Filler Masterbatch Advanced Granulation Production Lines na ngwa teknụzụ Extrusion

Site na mmepe ngwa ngwa nke ụlọ ọrụ plastik zuru ụwa ọnụ, ọchịchọ maka ngwaahịa plastik na-abawanye kwa ụbọchị, na ihe achọrọ maka ịrụ ọrụ ngwaahịa, njikwa ọnụ ahịa na nchekwa gburugburu ebe obibi na-aghọwanye nke siri ike. Filler masterbatch, dị ka isi ihe mgbakwunye na-arụ ọrụ na nhazi plastik, ejirila ya mee ihe n'ọtụtụ ebe dị iche iche nke mmepụta plastik n'ihi uru ya nke ibelata ọnụ ahịa mmepụta, na-emeziwanye arụmọrụ ngwaahịa na ịkwalite arụmọrụ nhazi. Anyị na-agba mbọ ịnye ahịrị mmepụta granulation dị elu na extruders dị elu maka ụdị dị iche iche nke Masterbatch., ịdabere na ahụmịhe bara ụba na nyocha teknụzụ extrusion na mmepe na nrụpụta, inye ezubere iche, Ngwọta nhazi nke ọma na nke a pụrụ ịdabere na ya maka ndị na-emepụta ihe nchịkwa masterbatch, na-enyere ụlọ ọrụ aka imeziwanye mmepụta mmepụta ihe, hụ na ngwaahịa dị mma, ma nweta uru asọmpi na asọmpi ahịa dị egwu.

Edemede a ga-elekwasị anya na ubi nke filler masterbatch, n'ime omimi na-akọwapụta echiche ndị bụ isi, nhazi ọkwa, usoro mmepụta nke filler masterbatch, isi ọrụ nke extrusion technology na ya granulation mmepụta, Uru nke usoro extruder anyị na mmegharị ha ezubere maka nhazi nhazi masterbatch, yana mpaghara ngwa ndị akọwapụtara, ụzọ ojiji na nsogbu nkịtị na ngwọta na mmepụta. Ọ ga-agbakwunyere paramita teknụzụ zuru ezu, nkọwa usoro na ihe mgbu ụlọ ọrụ na-atụ aka ime ka ọdịnaya dịkwuo mma, zute ihe a chọrọ n'ọnụ okwu 3000-4000 okwu, ma nye nkọwa zuru oke na ọkachamara maka ụlọ ọrụ na ndị na-eme ihe na ụlọ ọrụ Masterbatch filler.

1. Nchịkọta nke ụlọ ọrụ Filler Masterbatch na njirimara ngwaahịa

1.1 Ọnọdụ ugbu a na mmepe mmepe nke ụlọ ọrụ Filler Masterbatch

N'afọ adịbeghị anya, na-akwalite site na mmepe ngwa ngwa nke ụlọ ọrụ ndị dị n'okpuru ala dị ka nkwakọ ngwaahịa, ihe owuwu, ụgbọ ala, ngwá electronic na ihe ndị dị mkpa kwa ụbọchị, ahịa Masterbatch filler zuru ụwa ọnụ egosila usoro uto na-aga n'ihu. Filler masterbatch bụ ụdị ihe mejupụtara nke a na-eme site na ịgwakọta, agbaze, extruding na granulating inorganic fillers (dị ka calcium carbonate, talc, barium sulfate, wdg.) na ndị na-ebu polymer (dị ka polyethylene, polypropylene, polyvinyl chloride, wdg.) na ihe mgbakwunye kwesịrị ekwesị (dị ka ndị na-ekesa, dakọtara, mmanu mmanu, wdg.) n'ókè ụfọdụ. Isi ọrụ ya bụ ibelata ọnụ ahịa mmepụta nke ngwaahịa rọba ebe ọ na-emeziwanye ma ọ bụ na-ejigide arụmọrụ bụ isi nke ngwaahịa rọba.

Dị ka ọnụ ọgụgụ data dị mkpa si dị, oke ahịa Masterbatch filler zuru ụwa ọnụ agafeela 20 ijeri US dollar, na ọ na-atụ anya ịnọgide na-enwe uto ọnụego nke 6%-9% n'ime afọ ole na ole sochirinụ. N'etiti ha, calcium carbonate (CaCO3) filler masterbatch bụ ụdị ngwaahịa a na-ejikarị eme ihe, aza ajụjụ karịa 60% nke mkpokọta filler masterbatch ahịa, sochiri talc filler masterbatch, barium sulfate (BaSO4) filler masterbatch na ndị ọzọ pụrụ iche filler masterbatches. Mpaghara Eshia-Pacific bụ ahịa ngwaahịa na-ere ihe na-emepụta ihe na-emepụta ihe n'ụwa niile, aza ajụjụ karịa 50% nke oke ahịa ahịa zuru ụwa ọnụ, nke kachasị n'ihi mmepe ngwa ngwa nke ụlọ ọrụ nhazi plastik na China, India na obodo ndị ọzọ, nnukwu ọchịchọ maka mbelata ọnụ ahịa na nkwalite arụmọrụ nke ngwaahịa plastik, na ọganihu na-aga n'ihu nke ikike ịkwado ụlọ ọrụ mmepụta ihe.

Usoro mmepe nke ụlọ ọrụ filler masterbatch na-egosipụtakarị n'akụkụ anọ: mbụ, elu arụmọrụ na functionalization. Na upgrading nke downstream plastic ngwaahịa chọrọ, Filler masterbatch ejedebeghị na mbelata ọnụ ahịa, ma nke nta nke nta na-amalite kwupụta functionalization, dị ka imeziwanye isi ike, ike, okpomọkụ na-eguzogide, iguzogide ihu igwe na ihe mgbochi nke ngwaahịa plastik, ma na-emepe ihe ndozi pụrụ iche dị ka ọkụ retardant, antistatic na antibacterial; nke abụọ, nnukwu ndochi ego na ezigbo dispersibility. N'okpuru ntọala nke ịhụ na arụmọrụ ngwaahịa, ịba ụba nke ndochi nke inorganic fillers nwere ike belata ọnụ ahịa mmepụta, nke na-etinye elu chọrọ na dispersibility nke filler masterbatch-ezigbo dispersibility nwere ike hụ na ndochi na-evenly kesara na plastic matriks., na-ezere ọdịdị nke ntụpọ ọcha, ntụpọ ojii ma ọ bụ agglomeration na ngwaahịa ikpeazụ; nke atọ, nchedo gburugburu ebe obibi na obere mmetọ. Site n'ịkwalite amụma nchedo gburugburu ebe obibi zuru ụwa ọnụ yana nkwalite mmata nchedo gburugburu ebe obibi, Ndị na-emepụta ihe na-emepụta ihe na-emepụta ihe na-eji nwayọọ nwayọọ na-agbaso ihe mgbakwunye enyi na gburugburu ebe obibi na usoro mmepụta, ibelata ntupu nke ihe na-emerụ ahụ, na ịzụlite Masterbatch filler na-emebi emebi iji mee mgbanwe maka mmepe mmepe nke plastik ndụ ndụ; nke anọ, ọgụgụ isi na arụmọrụ nke mmepụta ngwá ọrụ. Iji zute ọnụ ọgụgụ buru ibu, na-aga n'ihu na elu-mma mmepụta mkpa nke filler masterbatch, ndị na-emepụta ihe na-ewebata ahịrị mmepụta granulation dị elu na sistemụ njikwa ọgụgụ isi, imeziwanye mmepụta mmepụta ihe, ibelata ụgwọ ọrụ na ịhụ nkwụsi ike nke ngwaahịa.

Megide ndabere a, teknụzụ extrusion granulation, dị ka isi teknụzụ nke mmepụta masterbatch filler, abụrụla isi ihe iji chọpụta ogo nke filler masterbatch na asọmpi nke ụlọ ọrụ. Arụmọrụ nke extruders na-emetụta kpọmkwem dispersibility, urughuru udi, Ndekọ agbaze na ihe ngosi isi ndị ọzọ nke filler masterbatch. A na-emepụta ndị ọkachamara ọkachamara anyị na ahịrị mmepụta granulation maka filler masterbatch na nzaghachi maka njirimara nke ụlọ ọrụ na ọchịchọ ahịa., nke nwere ike dozie isi ihe mgbu na nhazi masterbatch nke ọma (dị ka ogbenye dispersibility, nha nha na-enweghị isi, obere ndochi ego, oriri ike dị elu, wdg.) ma na-enyere ụlọ ọrụ aka inweta mmepụta dị elu na nke ọma.

1.2 Nhazi nke Filler Masterbatch na njirimara ya bụ isi

Enwere ike kewaa Filler masterbatch n'ime ụdị dị iche iche dị ka ụdị ihe mkpuchi, ebu resin, ubi ngwa na njuputa ego. Ụdị ihe ọ bụla nke masterbatch nwere njiri mara pụrụ iche yana ọnọdụ ọdabara. Ihe na-esonụ bụ mmeghe zuru ezu na nhazi ọkwa na njirimara bụ isi nke filler masterbatch:

1.2.1 Nhazi site na ụdị Filler:

This is the most common classification method for filler masterbatch. According to the type of inorganic filler, it can be mainly divided into calcium carbonate (CaCO3) filler masterbatch, talc filler masterbatch, barium sulfate (BaSO4) filler masterbatch, and other special filler masterbatches (such as kaolin filler masterbatch, carbon black filler masterbatch, glass fiber filler masterbatch, wdg.).

• Calcium Carbonate (CaCO3) Filler Masterbatch: It is the most widely used filler masterbatch with the lowest cost. The filler is mainly light calcium carbonate or heavy calcium carbonate. Light calcium carbonate has fine particle size, good dispersibility and high whiteness, which is suitable for plastic products with high requirements on appearance and fineness (such as plastic films, injection molding products); heavy calcium carbonate has high hardness, good wear resistance and low price, nke kwesịrị ekwesị maka ngwaahịa plastik nwere nnukwu ihe a chọrọ na nkwụsi ike na njikwa ego (dị ka akpa kpara akpa, eriri nkwakọ ngwaahịa, ọkpọkọ, wdg.). Calcium carbonate filler masterbatch enweghị ike ibelata ọnụ ahịa mmepụta, ma na-emeziwanye isi ike, iguzogide okpomọkụ na nkwụsi ike akụkụ nke ngwaahịa plastik, ma nwee mmetụta mmanye ụfọdụ, nke nwere ike melite nhazi fluidity nke plastik.
• Talc Filler Masterbatch: Ihe ndochi ahụ bụ ntụ ntụ talc nwere usoro nwere akwa. Talc ntụ ntụ nwere ezigbo ihe eji arụ ọrụ, okpomọkụ na-eguzogide na chemical kwụsie ike. A na-ejikarị Talc filler masterbatch eme ihe na polypropylene (PP) ngwaahịa plastik, nke nwere ike imeziwanye isi ike, okpomọkụ mgbagha okpomọkụ na mmetụta ike nke PP ngwaahịa, a na-ejikwa ya na akụkụ ụgbọ ala, shei ngwa ụlọ, ọkpọkọ plastik na ubi ndị ọzọ na-achọ ọrụ dị elu.
• Barium sulfate (BaSO4) Filler Masterbatch: Ihe mejupụtara ya bụ barium sulfate ntụ ntụ, nke nwere oke ọcha, ezi nghọta, chemical inertness na radieshon iguzogide. Barium sulfate filler masterbatch dabara adaba maka ngwaahịa rọba nwere nnukwu ihe achọrọ na nghọta, ọcha na nkwụsi ike kemịkalụ (such as plastic films, karama plastik, ngwaahịa rọba ọgwụ, wdg.), enwere ike iji ya mee ihe na ngwaahịa rọba na-egbochi ọkụ (dị ka akụrụngwa nchebe ahụike, ngwa agha ike nuklia, wdg.).

1.2.2 Nhazi site n'aka onye na-ebu resin:

Dị ka ụdị resin nke ebu ji si dị, Filler masterbatch nwere ike kewaa n'ime polyethylene (PE) filler masterbatch, polypropylene (PP) filler masterbatch, polyvinyl chloride (PVC) filler masterbatch, polyethylene terephthalate (PET) filler masterbatch, wdg. Nhọrọ nke resin ụgbọelu na-ekpebi nke ọma site n'ụdị ngwaahịa rọba dị ala. Ọmụmaatụ, PE filler masterbatch dabara maka ngwaahịa plastik PE (such as plastic films, akpa, ọkpọkọ); PP filler masterbatch dabara maka ngwaahịa plastik PP (dị ka akpa kpara akpa, akụkụ injection ịkpụzi, akụkụ ụgbọ ala); Masterbatch ihe mkpuchi PVC dabara adaba maka ngwaahịa plastik PVC (dị ka PVC ọkpọkọ, profaịlụ, mpempe akwụkwọ).

1.2.3 Nhazi site na mpaghara ngwa:

Dị ka ngwa ubi nke downstream plastic ngwaahịa, Enwere ike kewaa filler masterbatch ka ọ bụrụ ihe nkiri ọkwa ọkwa masterbatch, ihe ndochi injection-grade masterbatch, extrusion-ọkwa filler masterbatch, ịfụ ịkpụzi-ọkwa filler masterbatch, wdg. Ihe nkiri ọkwa ọkwa masterbatch chọrọ ezigbo dispersibility, ịdị mma dị elu na enweghị adịghị ọcha, iji hụ na ihe nkiri a na-efe efe enweghị ntụpọ ọcha, ntụpọ ojii ma ọ bụ pinholes, ma na-edobe ezi nghọta na ike; Masterbatch nke ọkwa injection chọrọ ezigbo mmiri na nha nha nha, iji mee mgbanwe na usoro ịkpụzi injection ngwa ngwa ma hụ na ọdịdị na nha nha nke ngwaahịa injection; extrusion-grade filler masterbatch chọrọ ezigbo nkwụsi ike ọkụ na akụrụngwa akụrụngwa, iji mee mgbanwe na usoro ikpo ọkụ dị elu na nke dị elu nke ọkpọkọ, profaịlụ na ngwaahịa ndị ọzọ.

1.2.4 Nhazi site na njuputa ego:

Dị ka ndochi ego nke inorganic fillers, Enwere ike kewaa filler masterbatch ka ọ bụrụ masterbatch dị obere (njuputa ego 30%-50%), ọkara-ejuputa masterbatch (njuputa ego 50%-70%) na nnukwu-ejuputa masterbatch (njuputa ego 70% na n'elu). A na-ekpebi ego ndochi dabere na ihe ndị chọrọ ịrụ ọrụ nke ngwaahịa ala na ikike nhazi nke akụrụngwa. Masterbatch dị elu nwere mmetụta mbelata ọnụ ahịa pụtara ìhè, ma ọ nwere elu chọrọ na dispersibility nke fillers na arụmọrụ nke extruders-naanị elu-arụmọrụ extruders nwere ike hụ na edo Ịgwakọta na agbaze nke elu-ejuputa ihe., na-ezere agglomeration na adịghị mma nhazi fluidity.

Ọ bụ ihe kwesịrị ịrịba ama na isi arụmọrụ egosi nke filler masterbatch tumadi gụnyere dispersibility, urughuru nha uniformity, index agbaze, ọcha (maka ngwaahịa na-acha ọkụ) na ndakọrịta na resin ụgbọelu. N'etiti ha, dispersibility bụ ihe kacha mkpa egosi — ogbenye dispersibility ga-eduga na-ekwekọghị ekwekọ nkesa nke fillers na rọba ngwaahịa, na-ebute ntụpọ dị ka ntụpọ ọcha, ntụpọ ojii, agglomeration na kenkuwa ngwaahịa, nke na-emetụta nnọọ ọdịdị na arụmọrụ nke ngwaahịa plastik. Ya mere, nhọrọ nke ngwa extrusion dị elu na teknụzụ nhazi sayensị dị oke mkpa iji hụ na mgbasa na ogo zuru oke nke filler masterbatch..

2. Teknụzụ Core nke Filler Masterbatch Mmepụta: Teknụzụ granulation Extrusion

Teknụzụ granulation extrusion bụ teknụzụ bụ isi nke mmepụta masterbatch filler, nke na-ejikọta ngwakọta, agbaze, ịkpacha ajị, mgbasa na granulation. Ọ nwere uru nke nrụpụta mmepụta dị elu, ezigbo ngwaahịa mma, ike mgbanwe ka akụrụngwa na mbara ngwa nso. Na mmepụta nke filler masterbatch, A na-eji teknụzụ extrusion granulation eme ihe iji ghọta ụdị mgbasa nke inorganic fillers na onye na-ebu polymer., gbazee na plasticize ngwakọta, wee extrude na granulate ka ọ bụrụ granular filler masterbatch nwere nha nha, ezigbo mmiri mmiri na arụmọrụ kwụsiri ike. Ogo nke extrusion granulation na-ekpebi kpọmkwem ihe ngosi arụmọrụ nke filler masterbatch, dị ka dispersibility, urughuru nha na agbaze index.

2.1 Njirimara nke Filler Masterbatch Raw Materials na ihe achọrọ maka ngwa extrusion.

Ngwa ngwa nke filler masterbatch na-agụnye akụkụ atọ: inorganic fillers (dị ka CaCO3, talc, BaSO4), ndị na-ebu polymer (dị ka PE, PP, PVC) na mgbakwunye (dị ka ndị na-ekesa, dakọtara, mmanu mmanu, antioxidants, wdg.). Njirimara nke akụrụngwa ndị a dị nnọọ iche, nke na-etinye n'ihu chọrọ pụrụ iche maka extrusion akụrụngwa:

Mbụ, ndị inorganic fillers nwere nnukwu ike ike, ndakọrịta adịghị mma na ndị na-ebu polymer, ma dị mfe agglomerate. Ọtụtụ inorganic fillers (dị ka CaCO3, talc) bụ hydrophilic, ebe ndị na-ebu polymer bụ hydrophobic, nke na-eduga na ndakọrịta adịghị mma n'etiti fillers na ndị na-ebu. Ọ bụrụ na ịgwakọta na ịkwa osisi ezughị ezu, ndị na-ejuputa ga-emewanyewanye, nke a na-apụghị ịgbasa n'otu n'otu na ụgbọelu ahụ, na-akpata adịghị mma nke filler masterbatch. Na mgbakwunye, ike siri ike nke ndị na-ahụ maka inorganic ga-eme ka ọkpụkpụ na gbọmgbọm nke extruder na-eyi akwa akwa n'oge usoro extruder., nke na-achọ ịghasa na gbọmgbọm nke extruder na-enwe oké elu eyi iguzogide.

Nke abụọ, ngwakọta nke filler masterbatch nwere nnukwu viscosity na adịghị mma fluidity. Mgbakwunye nke ọnụ ọgụgụ buru ibu nke inorganic fillers ga-abawanye viscosity nke ngwakọta, belata nhazi nhazi, na-achọ ka extruder nwere ike ibufe ike na ịkpacha ike iji hụ na ọganiihu nke agbaze, ngwakọta na extrusion.

Nke atọ, oke okpomọkụ nhazi dị warara. Resin ndị na-ebu dị iche iche nwere ebe mgbaze dị iche iche na nkwụsi ike ọkụ. Ọmụmaatụ, Ebe agbaze nke PE bụ 100-130 ℃, Ebe agbaze nke PP bụ 160-170 ℃, na PVC dị mfe ire ere na oke okpomọkụ (n'elu 160 ℃). Ya mere, akụrụngwa extrusion kwesịrị inwe ikike njikwa okpomọkụ nke ọma iji hụ na ngwakọta ahụ gbazee nke ọma na-enweghị ire ere., na iji zere ire ere nke ihe mgbakwunye na mmebi nke arụmọrụ ngwaahịa.

Dabere na njirimara ndị dị n'elu, otu ihe nkedo extruders adịghị adabara maka nnukwu mmepụta na mmepụta dị elu nke filler masterbatch. N'ihi na otu-skru extruder nwere warara shiee nso, Ike mgbapụta na-adịghị mma na enweghị mmetụta na-ehicha onwe ya. Mgbe ị na-edozi nnukwu viscosity na ngwakọta dị elu, ọ dị mfe ime ka mkpokọta ihe onwunwe, nkwụsịtụ na ngwakọta na-enweghị isi na gbọmgbọm extruder, na-akpata adịghị mma dispersibility nke filler masterbatch, ubara urughuru size na ejighị n'aka ngwaahịa àgwà. Na mgbakwunye, onye na-ekpochapụ otu-screw extruder nwere nnukwu ike oriri mgbe ọ na-edozi ihe ndị dị elu, na ịghasa na gbọmgbọm na-eyi nke ukwuu, nke na-abawanye mmepụta ihe na-eri na akụrụngwa mmezi ego nke ụlọ ọrụ.

Ejima-skru extruders, n'akụkụ aka nke ọzọ, nwere uru doro anya na mmepụta ihe nchịkwa masterbatch wee bụrụ akụrụngwa bụ isi maka filler masterbatch extrusion granulation.. Ejima-screw extruders nwere oke shiee sara mbara, mmetụta mgbapụta dị irè karị na mmetụta nhicha onwe ya, nke nwere ike dozie nsogbu nke ndakọrịta dara ogbenye, agglomeration dị mfe na mmiri adịghị mma nke akụrụngwa akụrụngwa masterbatch. Ntugharị na ntụgharị nke skru ejima nwere ike iwepụta ike shiee siri ike na ike igwakorita, nke nwere ike imebi agglomerates nke inorganic fillers n'ụzọ zuru ezu, mee ka ihe ndị na-ejupụta n'otu n'otu gbasasịa na ebu polymer, ma hụ na dispersibility na nkwụsi ike nke ngwaahịa. Na mgbakwunye, ejima-screw extruder nwere ezigbo njikwa okpomọkụ, ike ime mgbanwe na akụrụngwa, ma nwee ike imeghari na nhazi nke ụdị dị iche iche, dị iche iche ndochi ego nke filler masterbatch, ma nwee nnukwu mmepụta mmepụta na obere ike oriri.

2.2 Ụkpụrụ na-arụ ọrụ nke Filler Masterbatch Extrusion granulation

Usoro extrusion granulation nke filler masterbatch bụ usoro anụ ahụ na kemịkal dị mgbagwoju anya, nke na-agụnye mmekọrịta nke ọtụtụ ihe dị ka okpomọkụ, nrụgide, shii ike na oge. Ụkpụrụ na-arụ ọrụ kpọmkwem na usoro usoro bụ ndị a:

Mbụ, akụrụngwa pretreatment. The akụrụngwa nke filler masterbatch (inorganic fillers, ebu resin, ihe mgbakwunye) ọ dị mkpa ka edozi ya iji hụ na ịdị mma nke ngwaahịa ikpeazụ. Usoro ndị akọwapụtara gụnyere: 1) ọgwụgwọ ihicha: Inorganic fillers (dị ka CaCO3, talc) na-abụkarị hydrophilic ma nwee ụfọdụ mmiri mmiri. Ọ bụrụ na ọdịnaya mmiri dị oke elu, ọ ga-emetụta mmetụta ngwakọta na dispersibility nke ihe, na ọbụna mee ka afụ na extruded masterbatch. Ya mere, ihe ndochi kwesịrị ka akpọọ nkụ na nkụ (dị ka igwe ikuku na-ekpo ọkụ, ihe na-ekpo ọkụ ọkụ) iji belata ọdịnaya mmiri n'okpuru 0.5%. 2) Ịzọpịa na sieving: Onye na-ebu resin (dị ka PE, PP) na-echi ọnụ n'ala n'ime obere ahụ ma ọ bụ ntụ ntụ na a urughuru size nke 20-40 ntupu, nke na-enyere aka ịgwakọta edo na ihe ndị na-emepụta ihe na ihe mgbakwunye. A na-echekwa ihe ndị na-emepụta ihe na-adịghị ahụkebe iji wepụ adịghị ọcha na ihe ndị buru ibu, na-eme ka ịdị mma na ịdị n'otu nke ndị na-ejuputa. 3) Premixing: Dị ka usoro usoro si dị, ihe ndị a mịrị amị, ihe na-ebu resin particles na ihe mgbakwunye (ndị na-ekesa, dakọtara, mmanu mmanu, wdg.) na-etinye n'ime ngwa ngwa ngwakọ maka premixing. The agwakọta ọsọ bụ n'ozuzu 800-1200 rpm, na oge ngwakọta bụ 5-10 nkeji. Ebumnobi nke premixing bụ ime ka ihe mgbakwunye na-arapara n'elu nke ihe na-ejuputa na resin ụgbọelu., 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.

Nke abụọ, feeding and conveying. The premixed mixture is sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. 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. The feeding device of the extruder is usually equipped with a frequency conversion speed regulation function, which can adjust the feeding speed according to the actual production situation.

Nke atọ, agbaze, mixing and shearing. The materials entering the extrusion cavity of the twin-screw extruder are pushed forward continuously by the rotating screws. The extrusion cavity is composed of a screw and a barrel, na olu nke oghere extrusion nke nta nke nta na-ebelata n'akụkụ ụzọ axis. When the screws rotate, the materials are gradually compressed under the action of the screws and the barrel, na nrụgide dị na oghere extrusion nke nta nke nta na-abawanye (generally 3-15MPa). N'otu oge ahụ, the materials are subjected to strong shear force and friction force generated by the relative movement between the screws and the barrel, yana n'etiti ịghasa ụgbọ elu.

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. The friction force can also generate a certain amount of heat, which is combined with the external heating of the barrel (electric heating or steam heating) to make the carrier resin gradually melt and plasticize. The barrel of the extruder is usually divided into 3-6 ngalaba njikwa okpomọkụ (ngalaba nri, ngalaba agbaze, ngwakọta ngalaba, ngalaba homogenizing, wdg.), and the temperature of each section is precisely controlled according to the type of carrier resin and filler. Ọmụmaatụ, when processing PE carrier filler masterbatch, the temperature of the feeding section is 80-100℃, Nkeji agbaze bụ 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.

Nke anọ, extrusion and shaping. Agbazere nke ọma, Ngwakọta agwakọta na achụsasịwo ihe a na-akwali na-anwụ anwụ isi nke extruder site kposara. 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. The temperature of the die head is slightly lower than that of the homogenizing section, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the strips.

Fifth, cooling and cutting. The extruded strips are sent to a cooling device (such as a water tank, an air-cooled conveyor) for rapid cooling. The cooling temperature is generally 20-30℃, and the cooling time is 2-5 nkeji. Rapid cooling can make the strips solidify quickly, maintain the shape and size of the strips, and avoid deformation. Mgbe obi jụrụ, the strips are sent to a granulator for cutting. The granulator is equipped with a rotary knife, which can cut the strips into granular filler masterbatch with uniform size (the particle size is generally 2-5mm, which can be adjusted according to customer needs). 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, screening and packaging. The cut granular filler masterbatch is sent to a vibrating screen for screening, which can remove unqualified particles (such as too large, too small or agglomerated particles) 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, cool and ventilated warehouse.

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, mainly including raw material characteristics, formula ratio, premixing effect, extrusion parameters and die head structure. 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 Raw Material Characteristics:

The type, particle size, moisture content and purity of raw materials have a great impact on the granulation effect. Ọmụmaatụ, the particle size of inorganic fillers directly affects the dispersibility and fineness of the masterbatch. The finer the particle size of the filler (generally 800-2000 ntupu), 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%; if the moisture content is too high, it will cause bubbles in the masterbatch, affect the density and mechanical properties of the product. The purity of raw materials is also very important; impurities in raw materials (such as stones, ọla, uzuzu) will not only affect the quality of the masterbatch, but also wear the screw and barrel of the extruder, and even cause equipment blockage.

2.3.2 Formula Ratio:

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. The type and dosage of additives also need to be reasonably matched. Ọmụmaatụ, 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 Premixing Effect:

Premixing is the foundation of extrusion granulation. The uniformity of premixing directly affects the dispersibility of the filler in the carrier resin. If the premixing is uneven, 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, mixing time and mixing temperature. The agwakọta ọsọ bụ n'ozuzu 800-1200 rpm, the mixing time is 5-10 nkeji, and the mixing temperature is controlled at 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.

• Ịghasa Ọsọ: The screw speed generally ranges from 150 ka 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. Agbanyeghị, 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, and the production efficiency is low. 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.
• Extrusion Temperature: The extrusion temperature is divided into multiple sections (ngalaba nri, ngalaba agbaze, ngwakọta ngalaba, ngalaba homogenizing, anwụ isi ngalaba), and the temperature of each section needs to be precisely controlled according to the type of carrier resin and filler. The temperature of the feeding section is lower (slightly higher than the melting point of the carrier resin), which is mainly to prevent the materials from caking and ensure smooth feeding; the temperature of the melting section is medium, which is mainly to promote the melting and plasticization of the carrier resin; the temperature of the mixing section is higher, which is mainly to enhance the shear and mixing effect, and promote the uniform dispersion of the filler; the temperature of the homogenizing section is slightly lower than the mixing section, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, which is to ensure the shaping effect of the strips.
• Nrụgide Extrusion: The extrusion pressure is generally 3-15MPa. The pressure in the extrusion cavity is mainly determined by the compression ratio of the screw, the die hole size and the screw speed. The higher the extrusion pressure, the better the mixing and dispersing effect of the materials, and the denser the masterbatch particles. Agbanyeghị, if the pressure is too high, it will increase the energy consumption and wear of the equipment, and even cause the die head to block; if the pressure is too low, the materials cannot be fully compressed and mixed, the masterbatch particles are loose, and the performance is unstable.

2.3.5 Die Head Structure:

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, elu viscosity) and processing requirements (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, njikwa okpomọkụ ziri ezi, stable performance and low operating cost, which can meet the processing needs of various types, dị iche iche ndochi ego nke filler masterbatch (CaCO3, talc, BaSO4, wdg.), 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 High Wear Resistance, Ogologo ndụ ije ozi:

Aiming at the problem that inorganic fillers (dị ka CaCO3, talc) 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 (such as 38CrMoAlA), and after nitriding treatment or bimetallic composite treatment, the surface hardness can reach ≥65 HRC, which has extremely strong wear resistance and corrosion resistance, 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. Na mgbakwunye, 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, with a reasonable screw pitch, lead and compression ratio design. Ntugharị na ntụgharị nke skru ejima nwere ike iwepụta ike shiee siri ike na ike igwakorita, nke nwere ike imebi agglomerates nke inorganic fillers n'ụzọ zuru ezu, 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 (such as conveying elements, agwakọta ihe, shearing elements) 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. Ọmụmaatụ, 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 Precise Temperature Control, Stable Performance:

Our extruders adopt advanced intelligent temperature control systems, which can realize precise control of the temperature of each section of the barrel and the die head. 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. The temperature control system is equipped with a real-time monitoring and alarm function. If the temperature of any section exceeds the set range, the system will issue an alarm prompt in time, and even automatically adjust the heating power or shut down the equipment if necessary, to avoid equipment failure and product quality problems. Na mgbakwunye, 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 Oke ngwa ngwa, Strong Flexibility:

Our extruder series can adapt to the processing needs of various types of filler masterbatch, including CaCO3 filler masterbatch, talc filler masterbatch, BaSO4 filler masterbatch, and other special filler masterbatches. The filling amount can be adjusted from 30% ka 80%, which can meet the different cost and performance requirements of customers. The modular design of the extruder (ịghasa, gbọmgbọm, nwuo isi, wdg.) 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, without replacing the entire equipment, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. Na mgbakwunye, our extruders can also be matched with different auxiliary equipment (dị ka nnukwu ngwa ngwa mixers, igwe nkụ, ngwa nju oyi, granulators, 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 Ịmepụta arụmọrụ dị elu, Low Energy Consumption:

Anyị ejima-ịghasa extruders nwere elu mmepụta arụmọrụ, nke dị elu karịa nke ndị na-ebupụ otu-screw. The production capacity of our extruders ranges from 100kg/h to 3000kg/h, nke nwere ike izute mkpa mmepụta nke ọnụ ọgụgụ dị iche iche nke ụlọ ọrụ (obere, ọkara na nnukwu). The elu-torque mbanye usoro na kacha ịghasa imewe nke extruder nwere ike n'ụzọ dị irè na-mma n'ibufe ikike na plasticization arụmọrụ nke ihe., ibelata oge obibi nke ihe na oghere extrusion na imeziwanye mmepụta mmepụta ihe. N'otu oge ahụ, the extruder adopts an energy-saving design, such as a high-efficiency motor, a heat recovery device, wdg., which can reduce the unit energy consumption by 15%-25% tụnyere ndị nkịtị extruders, 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. The screw, gbọmgbọm, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Our after-sales service team will provide professional installation, commissioning and training services for customers, ensuring that customers can use the equipment smoothly.

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, including HTS BASIC series, Usoro HTS PLUS, HTS SUPER series, ZTE series and HTE series. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, product type, budget and other factors.

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, obere mkpọtụ, 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.

N'ihe gbasara nhazi nhazi, 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, automatic temperature control, 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, nwuo isi, 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.

The HTS PLUS series extruders adopt high-torque gearboxes independently developed and manufactured by us, 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 (such as PP, PA, PC).

The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～600 rpm. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance, and can adapt to the processing of high-hardness fillers (such as heavy calcium carbonate, talc) and high-filling materials. The extruder is equipped with an advanced intelligent control system, which can realize precise control of extrusion parameters and real-time monitoring of production data. The production capacity ranges from 500kg/h to 2000kg/h, nke dabara maka ụlọ ọrụ na-ahụ maka ọkara na nnukwu nnukwu ụlọ ọrụ masterbatch na-achụso arụmọrụ dị elu na oke njuputa.

Na mgbakwunye, ndị HTS PLUS usoro extruders nwere ike ịgwakọta na ịkwa osisi, nke nwere ike gbasaa n'ụzọ zuru ezu ihe ndị na-ejuputa ihe dị elu na resin ụgbọelu, n'ịhụ na dispersibility na nkwụsi ike nke masterbatch. Ọ dabara adaba maka mmepụta nke filler masterbatch eji na akụkụ ụgbọ ala, shei ngwa ụlọ, ihe nkiri plastik dị elu na ngwaahịa plastik ndị ọzọ na-arụ ọrụ dị elu.

3.2.3 HTS SUPER Series Extruders: Nhọrọ kachasị elu maka Masterbatch Filler dị elu.

HTS SUPER usoro extruders na-ewere ngwaọrụ nnyefe kacha ọhụrụ dị elu nke anyị mepụtara n'onwe ya.. Achọ na elu torque na elu ọsọ àgwà nke usoro isiokwu a, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. 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 sulfate) 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, production data monitoring and predictive maintenance of equipment, na-aghọta njikwa mmepụta ọgụgụ isi.

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, njuputa ego, 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. Ọmụmaatụ, 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, Ọkụ na-egbochi ire ọkụ), 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 tọn), 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 tọn), 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, talc) 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 (such as energy consumption, maintenance cost, spare parts cost). Ọmụmaatụ, 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, inye ọrụ, ọzụzụ, 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 awa) 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. Ya mere, 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

Filler masterbatch, dị ka isi ihe mgbakwunye na-arụ ọrụ na nhazi plastik, has a wide range of application fields, covering various fields such as plastic packaging, ihe owuwu, ụgbọ ala, ngwá electronic, 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, aza ajụjụ karịa 50% of the total application amount. Filler masterbatch is widely used in the production of plastic films, akpa rọba, woven bags, eriri nkwakọ ngwaahịa, packaging containers and other packaging products.

• Plastic Films: Including plastic thin films, thick films, stretch films, greenhouse films, wdg. The filler masterbatch used for plastic films is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires good dispersibility, ịdị mma dị elu na enweghị adịghị ọcha, iji hụ na ihe nkiri a na-efe efe enweghị ntụpọ ọcha, ntụpọ ojii ma ọ bụ pinholes, 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, ma na-emeziwanye isi ike, heat resistance and dimensional stability of the film, and reduce the shrinkage rate of the film. Ọmụmaatụ, in the production of plastic shopping bags, na-agbakwụnye 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, wdg. 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, simenti, 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, wdg. 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, PE ọkpọkọ, PP pipes, wdg., which are used for water supply, drainage, 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, wdg. 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, Ibé akwụkwọ PE, PP mpempe akwụkwọ, wdg., which are used for indoor decoration, nkwakọ ngwaahịa, 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, adịghị egbu egbu, 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 (n'elu 1250 ntupu) 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, wdg. 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. Ọmụmaatụ, in the production of automotive interior parts (such as instrument panels, ọnụ ụzọ ụzọ), na-agbakwụnye 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), na-agbakwụnye 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, na 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, ọnụ ụzọ ụzọ, seat cushions, armrests, wdg. These parts have high requirements on rigidity, okpomọkụ na-eguzogide, 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 (PP) ihe, 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. Ọmụmaatụ, na-agbakwụnye 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, wdg. 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, wdg. 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. Ọmụmaatụ, na-agbakwụnye 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, mkpuchi, dimensional accuracy and heat resistance of plastic materials. Filler masterbatch is widely used in the production of plastic parts of electronic and electrical products, such as wire and cable sheaths, transformer casings, connector housings, wdg.

• Wire and Cable Sheaths: The plastic sheaths of wires and cables need to have good insulation, eyi iguzogide, flame retardancy and weather resistance. The filler masterbatch used for wire and cable sheaths is mainly calcium carbonate filler masterbatch or flame-retardant filler masterbatch. Adding 3%-6% of calcium carbonate filler masterbatch can improve the wear resistance and rigidity of the sheath, reduce the cost; flame-retardant filler masterbatch (such as magnesium hydroxide, aluminum hydroxide filler masterbatch) can improve the flame retardancy of the sheath, preventing the spread of fire in case of short circuit, ensuring the safety of the circuit.
• Transformer Casings and Connector Housings: These parts need to have good insulation, heat resistance and dimensional accuracy. 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: Ngwaahịa ndị a kwesịrị inwe nghọta dị mma, ike, iguzogide ihu igwe na ihe mgbochi ịka nká. Ihe eji eme ihe eji eme ihe bụ nke kachasị ọkụ calcium carbonate filler masterbatch ma ọ bụ barium sulfate filler masterbatch.. Adding 1%-4% nke ìhè calcium carbonate filler masterbatch nwere ike ibelata ọnụ ahịa ihe nkiri ahụ, melite ike ya na mgbochi ịka nká, ma gbasaa ndụ ihe nkiri ahụ; barium sulfate filler masterbatch nwere ike imeziwanye nghọta na nnyefe ọkụ nke ihe nkiri ahụ, nke na-eme ka photosynthesis nke ihe ọkụkụ.
• Ọkụ mmiri na akpa fatịlaịza: Ọkụ ọkpọ mmiri kwesịrị inwe ezigbo nguzogide nrụgide ma na-eyi nguzogide; Akpa fatịlaịza kwesịrị inwe ezigbo ike ma na-eyi nguzogide. Ihe eji eme ihe eji eme ihe bụ nnukwu calcium carbonate filler masterbatch ma ọ bụ 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; na-agbakwụnye 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 (such as plastic films, 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 (such as automotive parts, 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 (n'elu 1250 ntupu) 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 (dị ka PE, PP, PVC). The specific steps are: mbụ, 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. The agwakọta ọsọ bụ n'ozuzu 500-800 rpm, na oge ngwakọta bụ 3-5 nkeji. Mgbe agwakọtachara, the mixture can be directly sent to the extruder or injection molding machine for processing. The advantages of dry mixing are simple operation, elu arụmọrụ, 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. Ya mere, 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, nrụgide, ịghasa ọsọ) 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. Ọmụmaatụ, 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 (extrusion nrụgide, injection pressure) needs to be appropriately increased by 10%-20%. Ọmụmaatụ, 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: Filler masterbatch (especially calcium carbonate, talc masterbatch) is easy to absorb moisture, which will cause bubbles, pinholes and other defects in the final product. Ya mere, the masterbatch should be stored in a dry, cool and ventilated warehouse, and should be dried before use (the drying temperature is 80-100℃, and the drying time is 2-4 awa).
• Ndakọrịta: The carrier resin of the filler masterbatch should be consistent with or compatible with the base plastic of the product. Ọmụmaatụ, 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, na-ebute ntụpọ dị ka ntụpọ ọcha, 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 (generally 6-12 ọnwa). If the storage period is exceeded, the masterbatch may absorb moisture, agglomerate or the performance of additives may degrade, affecting the use effect. Ya mere, 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, black spots or agglomeration appear in the final product, which affects the appearance and performance of the product.

Causes: 1) The particle size of the inorganic filler is too large or uneven, and the agglomerates are not broken during premixing; 2) The dosage of dispersant is insufficient or the type of dispersant is inappropriate, which cannot effectively prevent the agglomeration of the filler; 3) The premixing effect is poor, and the filler, carrier resin and additives are not mixed uniformly; 4) The shear force of the extruder is insufficient, and the agglomerates of the filler cannot be fully broken during extrusion; 5) The processing temperature is too low, and the carrier resin is not fully melted, which affects the dispersion of the filler.

Ngwọta: 1) Select inorganic fillers with fine and uniform particle size (generally 800-2000 ntupu), 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, mụbaa ngwa ngwa ngwakọta (800-1200 rpm) and mixing time (5-10 nkeji), 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.

Causes: 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.

Ngwọta: 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.

Causes:

• 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);
• The processing temperature is too low, and the carrier resin is not fully melted;
• The dosage of lubricant is insufficient, which increases the friction between the materials and affects the fluidity.

Ngwọta:

• 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 (ọmụmaatụ, 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).

Causes:

• The thermal stability of the carrier resin is poor, and thermal decomposition occurs at high processing temperatures;
• The additives (dị ka ndị na-ekesa, mmanu mmanu) 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.

Ngwọta:

• 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: afụ, pinholes and other defects appear in the final plastic product after the masterbatch is mixed with the base plastic.

Causes:

• 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.

Ngwọta:

• Extend the drying time of the filler (drying temperature 80-100℃, drying time 3-5 awa), 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, cool and ventilated warehouse, and seal the packaging to prevent moisture absorption;
• Carry out the premixing process in a dry environment, ma zere ihe ndị na-amịkọrọ mmiri sitere na ikuku.

5.2 Nsogbu Mmepụta A Na-ahụkarị na Ngwọta Ha

5.2.1 Mgbochi Extruder

Nke a bụ nsogbu akụrụngwa a na-ahụkarị na mmepụta masterbatch filler, nke na-emekarị na ngalaba nri, agbaze ngalaba ma ọ bụ anwụ isi nke extruder. The main manifestations are: ọsọ extrusion na-ebelata nke ukwuu, nrụgide extrusion na-ebili ngwa ngwa, na ọbụna akụrụngwa na-akwụsị ịgba ọsọ.

Causes:

• Ọdịnaya mmiri nke ihe ndị ahụ dị oke elu, na ihe caking n'oge extrusion;
• The processing temperature is too low, and the carrier resin is not fully melted, nke na-agbakọba na gbọmgbọm extruder;
• Ihe ndị ahụ nwere adịghị ọcha (such as stones, ọla), nke na-egbochi ịghasa ma ọ bụ nwụọ isi;
• Ọsọ ịghasa dị oke ala, na ihe agaghị aga n'ihu were were, na-akpata mkpokọta;
• A naghị ehicha isi ọnwụ mgbe niile, na ihe ndị fọdụrụnụ na-egbochi oghere ndị nwụrụ anwụ.

Ngwọta:

• Kwụsị igwe ozugbo, cut off the power supply, 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.

Causes:

• The filler has high hardness (such as heavy calcium carbonate, talc) and long-term friction with the screw and barrel;
• Ihe ndị ahụ nwere adịghị ọcha (such as metals, stones), which accelerate the wear of the screw and barrel;
• The processing temperature is too low, and the materials have high viscosity, which increases the friction between the materials and the screw, gbọmgbọm;
• The screw and barrel are made of materials with poor wear resistance.

Ngwọta:

• 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, gbọmgbọm.

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, and unstable product quality.

Causes:

• 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.

Ngwọta:

• 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

Filler masterbatch, as a key functional additive in the plastic processing industry, plays an irreplaceable role in reducing production costs, na-emeziwanye arụmọrụ ngwaahịa na ịkwalite arụmọrụ nhazi. 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, ịrụ ọrụ, high filling amount, nchekwa gburugburu ebe obibi na ọgụgụ isi. Extrusion granulation technology, dị ka isi teknụzụ nke mmepụta masterbatch filler, kpọmkwem na-ekpebi àgwà na asọmpi nke masterbatch. Arụmọrụ nke extruders bụ isi ihe iji hụ na nrụpụta kwụsiri ike nke nnukwu ihe ndozi masterbatch.

Anyị emepụtala ngwaahịa ejima-screw extruder zuru oke (HTS BASIC usoro, Usoro HTS PLUS, HTS SUPER series, Usoro ZTE, Usoro HTE) dị ka njirimara nke filler masterbatch akụrụngwa na nhazi chọrọ. Our extruders have the advantages of high wear resistance, ike ịkwa osisi na ike ịgwakọta, njikwa okpomọkụ ziri ezi, oke ngwa ngwa, nnukwu mmepụta mmepụta na obere ike oriri, nke nwere ike gboo mkpa nhazi nke ụdị dị iche iche na njuputa dị iche iche nke filler masterbatch. Site n'inye ngwaahịa extruder ezubere iche na ngwọta nhazi ọkachamara, anyị na-enyere ndị na-emepụta ihe nchịkwa masterbatch aka dozie isi ihe mgbu mmepụta, melite mmepụta arụmọrụ, hụ na ngwaahịa dị mma, ma nweta uru asọmpi na asọmpi ahịa dị egwu.

Na-atụ anya ọdịnihu, 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; n'akụkụ aka nke ọzọ, the intelligence and automation level of production equipment will continue to improve, and intelligent granulation production lines integrating raw material pretreatment, granulation extrusion, 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. N'otu oge ahụ, 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.