekstruder secara langsung mempengaruhi dispersibilitas, bentuk partikel, indeks leleh dan indikator utama lainnya dari masterbatch pengisi. Jalur produksi ekstruder dan granulasi profesional kami untuk masterbatch pengisi dikembangkan sebagai respons terhadap karakteristik industri dan permintaan pasar, yang secara efektif dapat mengatasi masalah dalam pemrosesan masterbatch pengisi (seperti dispersibilitas yang buruk, ukuran partikel tidak rata, jumlah pengisian yang rendah, konsumsi energi yang tinggi, dll.) dan membantu perusahaan mencapai produksi berkualitas tinggi dan efisien.

1.2 Klasifikasi Filler Masterbatch dan Karakteristik Intinya

Masterbatch pengisi dapat dibagi menjadi beberapa jenis sesuai dengan jenis pengisinya, resin pembawa, bidang aplikasi dan jumlah pengisian. Setiap jenis masterbatch pengisi memiliki karakteristik unik dan skenario yang dapat diterapkan. Berikut ini adalah pengenalan rinci tentang klasifikasi umum dan karakteristik inti masterbatch pengisi:

1.2.1 Klasifikasi berdasarkan Jenis Pengisi:

Ini adalah metode klasifikasi paling umum untuk masterbatch pengisi. Menurut jenis bahan pengisi anorganik, itu terutama dapat dibagi menjadi kalsium karbonat (CaCO3) masterbatch pengisi, masterbatch pengisi bedak, barium sulfat (BaSO4) masterbatch pengisi, dan masterbatch pengisi khusus lainnya (seperti masterbatch pengisi kaolin, masterbatch pengisi karbon hitam, masterbatch pengisi serat kaca, dll.).

• Kalsium Karbonat (CaCO3) Masterbatch Pengisi: Ini adalah masterbatch pengisi yang paling banyak digunakan dengan biaya terendah. Pengisinya terutama kalsium karbonat ringan atau kalsium karbonat berat. Kalsium karbonat ringan memiliki ukuran partikel yang halus, dispersibilitas yang baik dan tingkat keputihan yang tinggi, yang cocok untuk produk plastik dengan persyaratan penampilan dan kehalusan yang tinggi (seperti film plastik, produk cetakan injeksi); kalsium karbonat berat memiliki kekerasan yang tinggi, ketahanan aus yang baik dan harga murah, yang cocok untuk produk plastik dengan persyaratan kekakuan dan pengendalian biaya yang tinggi (seperti tas anyaman, sabuk pengepakan, pipa, dll.). Masterbatch pengisi kalsium karbonat tidak hanya dapat mengurangi biaya produksi, tetapi juga meningkatkan kekakuan, ketahanan panas dan stabilitas dimensi produk plastik, dan memiliki efek pelumas tertentu, yang dapat meningkatkan fluiditas pengolahan plastik.
• Masterbatch Pengisi Talk: Bahan pengisinya berupa bedak talk dengan struktur berlapis. Bedak talk memiliki sifat mekanik yang baik, tahan panas dan stabilitas kimia. Masterbatch pengisi bedak terutama digunakan dalam polipropilena (hal) produk plastik, yang secara signifikan dapat meningkatkan kekakuan, suhu distorsi panas dan kekuatan benturan produk PP, dan banyak digunakan pada suku cadang otomotif, cangkang peralatan rumah tangga, pipa plastik dan bidang lain yang membutuhkan kinerja tinggi.
• Barium Sulfat (BaSO4) Masterbatch Pengisi: Pengisinya adalah bubuk barium sulfat, yang mempunyai tingkat keputihan yang tinggi, transparansi yang baik, kelembaman kimia dan ketahanan terhadap radiasi. Masterbatch pengisi barium sulfat cocok untuk produk plastik dengan persyaratan transparansi yang tinggi, keputihan dan stabilitas kimia (seperti film plastik, botol plastik, produk plastik medis, dll.), dan juga dapat digunakan pada produk plastik tahan radiasi (seperti peralatan pelindung medis, aksesoris pembangkit listrik tenaga nuklir, dll.).

1.2.2 Klasifikasi berdasarkan Resin Pembawa:

Menurut jenis resin pembawa yang digunakan, masterbatch pengisi dapat dibagi menjadi polietilen (PE) masterbatch pengisi, polipropilena (hal) masterbatch pengisi, polivinil klorida (PVC) masterbatch pengisi, polietilen tereftalat (PELIHARAAN) masterbatch pengisi, dll.. Pemilihan resin pembawa terutama ditentukan oleh jenis produk plastik hilir. Misalnya, Masterbatch pengisi PE cocok untuk produk plastik PE (seperti film plastik, tas, pipa); Masterbatch pengisi PP cocok untuk produk plastik PP (seperti tas anyaman, bagian cetakan injeksi, suku cadang otomotif); Masterbatch pengisi PVC cocok untuk produk plastik PVC (seperti pipa PVC, profil, lembaran).

1.2.3 Klasifikasi berdasarkan Bidang Aplikasi:

Sesuai dengan bidang penerapan produk plastik hilir, masterbatch pengisi dapat dibagi menjadi masterbatch pengisi tingkat film, masterbatch pengisi tingkat injeksi, masterbatch pengisi tingkat ekstrusi, masterbatch pengisi tingkat cetakan tiup, dll.. Masterbatch pengisi tingkat film memerlukan dispersibilitas yang baik, kehalusan tinggi dan tidak ada kotoran, untuk memastikan bahwa film yang ditiup tidak memiliki bintik putih, bintik hitam atau lubang kecil, dan menjaga transparansi dan ketangguhan yang baik; Masterbatch pengisi tingkat injeksi memerlukan fluiditas yang baik dan ukuran partikel yang seragam, untuk beradaptasi dengan proses pencetakan injeksi yang cepat dan memastikan penampilan dan keakuratan dimensi produk injeksi; masterbatch pengisi tingkat ekstrusi memerlukan stabilitas termal dan sifat mekanik yang baik, untuk beradaptasi dengan proses ekstrusi pipa bersuhu tinggi dan bertekanan tinggi, profil dan produk lainnya.

1.2.4 Klasifikasi berdasarkan Jumlah Pengisian:

Menurut jumlah pengisian bahan pengisi anorganik, masterbatch pengisi dapat dibagi menjadi masterbatch dengan pengisian rendah (jumlah pengisian 30%-50%), masterbatch dengan pengisian sedang (jumlah pengisian 50%-70%) dan masterbatch dengan pengisian tinggi (jumlah pengisian 70% dan di atasnya). Jumlah pengisian ditentukan sesuai dengan persyaratan kinerja produk hilir dan kapasitas pemrosesan peralatan. Masterbatch dengan pengisian tinggi memiliki efek pengurangan biaya yang lebih jelas, namun memiliki persyaratan yang lebih tinggi dalam hal dispersibilitas bahan pengisi dan kinerja ekstruder—hanya ekstruder berperforma tinggi yang dapat memastikan pencampuran dan peleburan bahan pengisi tinggi secara seragam, menghindari aglomerasi dan fluiditas pemrosesan yang buruk.

Perlu dicatat bahwa indikator kinerja inti masterbatch pengisi terutama mencakup dispersibilitas, keseragaman ukuran partikel, indeks leleh, putihnya (untuk produk berwarna terang) dan kompatibilitas dengan resin pembawa. Diantaranya, dispersibilitas adalah indikator yang paling penting—dispersibilitas yang buruk akan menyebabkan distribusi bahan pengisi yang tidak merata pada produk plastik, mengakibatkan cacat seperti bercak putih, bintik hitam, aglomerasi dan produk rapuh, yang sangat mempengaruhi penampilan dan kinerja produk plastik. Karena itu, pemilihan peralatan ekstrusi canggih dan teknologi pemrosesan ilmiah sangat penting untuk memastikan dispersibilitas dan kualitas masterbatch pengisi secara keseluruhan.

2. Teknologi Inti Produksi Filler Masterbatch: Teknologi Granulasi Ekstrusi

Teknologi granulasi ekstrusi adalah teknologi inti produksi masterbatch pengisi, yang mengintegrasikan pencampuran, meleleh, pencukuran, dispersi dan granulasi. Ini memiliki keunggulan efisiensi produksi yang tinggi, kualitas produk yang baik, kemampuan beradaptasi yang kuat terhadap bahan baku dan jangkauan aplikasi yang luas. Dalam produksi masterbatch pengisi, teknologi granulasi ekstrusi terutama digunakan untuk mewujudkan dispersi seragam pengisi anorganik dalam pembawa polimer, melelehkan dan membuat campuran menjadi plastis, lalu ekstrusi dan granulasi untuk membentuk masterbatch pengisi granular dengan ukuran seragam, fluiditas yang baik dan kinerja yang stabil. Kualitas granulasi ekstrusi secara langsung menentukan indikator kinerja utama masterbatch pengisi, misalnya dispersibilitas, ukuran partikel dan indeks leleh.

2.1 Karakteristik Bahan Baku Filler Masterbatch dan Persyaratan Peralatan Ekstrusi

Bahan baku masterbatch pengisi terutama mencakup tiga bagian: pengisi anorganik (seperti CaCO3, talek, BaSO4), pembawa polimer (seperti PE, hal, PVC) dan bahan tambahan (seperti dispersan, kompatibel, pelumas, antioksidan, dll.). Karakteristik bahan baku tersebut sangat berbeda, which puts forward special requirements for extrusion equipment:

Pertama, the inorganic fillers have high hardness, poor compatibility with polymer carriers, and are easy to agglomerate. Most inorganic fillers (seperti CaCO3, talek) are hydrophilic, while polymer carriers are hydrophobic, which leads to poor compatibility between fillers and carriers. If the mixing and shearing are insufficient, the fillers will agglomerate, which cannot be uniformly dispersed in the carrier, resulting in poor quality of filler masterbatch. Selain itu, the high hardness of inorganic fillers will cause serious wear to the screw and barrel of the extruder during the extrusion process, which requires the screw and barrel of the extruder to have extremely high wear resistance.

Kedua, the mixture of filler masterbatch has high viscosity and poor fluidity. Penambahan bahan pengisi anorganik dalam jumlah besar akan meningkatkan viskositas campuran secara signifikan, mengurangi fluiditas pemrosesan, dan mengharuskan ekstruder memiliki kapasitas pengangkutan dan gaya geser yang kuat untuk memastikan kelancaran proses peleburan, pencampuran dan ekstrusi.

Ketiga, kisaran suhu pemrosesan sempit. Resin pembawa yang berbeda memiliki titik leleh dan stabilitas termal yang berbeda. Misalnya, titik leleh PE adalah 100-130℃, titik leleh PP adalah 160-170℃, dan PVC mudah terurai pada suhu tinggi (di atas 160℃). Karena itu, peralatan ekstrusi harus memiliki kapasitas kontrol suhu yang tepat untuk memastikan bahwa campuran meleleh sepenuhnya tanpa dekomposisi termal, dan untuk menghindari penguraian bahan tambahan dan penurunan kinerja produk.

Based on the above characteristics, single-screw extruders are not suitable for large-scale and high-quality production of filler masterbatch. Because the single-screw extruder has a narrow shear range, poor pumping capacity and no self-cleaning effect. When processing high-viscosity and high-filler mixtures, it is easy to cause material accumulation, blockage and uneven mixing in the extruder barrel, resulting in poor dispersibility of filler masterbatch, uneven particle size and unstable product quality. Selain itu, the single-screw extruder has high energy consumption when processing high-filler materials, and the screw and barrel are severely worn, which increases the production cost and equipment maintenance cost of enterprises.

Ekstruder sekrup kembar, di sisi lain, memiliki keunggulan yang jelas dalam produksi masterbatch pengisi dan telah menjadi peralatan utama untuk granulasi ekstrusi masterbatch pengisi. Ekstruder sekrup kembar memiliki rentang geser yang lebih luas, efek pemompaan yang lebih efektif dan efek pembersihan diri, Yang secara efektif dapat memecahkan masalah kompatibilitas yang buruk, aglomerasi yang mudah dan fluiditas yang buruk dari bahan baku masterbatch pengisi. Jalinan dan putaran sekrup kembar dapat menghasilkan gaya geser dan gaya pengadukan yang kuat, yang sepenuhnya dapat memecah gumpalan pengisi anorganik, membuat bahan pengisi terdispersi secara merata dalam pembawa polimer, dan memastikan dispersibilitas dan stabilitas produk. Selain itu, ekstruder sekrup kembar memiliki akurasi kontrol suhu yang baik, kemampuan beradaptasi yang kuat terhadap bahan baku, dan dapat beradaptasi dengan pemrosesan berbagai jenis, different filling amounts of filler masterbatch, and has high production efficiency and low energy consumption.

2.2 Working Principle of Filler Masterbatch Extrusion Granulation

The extrusion granulation process of filler masterbatch is a complex physical and chemical process, which involves the interaction of multiple factors such as temperature, tekanan, shear force and time. Prinsip kerja spesifik dan alur proses adalah sebagai berikut:

Pertama, raw material pretreatment. The raw materials of filler masterbatch (pengisi anorganik, resin pembawa, aditif) need to be pretreated to ensure the quality of the final product. The specific steps include: 1) Drying treatment: Inorganic fillers (seperti CaCO3, talek) are usually hydrophilic and contain a certain amount of moisture. Jika kadar air terlalu tinggi, it will affect the mixing effect and dispersibility of the materials, and even cause bubbles in the extruded masterbatch. Karena itu, the fillers need to be dried in a dryer (such as a hot air dryer, a vacuum dryer) to reduce the moisture content to below 0.5%. 2) Crushing and sieving: The carrier resin (seperti PE, hal) is crushed into small particles or powder with a particle size of 20-40 jaring, which is conducive to uniform mixing with fillers and additives. Inorganic fillers are also sieved to remove impurities and large particles, ensuring the fineness and uniformity of fillers. 3) Pencampuran awal: Sesuai dengan rumus perbandingannya, the dried fillers, carrier resin particles and additives (dispersan, kompatibel, pelumas, dll.) are put into a high-speed mixer for premixing. Kecepatan pencampuran umumnya 800-1200 rpm, and the mixing time is 5-10 menit. The purpose of premixing is to make the additives evenly adhere to the surface of fillers and carrier resin, improve the compatibility between fillers and carrier, and lay a foundation for subsequent extrusion mixing. The dispersant is a key additive in premixing, which can form a protective film on the surface of the filler, reduce the surface energy of the filler, prevent the filler from agglomerating, and improve the dispersibility of the filler in the carrier resin.

Kedua, feeding and conveying. Campuran yang telah dicampur sebelumnya dikirim ke hopper pengumpan ekstruder sekrup kembar melalui pengumpan sekrup atau pengumpan sabuk. The feeding speed needs to be uniform and stable, which is matched with the screw speed and extrusion speed of the extruder, to ensure that the materials enter the extrusion cavity stably and avoid material accumulation or insufficient feeding. Perangkat pengumpanan ekstruder biasanya dilengkapi dengan fungsi pengaturan kecepatan konversi frekuensi, which can adjust the feeding speed according to the actual production situation.

Ketiga, meleleh, pencampuran dan pemotongan. Bahan yang memasuki rongga ekstrusi ekstruder sekrup kembar didorong ke depan secara terus menerus oleh sekrup yang berputar. Rongga ekstrusi terdiri dari sekrup dan laras, dan volume rongga ekstrusi secara bertahap berkurang sepanjang arah sumbu. Saat sekrup berputar, bahan-bahan tersebut secara bertahap dikompresi di bawah aksi sekrup dan laras, dan tekanan di rongga ekstrusi secara bertahap meningkat (generally 3-15MPa). Pada saat yang sama, material terkena gaya geser dan gaya gesekan yang kuat yang dihasilkan oleh gerakan relatif antara sekrup dan laras, serta di antara penerbangan sekrup.

The shear force and friction force can fully break the agglomerates of inorganic fillers, make the fillers uniformly dispersed in the melted carrier resin, and promote the fusion and compatibility between the fillers and the carrier. Gaya gesekan juga dapat menghasilkan sejumlah panas, yang dikombinasikan dengan pemanasan eksternal laras (pemanas listrik atau pemanas uap) to make the carrier resin gradually melt and plasticize. Laras ekstruder biasanya dibagi menjadi 3-6 bagian pengatur suhu (bagian makan, bagian leleh, bagian pencampuran, bagian homogenisasi, dll.), and the temperature of each section is precisely controlled according to the type of carrier resin and filler. Misalnya, when processing PE carrier filler masterbatch, the temperature of the feeding section is 80-100℃, the melting section is 120-140℃, the mixing section is 140-150℃, and the homogenizing section is 130-140℃; when processing PP carrier filler masterbatch, the temperature of each section is 20-30℃ higher than that of PE carrier.

Keempat, extrusion and shaping. Sepenuhnya meleleh, bahan yang tercampur dan tersebar didorong ke kepala cetakan ekstruder dengan sekrup. The die head is equipped with multiple die holes (the number and size of die holes are determined according to the particle size of the masterbatch), and the material is extruded from the die holes at a high speed to form continuous strips of uniform thickness. Suhu kepala cetakan sedikit lebih rendah dibandingkan suhu bagian homogenisasi, yang dapat mencegah bahan membusuk karena suhu berlebihan dan memastikan efek pembentukan strip.

Kelima, pendinginan dan pemotongan. Strip yang diekstrusi dikirim ke perangkat pendingin (seperti tangki air, konveyor berpendingin udara) untuk pendinginan cepat. Suhu pendinginan umumnya 20-30℃, dan waktu pendinginannya adalah 2-5 menit. Pendinginan yang cepat dapat membuat strip mengeras dengan cepat, menjaga bentuk dan ukuran strip, dan menghindari deformasi. Setelah dingin, strip dikirim ke granulator untuk dipotong. Granulator dilengkapi dengan pisau putar, yang dapat memotong strip menjadi masterbatch pengisi granular dengan ukuran seragam (ukuran partikel umumnya 2-5mm, yang dapat disesuaikan dengan kebutuhan pelanggan). The speed of the rotary knife is matched with the conveying speed of the strips to ensure that the particle size of the masterbatch is uniform.

Sixth, penyaringan dan pengemasan. The cut granular filler masterbatch is sent to a vibrating screen for screening, which can remove unqualified particles (misalnya terlalu besar, partikel yang terlalu kecil atau diaglomerasi) and ensure the uniformity of the product. The qualified masterbatch is then sent to an automatic packaging machine for packaging. The packaging specifications can be adjusted according to customer needs (such as 25kg/bag, 50kg/bag), and the packaging should be sealed and moisture-proof to prevent the masterbatch from absorbing moisture and affecting the quality. After packaging, the products are stored in a dry, gudang sejuk dan berventilasi.

2.3 Key Factors Affecting Filler Masterbatch Extrusion Granulation Effect

The effect of extrusion granulation directly affects the quality of filler masterbatch. There are many factors affecting the granulation effect, terutama termasuk karakteristik bahan baku, rasio rumus, efek pencampuran awal, parameter ekstrusi dan struktur kepala mati. Mastering these key factors and making scientific adjustments can ensure the stability of the granulation effect and the consistency of product quality.

2.3.1 Karakteristik Bahan Baku:

Jenisnya, ukuran partikel, moisture content and purity of raw materials have a great impact on the granulation effect. Misalnya, the particle size of inorganic fillers directly affects the dispersibility and fineness of the masterbatch. The finer the particle size of the filler (umumnya 800-2000 jaring), the better the dispersibility, but the higher the cost and the easier it is to agglomerate; the coarser the particle size, the lower the cost, but the dispersibility is poor, which will affect the appearance and performance of the masterbatch. The moisture content of raw materials (especially fillers) should be controlled below 0.5%; jika kadar air terlalu tinggi, it will cause bubbles in the masterbatch, affect the density and mechanical properties of the product. Kemurnian bahan baku juga sangat penting; pengotor pada bahan mentah (such as stones, logam, debu) will not only affect the quality of the masterbatch, tetapi juga memakai sekrup dan laras ekstruder, dan bahkan menyebabkan penyumbatan peralatan.

2.3.2 Rasio Rumus:

The formula ratio of filler masterbatch (the ratio of filler, carrier resin and additives) is the key to determining the performance and cost of the product. The filling amount of the filler should be determined according to the performance requirements of the downstream product and the processing capacity of the equipment. Too high filling amount will lead to poor dispersibility, low toughness and poor processing fluidity of the masterbatch; too low filling amount will reduce the cost reduction effect. Jenis dan dosis bahan tambahan juga harus disesuaikan secara wajar. Misalnya, the dispersant dosage is generally 1%-3% of the filler dosage; too little dispersant will lead to poor dispersibility of the filler, and too much dispersant will affect the compatibility between the masterbatch and the downstream plastic products, and reduce the mechanical properties of the products. The compatibilizer is used to improve the compatibility between the filler and the carrier resin; the dosage is generally 0.5%-2%, which can significantly improve the dispersibility and mechanical properties of the masterbatch. The lubricant is used to reduce the friction between the materials and the screw, barrel and die head, improve the processing fluidity, and prevent the materials from sticking to the equipment; the dosage is generally 0.3%-1%.

2.3.3 Efek Pencampuran Awal:

Premixing is the foundation of extrusion granulation. The uniformity of premixing directly affects the dispersibility of the filler in the carrier resin. Jika premixing tidak merata, the additives cannot be uniformly adhered to the surface of the filler and carrier, resulting in local agglomeration of the filler, uneven mixing of the materials during extrusion, and poor quality of the masterbatch. To ensure the premixing effect, it is necessary to control the mixing speed, waktu pencampuran dan suhu pencampuran. Kecepatan pencampuran umumnya 800-1200 rpm, waktu pencampuran adalah 5-10 menit, dan suhu pencampuran dikontrol pada 40-60℃ (appropriate temperature can improve the adhesion of additives and promote uniform mixing).

2.3.4 Extrusion Parameters:

Extrusion parameters are the most important factors affecting the granulation effect, mainly including screw speed, extrusion temperature and extrusion pressure.

• Kecepatan Sekrup: The screw speed generally ranges from 150 ke 600 rpm. The higher the screw speed, the greater the shear force and friction force received by the materials, the better the mixing and dispersing effect of the filler, and the higher the production efficiency. Namun, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete melting of the carrier resin, insufficient mixing of the materials, and uneven particle size of the masterbatch; if the screw speed is too low, the shear force and friction force are insufficient, the filler cannot be fully dispersed, dan efisiensi produksinya rendah. The screw speed should be adjusted according to the filling amount and type of filler masterbatch—for high-filling masterbatch, a higher screw speed is needed to ensure sufficient shearing and mixing.
• Suhu Ekstrusi: The extrusion temperature is divided into multiple sections (bagian makan, bagian leleh, bagian pencampuran, bagian homogenisasi, bagian kepala mati), and the temperature of each section needs to be precisely controlled according to the type of carrier resin and filler. Suhu bagian pemberian makan lebih rendah (slightly higher than the melting point of the carrier resin), yang terutama untuk mencegah bahan menggumpal dan memastikan kelancaran pengumpanan; suhu bagian lelehnya sedang, which is mainly to promote the melting and plasticization of the carrier resin; suhu bagian pencampuran lebih tinggi, yang terutama untuk meningkatkan efek geser dan pencampuran, and promote the uniform dispersion of the filler; suhu bagian homogenisasi sedikit lebih rendah dari bagian pencampuran, yang terutama untuk memastikan suhu dan viskositas bahan yang seragam, dan menghindari dekomposisi termal; suhu bagian kepala cetakan sedikit lebih rendah dari bagian homogenisasi, which is to ensure the shaping effect of the strips.
• Tekanan Ekstrusi: The extrusion pressure is generally 3-15MPa. Tekanan dalam rongga ekstrusi terutama ditentukan oleh rasio kompresi sekrup, ukuran lubang cetakan dan kecepatan sekrup. Semakin tinggi tekanan ekstrusi, the better the mixing and dispersing effect of the materials, and the denser the masterbatch particles. Namun, jika tekanannya terlalu tinggi, itu akan meningkatkan konsumsi energi dan keausan peralatan, dan bahkan menyebabkan kepala cetakan tersumbat; jika tekanannya terlalu rendah, bahan tidak dapat dikompresi dan dicampur sepenuhnya, the masterbatch particles are loose, and the performance is unstable.

2.3.5 Struktur Kepala Mati:

The die head structure mainly includes the number, shape and size of die holes. The shape of the die hole determines the cross-sectional shape of the extruded strips (such as circular, square), and the size of the die hole determines the initial diameter of the strips and the final particle size of the masterbatch. The smaller the die hole size, the greater the extrusion pressure, the better the mixing and dispersing effect, but the production capacity will be reduced; the larger the die hole size, the lower the extrusion pressure, the lower the production efficiency, but the particle size of the masterbatch is larger. The number of die holes affects the production capacity; the more the number of die holes, the higher the production capacity, but it is necessary to ensure that the pressure distribution is uniform, so as to avoid uneven thickness of the strips and uneven particle size of the masterbatch.

3. Our Extruders: Advantages and Product Series for Filler Masterbatch Production

We have long been engaged in the research, development and production of high-performance extruders and granulation production lines, and have accumulated rich experience in the field of filler masterbatch processing. According to the characteristics of filler masterbatch raw materials (high hardness, poor compatibility, viskositas tinggi) dan persyaratan pemrosesan (good dispersibility, uniform particle size, high filling amount), we have developed a series of twin-screw extruders specially suitable for filler masterbatch production. Our extruders have the advantages of high wear resistance, strong shearing force, kontrol suhu yang tepat, stable performance and low operating cost, which can meet the processing needs of various types, different filling amounts of filler masterbatch (CaCO3, talek, BaSO4, dll.), and help enterprises improve production efficiency, ensure product quality and reduce production costs.

3.1 Main Advantages of Our Extruders for Filler Masterbatch Production

3.1.1 Ketahanan Aus yang Tinggi, Umur Panjang:

Aiming at the problem that inorganic fillers (seperti CaCO3, talek) have high hardness and easy to wear the screw and barrel, we adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components of the extruder. The screw and barrel are made of imported wear-resistant alloy steel (seperti 38CrMoAlA), and after nitriding treatment or bimetallic composite treatment, the surface hardness can reach ≥65 HRC, yang memiliki ketahanan aus dan ketahanan korosi yang sangat kuat, and can effectively resist the wear caused by the friction between the high-hardness filler and the components. This greatly extends the service life of the screw and barrel, reduces the frequency of component replacement, and reduces the maintenance cost of the equipment. Selain itu, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, issue a detailed wear report, and put forward targeted replacement and maintenance suggestions, ensuring that customers only replace components when necessary, avoiding unnecessary waste.

3.1.2 Strong Shearing and Mixing Capacity, Excellent Dispersibility:

The key to filler masterbatch production is to ensure the uniform dispersion of fillers. Our twin-screw extruders adopt an intermeshing co-rotating twin-screw structure, dengan pitch sekrup yang masuk akal, desain rasio timbal dan kompresi. Jalinan dan putaran sekrup kembar dapat menghasilkan gaya geser dan gaya pengadukan yang kuat, yang sepenuhnya dapat memecah gumpalan pengisi anorganik, make the fillers uniformly dispersed in the melted carrier resin, and ensure the dispersibility of the masterbatch. The screw is designed with a modular structure, and different screw elements (seperti menyampaikan elemen, elemen pencampuran, elemen geser) can be freely combined according to the type and filling amount of filler masterbatch, so as to adjust the shear force and mixing effect, and achieve the best processing effect. Misalnya, when processing high-filling CaCO3 masterbatch, we can configure more shearing elements to enhance the shearing effect and ensure the uniform dispersion of the filler; when processing talc masterbatch which requires high mixing uniformity, we can configure more mixing elements to improve the mixing effect.

3.1.3 Kontrol Suhu Yang Tepat, Stable Performance:

Our extruders adopt advanced intelligent temperature control systems, yang dapat mewujudkan kontrol yang tepat terhadap suhu setiap bagian laras dan kepala cetakan. The temperature control accuracy can reach ±1℃, which can ensure that the carrier resin is fully melted without thermal decomposition, and the additives are not decomposed, ensuring the stability of the product performance. Sistem pengatur suhu dilengkapi dengan fungsi pemantauan dan alarm waktu nyata. If the temperature of any section exceeds the set range, sistem akan mengeluarkan peringatan alarm tepat waktu, dan bahkan secara otomatis menyesuaikan daya pemanas atau mematikan peralatan jika perlu, untuk menghindari kegagalan peralatan dan masalah kualitas produk. Selain itu, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time. If the pressure is too high or too low, the system will adjust the screw speed or feeding speed automatically, ensuring the stability of the extrusion process.

3.1.4 Rentang Aplikasi yang Luas, Strong Flexibility:

Our extruder series can adapt to the processing needs of various types of filler masterbatch, including CaCO3 filler masterbatch, masterbatch pengisi bedak, BaSO4 filler masterbatch, dan masterbatch pengisi khusus lainnya. The filling amount can be adjusted from 30% ke 80%, which can meet the different cost and performance requirements of customers. The modular design of the extruder (baut, barel, mati kepala, dll.) makes the replacement of components more convenient and quick. When customers need to adjust the product type or filling amount, they only need to replace the corresponding components, tanpa mengganti seluruh peralatan, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. Selain itu, our extruders can also be matched with different auxiliary equipment (such as high-speed mixers, pengering, pendingin, granulator, screening machines, packaging machines) to form a complete automatic granulation production line, realizing continuous production from raw material pretreatment to product packaging.

3.1.5 Efisiensi Produksi Tinggi, Low Energy Consumption:

Our twin-screw extruders have high production efficiency, which is much higher than that of single-screw extruders. The production capacity of our extruders ranges from 100kg/h to 3000kg/h, which can meet the production needs of different scales of enterprises (small, medium and large). The high-torque drive system and optimized screw design of the extruder can effectively improve the conveying capacity and plasticization efficiency of materials, reducing the residence time of materials in the extrusion cavity and improving production efficiency. Pada saat yang sama, the extruder adopts an energy-saving design, such as a high-efficiency motor, a heat recovery device, dll., which can reduce the unit energy consumption by 15%-25% dibandingkan dengan ekstruder biasa, helping enterprises reduce production costs.

3.1.6 Easy Operation and Maintenance:

Our extruders adopt a PLC intelligent control system and a touch screen operation interface, which is simple and intuitive, easy to operate. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of filler masterbatch, they only need to call the corresponding formula and parameters, without repeated debugging, which saves time and improves production efficiency. The modular design of the equipment makes the maintenance more convenient. Sekrup, barel, die head dan komponen lainnya dapat dibongkar dan dirakit dengan cepat, Yang mengurangi waktu pemeliharaan dan intensitas tenaga kerja. Tim layanan purna jual kami akan menyediakan instalasi profesional, layanan commissioning dan pelatihan untuk pelanggan, memastikan bahwa pelanggan dapat menggunakan peralatan dengan lancar.

3.2 Our Extruder Product Series and Their Adaptation to Filler Masterbatch

In order to meet the diverse production needs of filler masterbatch enterprises of different scales and product types, we have launched a full range of twin-screw extruder products, termasuk seri HTS BASIC, Seri HTS PLUS, Seri HTS SUPER, Seri ZTE dan seri HTE. Setiap seri memiliki karakteristik dan skenario adaptasi yang ditargetkan, yang dapat dipilih oleh pelanggan sesuai dengan skala produksinya sendiri, jenis produk, anggaran dan faktor lainnya.

3.2.1 HTS BASIC Series Extruders: Cost-Effective Choice for Medium and Small-Scale Enterprises.

The HTS BASIC series extruders are a cost-effective product series independently developed by us, which are specially designed for filler masterbatch processing enterprises with medium and small production scales or initial entry into the industry. This series of extruders uses medium-torque gearboxes from leading European manufacturers, which have the advantages of stable performance, kebisingan rendah, high efficiency and long service life. The medium-torque design can meet the processing needs of most common filler masterbatch (such as low-to-medium filling CaCO3 masterbatch, PE/PP carrier masterbatch), and at the same time, it has a reasonable price, which can help enterprises reduce the initial investment cost.

In terms of structural design, the HTS BASIC series extruders adopt a twin-screw parallel structure, with a screw diameter ranging from 30mm to 65mm, and a compression ratio of 4～8, which can be adjusted according to the type and filling amount of filler 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. The extruder is equipped with a PLC control system and a touch screen operation interface, which can realize automatic feeding, kontrol suhu otomatis, automatic pressure control and automatic cutting, and is simple and easy to operate.

The production capacity of the HTS BASIC series extruders ranges from 100kg/h to 500kg/h, which is suitable for medium and small-sized filler masterbatch processing enterprises that mainly produce common filler masterbatch (such as CaCO3 masterbatch for plastic films, woven bags). One of the biggest advantages of this series is that it can provide flexible options through different configuration combinations. Customers can choose different screw elements, mati kepala, feeding devices, drying devices and post-processing equipment according to their own product types, production capacity and budget, so as to form a production line suitable for their own needs.

3.2.2 HTS PLUS Series Extruders: High-Performance Choice for Engineering Plastic and Filler Masterbatch.

Ekstruder seri HTS PLUS mengadopsi gearbox torsi tinggi yang dikembangkan dan diproduksi secara independen oleh kami, which have stronger torque and load-bearing capacity than the HTS BASIC series. This series of extruders is mainly used for the processing of high-performance filler masterbatch, such as high-filling CaCO3 masterbatch (filling amount ≥60%), talc masterbatch, BaSO4 masterbatch, and filler masterbatch for engineering plastics (seperti PP, PA, komputer).

Ekstruder seri HTS PLUS memiliki diameter sekrup mulai dari 65mm hingga 110mm, rasio kompresi 5～10, and a screw speed range of 200～600 rpm. Sekrup dan laras mengadopsi perlakuan komposit bimetalik, yang memiliki ketahanan aus dan ketahanan korosi yang lebih tinggi, and can adapt to the processing of high-hardness fillers (such as heavy calcium carbonate, talek) and high-filling materials. The extruder is equipped with an advanced intelligent control system, yang dapat mewujudkan kontrol yang tepat terhadap parameter ekstrusi dan pemantauan data produksi secara real-time. The production capacity ranges from 500kg/h to 2000kg/h, which is suitable for medium and large-scale filler masterbatch enterprises that pursue high performance and high filling amount.

Selain itu, the HTS PLUS series extruders have a stronger mixing and shearing capacity, which can fully disperse the high-filling fillers in the carrier resin, ensuring the dispersibility and stability of the masterbatch. It is especially suitable for the production of filler masterbatch used in automotive parts, cangkang peralatan rumah tangga, high-grade plastic films and other high-performance plastic products.

3.2.3 Ekstruder Seri SUPER HTS: Top-End Choice for High-End Filler Masterbatch.

Ekstruder seri HTS SUPER mengadopsi perangkat transmisi torsi ultra-tinggi terbaru yang kami kembangkan secara independen. Mengincar karakteristik torsi tinggi dan kecepatan tinggi dari seri ini, desain struktural setiap komponen utama ekstruder telah dioptimalkan sepenuhnya, yang merupakan seri ekstruder kelas atas kami, mewakili tingkat lanjutan pengembangan ekstruder Tiongkok. This series of extruders is mainly used for the processing of high-end, special and high-performance filler masterbatch, such as high-filling BaSO4 masterbatch (for medical plastics, high-grade films), glass fiber reinforced filler masterbatch, flame-retardant filler masterbatch, and filler masterbatch for special engineering plastics.

The HTS SUPER series extruders have a screw diameter ranging from 80mm to 130mm, a compression ratio of 6～12, and a screw speed range of 250～700 rpm. The screw and barrel adopt imported wear-resistant alloy steel and laser cladding technology, which has extremely high wear resistance and corrosion resistance, and can adapt to the processing of various special fillers (such as glass fiber, carbon black, barium sulfat) and high-filling materials (filling amount ≥70%). The extruder is equipped with an intelligent PLC + cloud touch screen control system, which can realize remote parameter adjustment, pemantauan data produksi dan pemeliharaan prediktif peralatan, mewujudkan manajemen produksi yang cerdas.

The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for large-scale high-end filler masterbatch enterprises that pursue high efficiency, high performance and intelligence. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end filler masterbatch.

3.2.4 ZTE Series Extruders: Cost-Effective Choice for General Filler Masterbatch.

The ZTE series extruders have excellent cost performance, and their designed parameters are suitable for most filler masterbatch materials (such as low-to-medium filling CaCO3 masterbatch, PE/PP carrier masterbatch). This series of extruders adopts a simplified and optimized structure, which reduces the production cost while ensuring the basic performance, and is suitable for small and medium-sized enterprises with limited budget and general product requirements.

The ZTE series extruders have a screw diameter ranging from 30mm to 50mm, a compression ratio of 4～7, and a screw speed range of 150～500 rpm. The production capacity ranges from 50kg/h to 300kg/h, which is suitable for small-scale production of common filler masterbatch. The extruder is easy to operate and maintain, and the after-sales service cost is low, which is a cost-effective choice for small enterprises and individual workshops.

3.2.5 HTE Series Extruders: High-Efficiency and Energy-Saving Choice for Large-Scale Production.

The HTE series extruders combine high performance and high cost performance, and are designed to reduce energy consumption with higher output. This series of extruders adopts a high-efficiency motor, an optimized screw structure and a heat recovery device, which can reduce the unit energy consumption by 20%～25% compared with ordinary extruders, and has higher production efficiency.

The HTE series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～9, and a screw speed range of 200～600 rpm. The production capacity ranges from 500kg/h to 2500kg/h, which is suitable for large-scale continuous production of common filler masterbatch (such as CaCO3 masterbatch, talc masterbatch). The extruder is equipped with a precise temperature control system and a stable pressure control system, which can ensure the uniformity and stability of the product quality. It is suitable for large-scale filler masterbatch enterprises that pursue high efficiency, energy saving and cost control.

3.3 Selection Suggestions for Filler Masterbatch Extruders

When selecting extruders for filler masterbatch production, enterprises need to comprehensively consider their own production needs, product types, jumlah pengisian, budget and other factors to ensure that the selected equipment can meet the actual production needs and bring maximum economic benefits. The following are some specific selection suggestions:

3.3.1 Determine the Extruder Series According to Product Type and Filling Amount:

Different types and filling amounts of filler masterbatch have different requirements for extruders. Misalnya, if the enterprise mainly produces low-to-medium filling CaCO3 masterbatch (filling amount ≤60%) and common PE/PP carrier masterbatch, the HTS BASIC series or ZTE series extruders are suitable; if the enterprise produces high-filling masterbatch (filling amount ≥60%), talc masterbatch or BaSO4 masterbatch, the HTS PLUS series extruders are recommended; if the enterprise produces high-end, special filler masterbatch (such as glass fiber reinforced masterbatch, masterbatch tahan api), the HTS SUPER series extruders are the best choice; if the enterprise pursues large-scale, energy-saving and high-efficiency production, the HTE series extruders are suitable.

3.3.2 Determine the Production Capacity of the Extruder According to the Production Scale:

Enterprises should select the extruder with appropriate production capacity according to their own production scale and market demand. If the production scale is small (daily output less than 1 ton), the ZTE series or HTS BASIC series extruders with production capacity of 50-300kg/h are suitable; if the production scale is medium (daily output 1-5 ton), the HTS BASIC series or HTS PLUS series extruders with production capacity of 300-1000kg/h are suitable; if the production scale is large (daily output more than 5 ton), it is recommended to choose the HTS PLUS series, HTS SUPER series or HTE series extruders with production capacity of more than 1000kg/h.

3.3.3 Consider the Wear Resistance of the Equipment:

The wear resistance of the screw and barrel is a key factor affecting the service life and operating cost of the extruder. For enterprises that process high-hardness fillers (such as heavy calcium carbonate, talek) or high-filling masterbatch, it is necessary to select extruders with high wear resistance (such as screw and barrel with bimetallic composite treatment or laser cladding treatment), such as the HTS PLUS series and HTS SUPER series, to reduce the frequency of component replacement and maintenance cost.

3.3.4 Consider the Cost-Effectiveness of the Equipment:

Enterprises should not only pay attention to the initial investment cost of the equipment, but also consider the long-term operating cost (seperti konsumsi energi, maintenance cost, spare parts cost). Misalnya, although the initial investment of the HTS SUPER series extruders is high, their wear resistance, stability and production efficiency are better, and the long-term operating cost is lower; the ZTE series extruders have a low initial investment, but their production capacity and wear resistance are limited, which is suitable for enterprises with limited budget and small-scale production.

3.3.5 Pay Attention to the After-Sales Service of the Equipment:

The after-sales service of the equipment is crucial for the normal operation of the production line. Enterprises should select manufacturers with perfect after-sales service systems, which can provide professional installation, komisioning, pelatihan, maintenance and spare parts supply services. We have a professional after-sales service team, which can respond to customer needs in a timely manner (provide solutions within 24 jam) and send technicians to the site for maintenance if necessary, ensuring the normal operation of the production line.

3.3.6 Consider the Flexibility and Expandability of the Equipment:

With the changes of market demand, enterprises may need to adjust their product types and filling amounts. Karena itu, when selecting extruders, enterprises should consider the flexibility and expandability of the equipment. Our extruders adopt a modular design, which can be freely combined and upgraded according to the needs of enterprises, improving the flexibility and expandability of the equipment, and reducing the cost of equipment transformation.

4. Application Fields and Usage Methods of Filler Masterbatch

Masterbatch pengisi, sebagai aditif fungsional utama dalam pengolahan plastik, has a wide range of application fields, covering various fields such as plastic packaging, konstruksi, otomotif, elektronik, daily necessities and agriculture. Its core role is to reduce the production cost of plastic products while improving or maintaining the basic performance of plastic products. The following will introduce the specific application fields and usage methods of filler masterbatch in detail:

4.1 Application Fields of Filler Masterbatch

Filler masterbatch can be used in the processing of various plastic products, and different types of filler masterbatch have different application focuses. The main application fields are as follows:

4.1.1 Plastic Packaging Industry:

This is the largest application field of filler masterbatch, terhitung lebih dari 50% of the total application amount. Filler masterbatch is widely used in the production of plastic films, kantong plastik, woven bags, sabuk pengepakan, packaging containers and other packaging products.

• Plastic Films: Including plastic thin films, thick films, stretch films, greenhouse films, dll.. The filler masterbatch used for plastic films is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires good dispersibility, kehalusan tinggi dan tidak ada kotoran, untuk memastikan bahwa film yang ditiup tidak memiliki bintik putih, bintik hitam atau lubang kecil, and maintains good transparency, toughness and tensile strength. Adding an appropriate amount of filler masterbatch can not only reduce the production cost of the film, tetapi juga meningkatkan kekakuan, heat resistance and dimensional stability of the film, and reduce the shrinkage rate of the film. Misalnya, in the production of plastic shopping bags, menambahkan 1%-3% of CaCO3 filler masterbatch can reduce the cost by 5%-10% without affecting the toughness and load-bearing capacity of the bags.
• Plastic Bags: Including shopping bags, vest bags, garbage bags, food packaging bags, dll.. The filler masterbatch used for plastic bags is mainly heavy calcium carbonate filler masterbatch, which has low cost and good wear resistance. Adding 2%-5% of filler masterbatch can reduce the cost and improve the rigidity and wear resistance of the bags. For garbage bags, adding an appropriate amount of filler masterbatch can also improve the toughness and tear resistance of the bags, making them not easy to break.
• Woven Bags and Packaging Belts: Woven bags are widely used in the packaging of grain, fertilizer, semen, chemical products and other goods; packaging belts are used for the bundling of goods. The filler masterbatch used for woven bags and packaging belts is mainly heavy calcium carbonate filler masterbatch or talc filler masterbatch, which requires high rigidity and wear resistance. Adding 5%-10% of filler masterbatch can improve the rigidity, tensile strength and wear resistance of woven bags and packaging belts, reduce the cost, and extend the service life of the products.
• Packaging Containers: Including plastic bottles, plastic barrels, plastic boxes, dll.. The filler masterbatch used for packaging containers is mainly barium sulfate filler masterbatch or light calcium carbonate filler masterbatch, which requires good transparency and chemical stability. Adding an appropriate amount of filler masterbatch can reduce the cost and improve the rigidity and impact strength of the containers.

4.1.2 Plastic Construction Industry:

Filler masterbatch is widely used in the production of plastic pipes, plastic profiles, plastic sheets, plastic tiles and other construction products.

• Plastic Pipes: Including PVC pipes, pipa PE, PP pipes, dll., which are used for water supply, drainase, gas transmission, cable protection and other fields. The filler masterbatch used for plastic pipes is mainly calcium carbonate filler masterbatch or talc filler masterbatch, which requires high rigidity, heat resistance and pressure resistance. Adding 5%-15% of filler masterbatch can improve the rigidity, heat distortion temperature and pressure resistance of the pipes, reduce the cost, and prevent the pipes from deforming under high temperature and pressure.
• Plastic Profiles: Including PVC profiles for doors and windows, plastic decorative profiles, dll.. The filler masterbatch used for plastic profiles is mainly calcium carbonate filler masterbatch, which requires good weather resistance and impact strength. Adding 5%-10% of filler masterbatch can improve the rigidity, weather resistance and impact strength of the profiles, reduce the cost, and ensure the service life of the profiles in outdoor environments.
• Plastic Sheets: Including PVC sheets, lembaran PE, lembaran PP, dll., which are used for indoor decoration, kemasan, waterproofing and other fields. The filler masterbatch used for plastic sheets is mainly calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires good flatness and toughness. Adding 3%-8% of filler masterbatch can reduce the cost and improve the rigidity and toughness of the sheets.

4.1.3 Plastic Injection Molding Industry:

Filler masterbatch is widely used in the production of various injection molding products, such as plastic daily necessities, plastic toys, plastic parts, plastic shells and so on.

• Plastic Daily Necessities: Including plastic bowls, plastic plates, plastic cups, plastic baskets, plastic buckets and other daily necessities. The filler masterbatch used for these products is mainly calcium carbonate filler masterbatch, which has low cost and good safety. Adding 2%-5% of filler masterbatch can reduce the cost and improve the rigidity and impact strength of the products, making them not easy to break.
• Plastic Toys: Including various plastic toys for children. The filler masterbatch used for plastic toys is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires high safety, non-toxicity, good dispersibility and no odor, in line with international toy safety standards (such as EN 71, ASTM F963). The particle size of the filler should be fine (di atas 1250 jaring) to avoid scratching children’s skin and ensure the smoothness of the toy surface. Adding 1%-3% of light calcium carbonate filler masterbatch can reduce the production cost of toys without affecting the toughness and colorability of the toys; barium sulfate filler masterbatch is suitable for transparent or semi-transparent plastic toys, which can improve the transparency and surface gloss of the toys, making them more beautiful.
• Plastic Parts and Shells: Including plastic parts for home appliances, automotive interior parts, electronic product shells, dll.. The filler masterbatch used for these products is mainly talc filler masterbatch or glass fiber reinforced filler masterbatch, which requires high rigidity, heat resistance and impact strength. Misalnya, in the production of automotive interior parts (such as instrument panels, panel pintu), menambahkan 5%-8% of talc filler masterbatch can improve the rigidity and heat distortion temperature of the parts, reduce the shrinkage rate, and make the parts not easy to deform under high temperature environment in the car; in the production of electronic product shells (such as mobile phone shells, router shells), menambahkan 3%-5% of glass fiber reinforced filler masterbatch can improve the impact strength and dimensional accuracy of the shells, enhancing the durability of the products.

4.1.4 Automotive Plastic Industry:

With the trend of lightweight and energy saving in the automotive industry, plastic materials are widely used in automotive manufacturing, and filler masterbatch, as an important functional additive, plays a key role in reducing costs and improving performance. The application of filler masterbatch in the automotive plastic industry is mainly concentrated in automotive interior parts, exterior parts and functional parts.

• Automotive Interior Parts: Including instrument panels, panel pintu, seat cushions, armrests, dll.. These parts have high requirements on rigidity, tahan panas, low odor and environmental protection. Talc filler masterbatch and calcium carbonate filler masterbatch are the most commonly used products. Talc filler masterbatch can significantly improve the rigidity and heat resistance of polypropylene (hal) bahan, making the interior parts have good dimensional stability; calcium carbonate filler masterbatch has the advantages of low cost and good processing fluidity, which can reduce the production cost of interior parts. Misalnya, menambahkan 6%-10% of talc filler masterbatch to PP instrument panels can improve the heat distortion temperature by 15-25℃, and reduce the production cost by 8%-12%.
• Automotive Exterior Parts: Including bumpers, fenders, door handles, dll.. These parts are exposed to the outdoor environment for a long time, so they have high requirements on weather resistance, impact strength and UV resistance. The filler masterbatch used for exterior parts is mainly talc filler masterbatch or barium sulfate filler masterbatch, which is usually compounded with weather-resistant additives. Adding 4%-7% of talc filler masterbatch can improve the impact strength and rigidity of the exterior parts, enhance their resistance to external impact; barium sulfate filler masterbatch can improve the weather resistance and color retention of the exterior parts, making them not easy to fade and aging under the action of sunlight and rain.
• Automotive Functional Parts: Including air intake pipes, cooling system parts, battery casings, dll.. These parts have high requirements on heat resistance, chemical resistance and mechanical properties. The filler masterbatch used for functional parts is mainly glass fiber reinforced filler masterbatch or special mineral filler masterbatch. Misalnya, menambahkan 10%-15% of glass fiber reinforced filler masterbatch to the air intake pipe can improve the heat resistance and pressure resistance of the pipe, ensuring its normal operation under high temperature and high pressure; adding barium sulfate filler masterbatch to the battery casing can improve the radiation resistance and chemical stability of the casing, ensuring the safety of the battery.

4.1.5 Electronic and Electrical Plastic Industry:

Electronic and electrical products have high requirements on the flame retardancy, isolasi, dimensional accuracy and heat resistance of plastic materials. Filler masterbatch is widely used in the production of plastic parts of electronic and electrical products, seperti kawat dan selubung kabel, selubung transformator, rumah konektor, dll..

• Selubung Kawat dan Kabel: Selubung plastik dari kabel dan kabel harus memiliki insulasi yang baik, ketahanan aus, tahan api dan tahan cuaca. Masterbatch pengisi yang digunakan untuk selubung kawat dan kabel terutama adalah masterbatch pengisi kalsium karbonat atau masterbatch pengisi tahan api. Adding 3%-6% masterbatch pengisi kalsium karbonat dapat meningkatkan ketahanan aus dan kekakuan selubung, reduce the cost; flame-retardant filler masterbatch (seperti magnesium hidroksida, masterbatch pengisi aluminium hidroksida) dapat meningkatkan ketahanan api pada sarungnya, mencegah penyebaran api jika terjadi korsleting, memastikan keamanan sirkuit.
• Casing Transformator dan Rumah Konektor: Bagian-bagian ini harus memiliki insulasi yang baik, tahan panas dan akurasi dimensi. The filler masterbatch used is mainly talc filler masterbatch or glass fiber reinforced filler masterbatch. Adding 5%-8% of talc filler masterbatch can improve the heat resistance and dimensional stability of the parts, making them not easy to deform under long-term high temperature operation; glass fiber reinforced filler masterbatch can improve the impact strength and insulation of the parts, ensuring the normal operation of electronic and electrical products.

4.1.6 Agricultural Plastic Industry:

Agricultural plastic products (such as greenhouse films, mulch films, irrigation pipes, fertilizer bags) have the characteristics of large dosage, low cost and harsh use environment. Filler masterbatch can effectively reduce the production cost of agricultural plastic products and improve their service life.

• Greenhouse Films and Mulch Films: These products need to have good transparency, kekerasan, weather resistance and anti-aging properties. The filler masterbatch used is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch. Adding 1%-4% of light calcium carbonate filler masterbatch can reduce the cost of the film, improve its toughness and anti-aging properties, and extend the service life of the film; barium sulfate filler masterbatch can improve the transparency and light transmittance of the film, which is conducive to the photosynthesis of crops.
• Irrigation Pipes and Fertilizer Bags: Irrigation pipes need to have good pressure resistance and wear resistance; fertilizer bags need to have good toughness and wear resistance. The filler masterbatch used is mainly heavy calcium carbonate filler masterbatch or talc filler masterbatch. Adding 5%-10% of heavy calcium carbonate filler masterbatch can improve the pressure resistance and wear resistance of irrigation pipes, reduce the cost; menambahkan 3%-6% of talc filler masterbatch can improve the toughness and wear resistance of fertilizer bags, making them not easy to break during transportation and use.

4.2 Usage Methods of Filler Masterbatch

The correct use of filler masterbatch is crucial to ensure the quality of plastic products and give full play to the performance of the masterbatch. The usage methods of filler masterbatch mainly include mixing ratio, mixing method, processing parameter adjustment and precautions. The specific operation points are as follows:

4.2.1 Determination of Mixing Ratio:

The mixing ratio of filler masterbatch and base plastic (carrier resin of plastic products) is mainly determined by the filling amount of the masterbatch, the performance requirements of the final product and the processing capacity of the equipment. The general mixing ratio range is 1%-20%, and the specific ratio can be adjusted according to the following principles:

• For plastic products with low performance requirements and high cost control requirements (such as ordinary plastic bags, garbage bags), the mixing ratio can be 5%-20% (using low-to-medium filling calcium carbonate filler masterbatch);
• For plastic products with medium performance requirements (seperti film plastik, ordinary injection molding parts), the mixing ratio can be 2%-8% (using medium filling calcium carbonate, talc or barium sulfate filler masterbatch);
• For plastic products with high performance requirements (seperti suku cadang otomotif, electronic product shells, high-grade films), the mixing ratio can be 1%-5% (using high-filling, high-performance talc, barium sulfate or glass fiber reinforced filler masterbatch);
• For transparent or semi-transparent plastic products (such as plastic bottles, transparent films), the mixing ratio should be controlled at 1%-3%, and barium sulfate or light calcium carbonate filler masterbatch with fine particle size (di atas 1250 jaring) should be selected to avoid affecting the transparency of the products.

4.2.2 Mixing Method:

The mixing of filler masterbatch and base plastic should ensure uniformity, so as to avoid local agglomeration of the masterbatch and affect the performance of the final product. The common mixing methods include dry mixing and wet mixing, among which dry mixing is the most widely used in industrial production.

• Dry Mixing: This method is suitable for most filler masterbatch and base plastic (seperti PE, hal, PVC). The specific steps are: Pertama, dry the base plastic particles and filler masterbatch to remove moisture (the moisture content should be controlled below 0.5%); then, put the base plastic particles and filler masterbatch into a high-speed mixer according to the determined mixing ratio, and add an appropriate amount of lubricant (if necessary) to mix uniformly. Kecepatan pencampuran umumnya 500-800 rpm, and the mixing time is 3-5 menit. Setelah pencampuran, the mixture can be directly sent to the extruder or injection molding machine for processing. The advantages of dry mixing are simple operation, efisiensi tinggi, low cost and no pollution to the product.
• Wet Mixing: This method is suitable for filler masterbatch with poor dispersibility or base plastic with high viscosity (such as PVC paste). The specific steps are: mix the filler masterbatch with an appropriate amount of solvent (such as plasticizer, solvent oil) to form a paste, then add the paste to the base plastic and stir uniformly, and finally remove the solvent through heating or drying. The advantages of wet mixing are good mixing effect and uniform dispersion of the masterbatch; the disadvantages are complex operation, high cost, and easy residual solvent affecting the product quality. Karena itu, wet mixing is only used in special cases.

4.2.3 Adjustment of Processing Parameters:

When adding filler masterbatch to plastic processing, the processing parameters (such as temperature, tekanan, kecepatan sekrup) need to be properly adjusted according to the type and filling amount of the masterbatch to ensure the smooth progress of processing and the quality of the final product.

• Temperature Adjustment: The addition of filler masterbatch will increase the viscosity of the mixture, so the processing temperature needs to be appropriately increased by 5-15℃ compared with the processing temperature of pure base plastic. Misalnya, when processing PE plastic with calcium carbonate filler masterbatch, the processing temperature can be increased by 5-10℃; when processing PP plastic with talc filler masterbatch, the processing temperature can be increased by 10-15℃. It should be noted that the temperature should not be too high to avoid thermal decomposition of the base plastic and additives.
• Pressure Adjustment: The addition of filler masterbatch will increase the resistance during processing, so the processing pressure (tekanan ekstrusi, injection pressure) needs to be appropriately increased by 10%-20%. Misalnya, when extruding plastic pipes with filler masterbatch, the extrusion pressure can be increased by 10%-15% to ensure the compactness and dimensional accuracy of the pipes; when injecting plastic parts with filler masterbatch, the injection pressure can be increased by 15%-20% to avoid defects such as insufficient filling and shrinkage.
• Screw Speed Adjustment: The screw speed should be adjusted according to the type and filling amount of the masterbatch. For high-filling masterbatch or masterbatch with poor dispersibility, the screw speed can be appropriately increased by 10%-15% to enhance the shear force and mixing effect, ensuring the uniform dispersion of the filler; for low-filling masterbatch or masterbatch with good dispersibility, the screw speed can be kept unchanged or slightly reduced to reduce energy consumption and wear of equipment.

4.2.4 Precautions for Use:

In the process of using filler masterbatch, the following precautions should be paid attention to to avoid affecting the processing effect and product quality:

• Moisture Prevention: Masterbatch pengisi (especially calcium carbonate, talc masterbatch) is easy to absorb moisture, which will cause bubbles, pinholes and other defects in the final product. Karena itu, the masterbatch should be stored in a dry, gudang sejuk dan berventilasi, and should be dried before use (the drying temperature is 80-100℃, and the drying time is 2-4 jam).
• Kesesuaian: The carrier resin of the filler masterbatch should be consistent with or compatible with the base plastic of the product. Misalnya, PE filler masterbatch should be used with PE base plastic, and PP filler masterbatch should be used with PP base plastic. If the carrier resin is incompatible with the base plastic, it will affect the compatibility between the masterbatch and the base plastic, resulting in poor dispersibility and reduced product performance.
• Uniform Mixing: The filler masterbatch and base plastic must be mixed uniformly. If the mixing is uneven, local agglomeration of the masterbatch will occur, mengakibatkan cacat seperti bercak putih, black spots and agglomeration in the product, affecting the appearance and performance of the product.
• Dosage Control: The dosage of filler masterbatch should not exceed the maximum filling amount applicable to the equipment and product performance. Excessive dosage will lead to poor dispersibility, low toughness, poor processing fluidity and other problems of the product; insufficient dosage will not achieve the effect of cost reduction and performance improvement.
• Storage Period: The filler masterbatch has a certain storage period (umumnya 6-12 bulan). If the storage period is exceeded, the masterbatch may absorb moisture, agglomerate or the performance of additives may degrade, affecting the use effect. Karena itu, the masterbatch should be used within the storage period.

5. Common Problems and Solutions in Filler Masterbatch Production

In the production process of filler masterbatch, due to the influence of raw materials, formula, processing equipment and processing parameters, various problems may occur, which affect the quality and production efficiency of the masterbatch. This chapter will summarize the common problems in filler masterbatch production, analyze their causes, and put forward targeted solutions to help enterprises solve production pain points and improve product quality stability.

5.1 Common Quality Problems of Filler Masterbatch and Their Solutions

5.1.1 Poor Dispersibility of Filler Masterbatch:

This is the most common quality problem in filler masterbatch production. The main manifestations are: the masterbatch has agglomeration, and after mixing with the base plastic, white spots, bintik hitam atau aglomerasi muncul di produk akhir, yang mempengaruhi penampilan dan kinerja produk.

Penyebab: 1) Ukuran partikel pengisi anorganik terlalu besar atau tidak rata, dan aglomerat tidak pecah selama pencampuran awal; 2) Dosis dispersan tidak mencukupi atau jenis dispersan tidak sesuai, yang tidak dapat secara efektif mencegah aglomerasi pengisi; 3) Efek pencampuran awal buruk, dan pengisi, resin pembawa dan aditif tidak tercampur secara merata; 4) Kekuatan geser ekstruder tidak mencukupi, dan gumpalan pengisi tidak dapat dipecah sepenuhnya selama ekstrusi; 5) Suhu pemrosesan terlalu rendah, dan resin pembawa belum meleleh sepenuhnya, yang mempengaruhi dispersi bahan pengisi.

Solusi: 1) Pilih bahan pengisi anorganik dengan ukuran partikel halus dan seragam (umumnya 800-2000 jaring), and sieve the fillers before use to remove large particles and agglomerates; 2) Increase the dosage of dispersant appropriately (within the range of 1%-3% of the filler dosage) or replace with a dispersant compatible with the filler and carrier resin; 3) Optimize the premixing process, increase the mixing speed (800-1200 rpm) and mixing time (5-10 menit), and control the mixing temperature at 40-60℃ to improve the premixing uniformity; 4) Adjust the screw structure of the extruder, increase the number of shearing elements, or increase the screw speed to enhance the shear force; 5) Appropriately increase the processing temperature of the extruder to ensure that the carrier resin is fully melted, which is conducive to the dispersion of the filler.

5.1.2 Uneven Particle Size of Filler Masterbatch:

The main manifestations are: the particle size of the masterbatch varies greatly, some particles are too large, some are too small, and there are more powdery materials, which affects the fluidity of the masterbatch and the uniformity of mixing with the base plastic.

Penyebab: 1) The size of the die hole of the extruder die head is uneven or blocked; 2) The extrusion speed and the cutting speed of the granulator are not matched; 3) The cooling effect is poor, and the strips are not fully solidified before cutting, resulting in uneven cutting; 4) The viscosity of the mixture is uneven, and the extrusion speed of the strips is inconsistent.

Solusi: 1) Clean the die head regularly, check and replace the die plate with uneven die holes, ensure that the size of each die hole is consistent; 2) Adjust the extrusion speed and the cutting speed of the granulator to make them matched (the cutting speed should be slightly higher than the extrusion speed of the strips); 3) Optimize the cooling process, increase the cooling water flow or extend the cooling time, ensure that the strips are fully solidified (the surface temperature of the strips after cooling is 20-30℃); 4) Adjust the formula ratio and processing parameters to ensure the uniform viscosity of the mixture, and avoid the inconsistency of the extrusion speed of the strips.

5.1.3 Low Melting Index of Filler Masterbatch

The main manifestations are: the fluidity of the masterbatch is poor, it is difficult to mix with the base plastic during processing, and the processing efficiency is low, which even leads to equipment blockage.

Penyebab:

• The filling amount of the filler is too high, which increases the viscosity of the masterbatch and reduces the fluidity;
• The type of carrier resin is inappropriate (the melting index of the carrier resin is too low);
• Suhu pemrosesan terlalu rendah, dan resin pembawa belum meleleh sepenuhnya;
• The dosage of lubricant is insufficient, which increases the friction between the materials and affects the fluidity.

Solusi:

• Reduce the filling amount of the filler appropriately, or select a filler with better dispersibility to improve the fluidity;
• Replace the carrier resin with a higher melting index (Misalnya, use PE carrier resin with a melting index of 2-5g/10min for PE filler masterbatch);
• Appropriately increase the processing temperature of the extruder to ensure that the carrier resin is fully melted, improving the fluidity of the masterbatch;
• Increase the dosage of lubricant appropriately (within the range of 0.3%-1%), reduce the friction between the materials, and improve the fluidity.

5.1.4 Yellowing of Filler Masterbatch

The main manifestations are: the color of the masterbatch turns yellow, which affects the appearance of the final plastic product (especially light-colored products).

Penyebab:

• The thermal stability of the carrier resin is poor, and thermal decomposition occurs at high processing temperatures;
• The additives (seperti dispersan, pelumas) are decomposed at high temperatures, producing yellow substances;
• The processing temperature is too high, leading to the oxidation and yellowing of the masterbatch;
• The filler contains impurities (such as iron oxide), which causes the masterbatch to turn yellow.

Solusi:

• Select carrier resin with good thermal stability (such as adding antioxidants to the carrier resin);
• Replace additives with good thermal stability, avoid using additives that are easy to decompose at high temperatures;
• Reduce the processing temperature appropriately, avoid the oxidation and decomposition of the masterbatch;
• Screen the filler before use, remove impurities, and select fillers with high purity (such as calcium carbonate with a whiteness of ≥93).

5.1.5 High Moisture Content of Filler Masterbatch

The main manifestations are: gelembung, pinholes and other defects appear in the final plastic product after the masterbatch is mixed with the base plastic.

Penyebab:

• The filler is not dried thoroughly, and the moisture content exceeds 0.5%;
• The carrier resin or additives contain moisture;
• The masterbatch absorbs moisture during storage (stored in a humid environment);
• The premixing process is carried out in a humid environment, and the materials absorb moisture.

Solusi:

• Extend the drying time of the filler (drying temperature 80-100℃, drying time 3-5 jam), and detect the moisture content of the filler to ensure that it is below 0.5%;
• Dry the carrier resin and additives before use to remove moisture;
• Store the masterbatch in a dry, gudang sejuk dan berventilasi, and seal the packaging to prevent moisture absorption;
• Carry out the premixing process in a dry environment, and avoid the materials absorbing moisture from the air.

5.2 Common Production Equipment Problems and Their Solutions

5.2.1 Extruder Blockage

This is a common equipment problem in filler masterbatch production, which mainly occurs in the feeding section, melting section or die head of the extruder. The main manifestations are: the extrusion speed decreases sharply, the extrusion pressure rises rapidly, and even the equipment stops running.

Penyebab:

• The moisture content of the materials is too high, and the materials caking during extrusion;
• Suhu pemrosesan terlalu rendah, dan resin pembawa belum meleleh sepenuhnya, which accumulates in the extruder barrel;
• The materials contain impurities (such as stones, logam), which block the screw or die head;
• The screw speed is too low, and the materials cannot be pushed forward smoothly, resulting in accumulation;
• The die head is not cleaned regularly, and the residual materials block the die holes.

Solusi:

• Stop the machine immediately, memutus aliran listrik, and dry the materials thoroughly before restarting;
• Increase the processing temperature of the extruder, and wait for the materials in the barrel to be fully melted before continuing to extrude;
• Disassemble the extruder, remove the impurities blocking the screw or die head, and screen the materials before use to remove impurities;
• Increase the screw speed appropriately to ensure that the materials are pushed forward smoothly;
• Clean the die head regularly (after each production batch) to remove residual materials and avoid die hole blockage.

5.2.2 Severe Wear of Extruder Screw and Barrel

The main manifestations are: the shear force and extrusion pressure of the extruder decrease, the dispersibility of the masterbatch becomes poor, the production efficiency decreases, and the screw and barrel have obvious wear marks.

Penyebab:

• The filler has high hardness (such as heavy calcium carbonate, talek) and long-term friction with the screw and barrel;
• The materials contain impurities (seperti logam, batu), which accelerate the wear of the screw and barrel;
• Suhu pemrosesan terlalu rendah, and the materials have high viscosity, which increases the friction between the materials and the screw, barel;
• The screw and barrel are made of materials with poor wear resistance.

Solusi:

• Select extruders with high wear resistance (such as screw and barrel with bimetallic composite treatment or laser cladding treatment), such as our HTS PLUS series and HTS SUPER series extruders;
• Screen the materials before use to remove impurities, and select fillers with appropriate hardness;
• Appropriately increase the processing temperature to reduce the viscosity of the materials and reduce friction;
• Regularly check the wear degree of the screw and barrel, and replace the worn components in time;
• Add an appropriate amount of lubricant to the materials to reduce the friction between the materials and the screw, barel.

5.2.4 Unstable Temperature Control of Extruder

The main manifestations are: the temperature of each section of the extruder fluctuates greatly (exceeding ±1℃), resulting in uneven melting of the materials, poor dispersibility of the masterbatch, dan kualitas produk yang tidak stabil.

Penyebab:

• The temperature control system of the extruder is faulty (such as temperature sensor damage, heating ring failure);
• The cooling system of the extruder is abnormal (such as insufficient cooling water flow, cooling fan failure);
• The processing environment temperature fluctuates greatly, affecting the temperature control of the extruder;
• The heating power of the extruder is insufficient or uneven.

Solusi:

• Check the temperature control system regularly, replace the damaged temperature sensor and heating ring, and calibrate the temperature control instrument;
• Check the cooling system, ensure sufficient cooling water flow, and repair the faulty cooling fan;
• Control the processing environment temperature (keep it at 20-30℃), avoid large temperature fluctuations;
• Increase the heating power of the extruder appropriately, or check the heating circuit to ensure uniform heating of each section.

6. Conclusion and Outlook

Masterbatch pengisi, as a key functional additive in the plastic processing industry, plays an irreplaceable role in reducing production costs, meningkatkan kinerja produk dan mengoptimalkan efisiensi pemrosesan. With the rapid development of the global plastic industry and the continuous upgrading of downstream product requirements, the filler masterbatch industry is moving towards high performance, fungsionalisasi, high filling amount, perlindungan lingkungan dan intelijen. Extrusion granulation technology, sebagai teknologi inti produksi masterbatch pengisi, directly determines the quality and competitiveness of the masterbatch. The performance of extruders is the key to ensuring the stable production of high-quality filler masterbatch.

We have developed a full range of twin-screw extruder products (Seri HTS DASAR, Seri HTS PLUS, Seri HTS SUPER, seri ZTE, seri HTE) according to the characteristics of filler masterbatch raw materials and processing requirements. Our extruders have the advantages of high wear resistance, strong shearing and mixing capacity, kontrol suhu yang tepat, wide application range, high production efficiency and low energy consumption, which can meet the processing needs of various types and different filling amounts of filler masterbatch. By providing targeted extruder products and professional processing solutions, we help filler masterbatch manufacturers solve production pain points, improve production efficiency, memastikan kualitas produk, dan mendapatkan keunggulan kompetitif dalam persaingan pasar yang ketat.

Looking forward to the future, with the continuous advancement of science and technology and the increasingly strict environmental protection policies, the filler masterbatch industry will face new opportunities and challenges. On the one hand, the demand for high-performance, functional and environmental protection filler masterbatch (such as degradable filler masterbatch, flame-retardant and antistatic filler masterbatch) will continue to grow, which will put higher requirements on extrusion technology and equipment performance; di sisi lain, the intelligence and automation level of production equipment will continue to improve, and intelligent granulation production lines integrating raw material pretreatment, extrusion granulation, screening packaging and data monitoring will become the development trend.

We will continue to focus on the research and development of extrusion technology and equipment, keep up with the development trend of the filler masterbatch industry, continuously optimize product performance, develop more high-performance, energy-saving and intelligent extruders and granulation production lines, and provide more professional and comprehensive solutions for filler masterbatch manufacturers. Pada saat yang sama, we will strengthen cooperation with upstream and downstream enterprises in the industry, promote the technological progress and high-quality development of the filler masterbatch industry, and make greater contributions to the sustainable development of the global plastic industry.