Elastomer Termoplastik (TPE), kadhangkala disebut minangka Karet Thermoplastic (TPR), minangka kelas kopolimer utawa campuran fisik polimer - biasane plastik lan karet - sing nggabungake sifat termoplastik lan elastomer.. Kombinasi unik iki ngidini TPE diproses kaya termoplastik (liwat ekstrusi, ngecor injeksi, jotosan ngecor, lsp.) while retaining the elasticity and flexibility of rubbers. Unlike traditional vulcanized rubbers, TPEs can be melted and reprocessed multiple times without significant loss of performance, making them more environmentally friendly and cost-effective. Minangka dikarepake kanggo entheng, fleksibel, and recyclable materials grows across industries such as automotive, listrik, konstruksi, lan barang konsumen, TPEs have become increasingly popular, nyopir pangembangan masterbatch khusus lan teknologi ekstrusi sing cocog karo syarat pangolahan sing unik.
Masterbatch, minangka bahan kunci kanggo pewarnaan lan modifikasi fungsional TPE, main peran wigati kanggo nambah kinerja lan nggedhekake orane katrangan aplikasi produk TPE. Pangolahan masterbatch TPE mbutuhake kontrol campuran sing tepat, nyebarake, lan paramèter suhu, minangka TPEs duwe viskositas tartamtu, tahan panas, lan karakteristik elastisitas sing beda karo plastik tradisional. Twin-meneng extruders, kanthi kemampuan nyampur lan nyebar sing unggul, kontrol suhu sing tepat, lan adaptasi kanggo macem-macem bahan, wis dadi peralatan pangolahan inti kanggo masterbatch TPE. Zhuoyue, Produsèn profesional saka extruders kembar-meneng, offers a full range of advanced extrusion solutions specifically designed for TPE compounding and masterbatch processing, covering TPE/SBS/TPU/TPR/TPV and other major TPE categories, to meet the diverse needs of manufacturers in different industries.
1. Overview of Thermoplastic Elastomers (TPE): kategori, Properties and Key Characteristics
TPEs are a diverse family of materials, classified into six general commercial categories based on their chemical composition and structure. Each category has unique properties, karakteristik pangolahan, and application fields, which directly determine the requirements for masterbatch formulation and extrusion equipment. Understanding the classification and properties of TPEs is the foundation for optimizing masterbatch processing and selecting suitable twin-screw extruders.
1.1 Six General Commercial Categories of TPEs
1.1.1 Kopolimer Blok Styrenic (TPS, TPE-s).
TPS minangka kategori TPE sing paling akeh digunakake, accounting kanggo bagean gedhe saka pasar TPE global. Iki kasusun saka blok styrenic (kayata polystyrene, PS) lan blok elastomer (kayata polybutadiene, PB; poliisoprene, PI; utawa etilena-butilena, EB), disambungake dening ikatan kovalen. Jenis TPS sing paling umum kalebu SBS (Styrenes-Butadienes-Styrenes), SIS (Styrene-Isoprene-Styrene), SEBS (Styrene-Ethylene-Butylene-Styrene), lan SEPS (Styrene-Ethylene-Propylene-Styrene).
Sifat utama TPS kalebu keluwesan sing apik, elastisitas, lan kemampuan proses. SEBS lan SEPS, yaiku versi hidrogenasi SBS lan SIS, wis apik resistance panas, tahan cuaca, lan resistensi tuwa, nggawe cocok kanggo aplikasi ruangan lan suhu dhuwur. Bahan TPS gampang diwarnai lan diowahi nganggo masterbatch, lan suhu pangolahane antara 150 ℃ nganti 220 ℃, sing kompatibel karo paling extruders kembar-meneng. Aplikasi umum TPS kalebu komponen otomotif, kabel lan kabel, barang konsumen, lan piranti medis.
1.1.2 Elastomer Poliolefin Termoplastik (TPO, TPE-o).
TPO minangka campuran fisik poliolefin (kayata polypropylene, PP; utawa poliethelin, PE) lan elastomer (kayata monomer etilena-propilena-diene, EPDM). Iki nggabungake kaku poliolefin karo elastisitas elastomer, lan nduweni resistance kimia banget, tahan cuaca, lan keluwesan suhu kurang. TPO ora beracun, ora ana ambune, lan bisa didaur ulang, nggawe wong becik kanggo aplikasi sing mbutuhake ramah lingkungan.
Suhu pangolahan TPO kisaran saka 160 ℃ nganti 230 ℃, lan wis kompatibilitas apik karo macem-macem masterbatches (werna masterbatch, masterbatch tahan api, lsp.). TPO umume digunakake ing bagean njaba otomotif (kayata tutup bemper, fender liners), bahan bangunan (kayata segel, gasket), lan komponen listrik. Amarga kandungan polyolefin sing dhuwur, Proses masterbatch TPO mbutuhake extruder kanthi kemampuan campuran sing apik kanggo njamin panyebaran seragam pigmen lan aditif..
1.1.3 Vulkanisasi termoplastik (PPN, TPE v).
TPV minangka campuran poliolefin sing divulkanisasi kanthi dinamis (biasane PP) lan elastomer (biasane EPDM). Sajrone pangolahan, fase elastomer divulkanisir dadi partikel cilik lan disebarake kanthi seragam ing matriks poliolefin, asil ing elastisitas banget, resistance set komprèsi, lan tahan panas. TPV nduweni sifat mekanik lan stabilitas dimensi sing luwih apik tinimbang TPE tradisional, lan bisa tahan paparan suhu dhuwur jangka panjang (iki 150 ℃).
Proses TPV mbutuhake kontrol suhu sing tepat lan gaya geser sing kuat kanggo njamin vulkanisasi lan dispersi seragam. Suhu pangolahan antara 170 ℃ nganti 240 ℃, lan materi wis viskositas dhuwur sak Processing, kang panggonan syarat dhuwur ing torsi lan nyandhang resistance extruders kembar-meneng. TPV akeh digunakake ing segel otomotif, selang, gasket, lan komponen industri sing mbutuhake kinerja dhuwur lan kekiatan.
1.1.4 Poliuretan Termoplastik (TPU).
TPU minangka kopolimer blok sing kasusun saka segmen hard (diisosianat lan chain extender) lan perangan alus (poliol). Wis elastisitas banget, resistance abrasion, resistance lenga, lan kekuatan mekanik, lan bisa diatur ing atose saka banget alus (Pesisir A 30) kanggo hard banget (Pesisir D 85) kanthi ngganti rasio segmen hard lan alus.
Proses TPU sensitif marang suhu lan kelembapan. Suhu pangolahan antara 180 ℃ nganti 250 ℃, lan materi kudu garing sak tenane sadurunge proses (isi Kelembapan ≤0,05%) kanggo nyegah hidrolisis lan pembentukan gelembung. Proses masterbatch TPU mbutuhake extruder kanthi kontrol suhu sing tepat lan kemampuan knalpot vakum. TPU akeh digunakake ing kabel lan kabel, selang otomotif, alas kaki, kateter medis, lan peralatan olahraga.
1.1.5 Kopoliester termoplastik (TPC, TPE-E).
TPC minangka kopolimer blok sing kasusun saka segmen keras poliester lan segmen alus polieter utawa poliester.. Wis tahan panas banget, resistance kimia, lan sifat mekanik, lan bisa tahan suhu dhuwur nganti 150 ℃ kanggo wektu sing suwe. TPC uga nduweni keluwesan lan elastisitas sing apik, nggawe cocok kanggo aplikasi kinerja dhuwur.
Suhu pangolahan TPC kisaran saka 220 ℃ nganti 280 ℃, sing luwih dhuwur tinimbang kategori TPE liyane. Wis viskositas dhuwur sajrone proses lan mbutuhake extruder kanthi torsi dhuwur lan kontrol suhu sing tepat. Proses masterbatch TPC uga mbutuhake perhatian khusus kanggo panyebaran pigmen lan aditif supaya ora kena pengaruh sifat mekanik materi.. TPC akeh digunakake ing komponen otomotif (kayata selang asupan udara, segel transmisi), bagean aerospace, lan mesin industri.
1.1.6 Poliamida termoplastik (TPA, TPE-A).
TPA minangka kopolimer blok sing kasusun saka segmen keras poliamida lan segmen alus polieter. Iku nggabungake kekuatan dhuwur, nyandhang resistance, lan tahan kimia poliamida kanthi keluwesan lan elastisitas polieter. TPA nduweni resistance impact banget lan kinerja suhu kurang, lan bisa digunakake ing lingkungan sing atos.
Suhu Processing saka TPA kisaran saka 230 ℃ kanggo 290 ℃, lan nduweni panyerepan banyu sing dhuwur, mbutuhake pangatusan sak tenane sadurunge proses. Processing masterbatch TPA mbutuhake extruders karo resistance nyandhang dhuwur (amarga atose dhuwur saka poliamida) lan kontrol suhu sing tepat kanggo ngindhari degradasi materi. TPA akeh digunakake ing komponen otomotif (kayata gir, bantalan), konektor listrik, lan selang industri.
1.2 Properties Key TPEs mengaruhi Processing Masterbatch
TPE nduweni sifat unik sing mbedakake saka plastik tradisional, lan sifat kasebut langsung mengaruhi formulasi masterbatch lan pilihan peralatan ekstrusi. Properti utama sing kudu ditimbang ing pangolahan masterbatch yaiku kaya ing ngisor iki:
1.2.1 Elastisitas lan Fleksibilitas.
TPE nduweni elastisitas lan keluwesan sing dhuwur, tegese masterbatch kudu kompatibel karo matriks TPE supaya ora nyuda kinerja elastis materi.. Operator masterbatch kudu kompatibilitas apik karo TPE, and the dispersant should ensure uniform dispersion of pigments without forming agglomerates that could cause stress concentration and reduce flexibility.
1.2.2 Tahan panas.
Different TPE categories have different heat resistance (processing temperature ranges from 150℃ to 290℃). Masterbatch pigments and additives must have heat resistance matching the TPE processing temperature to avoid decomposition, owah-owahan warna, or performance degradation during extrusion. Contone, TPC and TPA require high-temperature resistant pigments and heat stabilizers.
1.2.3 Viscosity and Processability.
TPEs have varying viscosities during processing (TPV and TPC have higher viscosity, while TPS has lower viscosity). This affects the shear force and conveying requirements of the twin-screw extruder. High-viscosity TPEs require extruders with high torque and strong mixing capabilities, while low-viscosity TPEs require precise control of extrusion speed to avoid material overflow.
1.2.4 Moisture Absorption.
Some TPEs (such as TPU, TPA) duwe panyerepan banyu dhuwur, which can cause bubbles, hydrolysis, and other defects in the masterbatch. The raw materials (TPE, pigmen, aditif) must be thoroughly dried before processing, and the extruder should be equipped with a vacuum exhaust device to remove moisture and volatile substances.
1.2.5 Compatibility with Additives.
TPEs often require functional additives (such as antioxidants, penstabil UV, pelumas) to improve their performance. The masterbatch should be formulated to ensure that the additives are compatible with both the pigments and the TPE matrix, avoiding chemical reactions that could affect product quality.
2. Masterbatch for TPEs: Composition, Persyaratan Formulasi lan Pangolahan
Masterbatch kanggo TPE yaiku campuran pigmen/pewarna pekat, operator, lan aditif, dirancang kanggo werna TPE lan menehi fungsi tambahan (kayata flame retardancy, antistatik, antibakteri) nalika njaga sifat elastis lan pangolahan bahan kasebut. Formulasi lan pangolahan masterbatch TPE luwih nuntut tinimbang plastik tradisional, amarga sifat unik saka TPEs. Bagian iki rincian komposisi, prinsip formulasi, lan syarat pangolahan TPE masterbatch.
2.1 Komposisi inti saka TPE Masterbatch
Kaya masterbatch tradisional, TPE masterbatch kasusun saka telung komponen dhasar: pigmen/pewarna, operator, lan aditif. Pilihan lan proporsi saben komponen dicocogake karo jinis TPE lan syarat aplikasi.
2.1.1 Pigmen/Pewarna.
Pigmen / pewarna minangka komponen inti sing menehi warna kanggo TPE, akuntansi kanggo 10%-70% saka komposisi masterbatch (gumantung saka intensitas warna lan jinis TPE). Syarat utama kanggo pigmen / pewarna ing masterbatch TPE yaiku:
- – Tahan panas: Kudu tahan suhu pangolahan TPE target (150℃ -290 ℃) tanpa dekomposisi utawa discoloration. Kanggo TPE suhu dhuwur (TPC, TPA), pigmen organik tahan suhu dhuwur utawa pigmen anorganik luwih disenengi.
- – Kompatibilitas: Kudu kompatibel karo matriks TPE supaya ora migrasi, mekar, utawa nyuda elastisitas. Pigmen kanthi polaritas sing padha karo TPE luwih kompatibel (contone., pigmen polar kanggo TPU, pigmen non-polar kanggo TPS).
- – Dispersibility: Kudu gampang kasebar ing matriks TPE kanggo njamin pewarnaan seragam lan ngindhari bintik-bintik warna, coretan, utawa nyuda sifat mekanik. Pigmen partikel halus (20-40 bolong) kanthi aglomerasi kurang luwih disenengi.
- – Ramah Lingkungan: Kudu memenuhi standar perlindungan lingkungan global (kayata REACH, RoHS) kanggo nyegah zat beracun utawa mbebayani (kayata logam abot) sing bisa mengaruhi kesehatan manungsa lan lingkungan.
Pigmen umum sing digunakake ing masterbatch TPE kalebu: pigmen anorganik (titanium dioksida kanggo putih, karbon ireng kanggo ireng, oksida wesi kanggo abang / kuning), lan pigmen organik tahan suhu dhuwur (phthalocyanine biru / ijo, quinacridone abang).
2.1.2 Pembawa.
Pembawa minangka matriks masterbatch, akuntansi kanggo 20%-80% saka komposisi, lan muter peran tombol ing dispersing pigmen lan adhering kanggo matriks TPE. Operator kasebut kudu kompatibilitas banget karo pigmen lan target TPE, minangka kompatibilitas miskin bisa mimpin kanggo migrasi pigmen, pewarnaan sing ora rata, lan kinerja TPE suda. Pamilihan operator adhedhasar jinis TPE:
- – Kanggo TPS (SBS, SEBS): Gunakake TPS utawa PP minangka operator, which has good compatibility and processing fluidity.
- – For TPO/TPE-o: Use PP or PE as the carrier, matching the polyolefin component of the TPO.
- – For TPV/TPE-v: Use PP as the carrier, which is compatible with the PP matrix of the TPV.
- – For TPU: Use TPU as the carrier, ensuring compatibility with the TPU matrix and avoiding hydrolysis.
- – For TPC/TPE-E and TPA/TPE-A: Use TPC or TPA as the carrier, mungguh, to match the high-temperature processing requirements and compatibility.
Operator uga kudu nduweni fluiditas pangolahan sing apik, with a melting point and processing temperature consistent with or slightly lower than the target TPE, to ensure uniform mixing and avoid TPE degradation.
2.1.3 Aditif.
Aditif minangka komponen tambahan sing ditambahake kanggo nambah kinerja pangolahan, dispersibilitas, and functional performance of TPE masterbatch, akuntansi kanggo 1%-10% saka komposisi. The type and dosage of additives are determined by the TPE type and application requirements:
- – Dispersants: Aditif paling penting kanggo masterbatch TPE, digunakake kanggo ngurangi tegangan lumahing pigmen, nyegah aglomerasi, lan njamin sawur seragam ing matriks TPE. Dispersants umum kalebu lilin poliethelin, polypropylene wax, asam stearat, lan maleic anhydride grafted waxes. Kanggo TPEs viskositas dhuwur (PPN, TPC), dispersants dhuwur-efficiency karo kompatibilitas kuwat luwih disenengi.
- – Kompatibilitas: Digunakake kanggo nambah kompatibilitas antarane pigmen lan TPE, lan antarane masterbatch lan matriks TPE. Contone, maleic anhydride grafted PP digunakake minangka compatibilizer kanggo masterbatch TPO, lan lilin polyurethane digunakake kanggo masterbatch TPU.
- – Stabiliser panas: Digunakake kanggo nyegah dekomposisi pigmen lan degradasi TPE sajrone pangolahan suhu dhuwur. Stabilisator panas umum kalebu stabilisator timah organik (kanggo TPU), nyegah antioksidan fenol (kanggo TPS, TPO), lan antioksidan fosfat (kanggo TPC, TPA).
- – Stabiliser UV lan Antioksidan: Digunakake kanggo nambah resistance cuaca lan resistance tuwa produk TPE colored, nyegah luntur warna lan degradasi kinerja ing srengenge lan oksigen. Kanggo aplikasi njaba (kayata bagean njaba otomotif), Penyerap UV lan stabilisator cahya amine (HALS) ditambahake.
- – Pelumas: Digunakake kanggo nyuda gesekan ing antarane bahan lan peralatan ekstrusi (meneng, laras, sirahe mati), nambah fluidity Processing, lan supaya materi tetep ing peralatan. Pelumas umum kalebu asam stearat, kalsium stearat, lan lenga silikon. Kanggo TPU lan TPA, pelumas karo migrasi kurang luwih disenengi supaya ora mengaruhi kinerja produk.
- – Aditif Fungsional: Ditambahake kanggo menehi fungsi khusus kanggo TPE, kayata flame retardants (kanggo kabel lan kabel), agen antistatik (kanggo komponen listrik), lan agen antibakteri (kanggo piranti medis lan barang konsumen).
2.2 Prinsip Formulasi TPE Masterbatch
Formulasi masterbatch TPE kudu ngimbangi efek pewarnaan, kinerja pangolahan, lan sifat bawaan TPE. Prinsip utama kaya ing ngisor iki:
2.2.1 Kompatibilitas First.
Pembawa, pigmen, lan aditif kudu kompatibel karo target TPE supaya ngurangi elastisitas materi, keluwesan, lan sifat mekanik. Contone, nggunakake operator non-polar kanggo TPU polar bakal mimpin kanggo kompatibilitas miskin lan migrasi pigmen.
2.2.2 Cocokake Tahan Panas.
Pigmen lan aditif kudu tahan panas sing cocog karo suhu pangolahan TPE. Contone, Masterbatch TPC nggunakake pigmen tahan suhu dhuwur (tahan panas ≥280 ℃) kanggo nyegah dekomposisi sajrone proses.
2.2.3 Ngoptimalake Dispersibility.
Isi pigmen lan dosis dispersant diatur kanggo mesthekake sawur seragam. Masterbatch konsentrasi dhuwur (kandungan pigmen 50%-70%) mbutuhake luwih akeh dispersants lan kemampuan campuran sing luwih apik, nalika masterbatch konsentrasi rendah (10%-30%) fokus ing kompatibilitas.
2.2.4 Nyilikake Dampak ing Properti TPE.
The masterbatch should not significantly affect the TPE’s elasticity, compression set, or abrasion resistance. Contone, excessive dispersants or lubricants may reduce the TPE’s mechanical strength.
2.2.5 Environmental Protection Compliance.
The formulation must meet global environmental protection standards, avoiding toxic or harmful substances (kayata logam abot, phthalates) that could restrict market access.
2.3 Processing Requirements of TPE Masterbatch
TPE masterbatch processing is mainly carried out using twin-screw extrusion technology, which requires strict control of raw material pretreatment, premixing, extrusion parameters, and post-processing to ensure product quality. The key processing requirements are as follows:
2.3.1 Pretreatment Bahan Baku.
TPEs (especially TPU, TPA) duwe panyerepan banyu dhuwur, so all raw materials (TPE carrier, pigmen, aditif) must be thoroughly dried before processing. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 jam, TPS/TPO is dried at 80-100℃ for 3-5 jam, and pigments are dried at 60-80℃ for 2-4 jam. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
Kajaba iku, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 bolong) to improve dispersibility, and impurities (metal particles, bledug) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (pigmen, carrier, aditif) are mixed in a high-speed mixer according to the formula ratio to form a uniform preliminary mixture. The premixing parameters are adjusted based on the TPE type: mixing speed 800-1200 rpm, wektu nyampur 5-10 menit, mixing temperature 40-60℃. For high-concentration masterbatch or high-viscosity TPE carriers, the premixing time is extended, and dispersants are added first to coat the pigments, improving dispersibility.
2.3.3 Extrusion Parameters Control.
Twin-screw extrusion is the core step of TPE masterbatch processing, and the key parameters (suhu, kacepetan meneng, tekanan ekstrusi, kacepetan dipakani) must be precisely controlled to match the TPE type:
- – Kontrol suhu: The barrel is divided into 4-6 bagean kontrol suhu (bagean dipakani, bagean leleh, bagean nyawiji, bagean homogenizing, bagean sirah mati). The temperature of each section is adjusted according to the TPE processing temperature. Contone, TPS masterbatch: feeding section 100-120℃, melting section 160-180℃, mixing section 170-190℃, homogenizing section 160-180℃, die head section 150-170℃; TPC masterbatch: feeding section 150-170℃, melting section 230-250℃, mixing section 240-260℃, homogenizing section 230-250℃, die head section 220-240℃. The temperature control precision should reach ±1℃ to avoid TPE degradation and pigment decomposition.
- – Kacepetan meneng: The screw speed ranges from 200-800 rpm, adjusted based on TPE viscosity. TPEs viskositas dhuwur (PPN, TPC) mbutuhake kacepetan meneng luwih (500-800 rpm) kanggo ngasilake gaya geser sing cukup kanggo dispersi pigmen; TPEs kurang viskositas (TPS) nggunakake kacepetan moderat (300-500 rpm) kanggo nyegah kebanjiran materi.
- – Tekanan Ekstrusi: Tekanan antara 5-12MPa, tetep stabil (fluktuasi ≤±0.5MPa) kanggo mesthekake nyawiji seragam lan mbentuk. TPE viskositas dhuwur mbutuhake tekanan sing luwih dhuwur, nalika TPEs viskositas kurang nggunakake tekanan moderat.
- – Kacepetan Feed: Diatur kanggo cocog kacepetan meneng lan kacepetan extrusion, njamin dipakani stabil lan seragam. Kanggo TPEs viskositas dhuwur, piranti dipakani dipeksa digunakake kanggo ngindhari akumulasi materi.
2.3.4 Post-Processing.
Sawise extrusion, masterbatch shaped Strip digawe adhem (cooling tank banyu, 20-30℃), granulated (ukuran partikel 2-5 mm), disaring (kanggo mbusak partikel unqualified), lan dibungkus (kemasan sing disegel lan tahan kelembapan). Kanggo masterbatch TPE sing sensitif kelembapan (TPU, TPA), produk rampung wis pepe maneh sadurunge packaging kanggo nyegah panyerepan Kelembapan.
3. Bidang Aplikasi TPE Masterbatch lan Solusi Extruder Zhuoyue sing cocog
TPEs digunakake akeh ing otomotif, listrik, konstruksi, barang konsumen, lan industri liyane, lan lapangan aplikasi beda duwe syarat beda kanggo kinerja masterbatch TPE (werna, dispersibilitas, fungsi) lan efisiensi produksi. Zhuoyue seri lengkap extruders kembar-meneng (HTS BASIC/PLUS/SUPER, ZTE, HTE) dioptimalake khusus kanggo pangolahan masterbatch TPE, nyedhiyakake solusi sing ditargetake kanggo macem-macem kategori TPE lan lapangan aplikasi. Ing ngisor iki minangka introduksi rinci babagan lapangan aplikasi utama TPE masterbatch lan seri extruder Zhuoyue sing cocog..
3.1 Industri Otomotif: Bidang Aplikasi Paling gedhe saka TPE Masterbatch
Industri otomotif minangka konsumen paling gedhe saka TPE, accounting kanggo luwih saka 40% saka pasar TPE global. TPE digunakake ing macem-macem komponen otomotif amarga bobote entheng, fleksibel, lan properti sing bisa didaur ulang, lan masterbatch TPE nduweni peran penting ing pewarnaan lan modifikasi fungsional komponen kasebut. Aplikasi otomotif utama masterbatch TPE kalebu:
3.1.1 Seal lan Gasket Otomotif.
TPEs (utamane TPV, TPO) digunakake kanggo gawé segel lawang otomotif, segel jendhela, hood segel, lan gaskets, sing mbutuhake elastisitas sing apik, tahan cuaca, lan keluwesan suhu kurang. Masterbatch kanggo komponen kasebut mbutuhake pewarnaan seragam, resistance cuaca apik (resistance UV, resistance tuwa), lan kompatibilitas karo matriks TPV/TPO.
Extruders sing cocog: Seri HTS PLUS lan seri HTE. Seri HTS PLUS nduweni torsi dhuwur lan tahan nyandhang, cocok kanggo TPV masterbatch Processing (viskositas dhuwur, pasukan geser dhuwur dibutuhake); seri HTE nyawiji kinerja dhuwur lan biaya-efektifitas, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPEs (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, panel lawang, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (ora beracun, ora ana ambune). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Extruders sing cocog: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small and medium-sized manufacturers producing TPS interior masterbatch; the HTE series has good mixing dispersibility and low energy consumption, suitable for large-scale production of TPU/TPS interior masterbatch.
3.1.3 Automotive Hoses and Tubing.
TPEs (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, tahan panas, lan kekuatan mekanik. The masterbatch requires high-temperature resistance, resistance lenga, and uniform dispersibility to avoid affecting the hose’s performance.
Extruders sing cocog: HTS SUPER series and HTS PLUS series. The HTS SUPER series has ultra-high torque, kontrol suhu sing tepat, and high wear resistance, suitable for TPC/TPA masterbatch processing (suhu dhuwur, viskositas dhuwur); the HTS PLUS series has good heat resistance and mixing capabilities, suitable for TPU masterbatch processing.
3.1.4 Other Automotive Components.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, which require different properties (such as dust resistance, transparansi, resistance impact). The masterbatch is formulated according to specific requirements, and the matching extruders are selected based on TPE type and production scale.
3.2 Electrical and Electronic Industry: Functional TPE Masterbatch Applications
The electrical and electronic industry is another important application field of TPEs, where TPEs are used to produce wires and cables, konektor, lan komponen liyane, requiring functional masterbatch (antistatik, tahan geni, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPEs (mainly TPU, TPS, TPO) are used as insulation and sheath materials for wires and cables (power cables, ignition wires, headphone wires, connector plugs), which require good electrical insulation, retardancy geni, lan tahan abrasi. The masterbatch requires flame retardancy (meeting UL94 V-0 standar), sifat antistatik, and uniform coloring.
Extruders sing cocog: HTS PLUS series, HTE series, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, suitable for small and medium-sized production; seri HTS SUPER cocok kanggo dhuwur-mburi, pangolahan masterbatch tahan api konsentrasi dhuwur.
3.2.2 Konektor lan Plug Listrik.
TPEs (mainly TPU, TPA) digunakake kanggo gawé konektor electrical, colokan, lan omah soket, which require good electrical insulation, resistance impact, and environmental friendliness. Masterbatch mbutuhake pewarnaan seragam, resistance suhu dhuwur, and no migration.
Extruders sing cocog: Seri HTS PLUS lan seri HTS SUPER. Seri HTS PLUS nduweni kompatibilitas apik karo TPU/TPA, njamin dispersi seragam; seri HTS SUPER nduweni kontrol suhu sing tepat, ngindhari degradasi TPA sajrone pangolahan.
3.3 Industri Konstruksi lan Transportasi: Aplikasi Masterbatch TPE Tahan Cuaca
Ing industri konstruksi lan transportasi, TPE digunakake kanggo ngasilake segel, joints expansion, tikar subway, lan komponen liyane, mbutuhake tahan cuaca sing apik, resistance tuwa, lan keluwesan suhu kurang kanggo adaptasi karo lingkungan ruangan sing atos.
3.3.1 Konstruksi Seal lan Expansion Joints.
TPEs (utamane TPV, TPO) digunakake kanggo gawé lawang lan jendhela segel bangunan, segel tembok gorden, and expansion joints, which require good weather resistance, resistance UV, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Extruders sing cocog: Seri HTS PLUS lan seri HTE. The HTS PLUS series has good weather-resistant additive mixing capabilities, cocok kanggo TPV masterbatch Processing; the HTE series is energy-saving and efficient, suitable for large-scale production of TPO masterbatch.
3.3.2 Transportation Components.
TPEs are used to produce subway mats, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, lan nyandhang resistance. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Extruders sing cocog: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small-batch production; the HTE series has good mixing capabilities, ensuring uniform dispersion of shock-absorbing additives.
3.4 Consumer Goods and Other Industries: Diverse TPE Masterbatch Applications
TPEs are widely used in consumer goods and other industries, with diverse application scenarios and varying masterbatch requirements, focusing on color, soft touch, and environmental friendliness.
3.4.1 Footwear Industry.
TPEs (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, resistance abrasion, and soft touch. The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining socks).
Extruders sing cocog: HTS BASIC series and ZTE series. The ZTE series has excellent cost performance, suitable for small and medium-sized footwear manufacturers; the HTS BASIC series has good mixing dispersibility, ensuring uniform coloring of shoe sole masterbatch.
3.4.2 Household and Daily Necessities.
TPEs are used to produce handles, coasters, foot mats, dolanan, and other household items, which require non-toxic, ora ana ambune, soft touch, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Extruders sing cocog: Seri ZTE lan seri HTS BASIC. Seri ZTE gampang dioperasikake, kurang ing biaya pangopènan, cocok kanggo kelompok cilik, produksi macem-macem; seri HTS BASIC nduweni kompatibilitas masterbatch perlindungan lingkungan sing apik, ketemu standar kontak pangan.
3.4.3 Piranti Medis.
TPEs (mainly TPU, TPS) digunakake kanggo ngasilake kateter medis, jarum suntik, lan topeng medis, which require non-toxic, steril, lan biokompatibel. Masterbatch mbutuhake perlindungan lingkungan kelas medis (rapat ISO 10993 standar), transparansi dhuwur (kanggo kateter), lan dispersibility seragam.
Extruders sing cocog: HTS SUPER series and HTS PLUS series. Seri HTS SUPER nduweni desain produksi sing resik, kontrol suhu sing tepat, nyegah polusi materi; seri HTS PLUS nduweni kompatibilitas apik karo TPE kelas medis, njamin sterilitas lan biokompatibilitas produk.
3.4.4 Aplikasi Industri Liyane.
TPE uga digunakake kanggo ngasilake pipa saluran, gasket industri, lan komponen mekanik, kang mbutuhake resistance kimia apik, nyandhang resistance, lan kekuatan mekanik. The masterbatch is formulated according to specific industrial requirements, and the matching extruders are selected based on TPE type and production scale.
4. Zhuoyue’s Full Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue has long been engaged in the research, development, and production of high-performance twin-screw extruders, and has accumulated rich experience in TPE masterbatch processing. Based on the unique processing characteristics of TPEs (viskositas dhuwur, temperature sensitivity, moisture absorption) and the diverse needs of manufacturers (different TPE categories, production scales, application fields), Zhuoyue has launched a full series of extruders suitable for TPE masterbatch processing, including HTS BASIC, HTS PLUS, HTS SUPER, ZTE, and HTE series. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Efek Campuran lan Dispersing sing Apik banget.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. Kabeh extruders kembar-meneng Zhuoyue nganggo struktur co-puteran intermeshing, karo pitch meneng cukup, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, operator, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Kajaba iku, the screws adopt a modular design, kang bisa bebas gabungke unsur meneng beda (ngaturake, nyampur, nyukur) according to the TPE type. Contone, high-viscosity TPV/TPC masterbatch requires more mixing and shearing elements to enhance dispersion; low-viscosity TPS masterbatch uses more conveying elements to improve production efficiency.
4.1.2 Precise Temperature Control, Avoiding TPE Degradation.
TPEs are sensitive to temperature, and excessive temperature or temperature fluctuation can lead to material degradation (such as TPU hydrolysis, TPC chain scission). All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, karo 4-6 independent temperature control sections, temperature control precision of ±1℃, and real-time temperature monitoring and alarm functions. The barrel adopts a double-layer jacket design, realizing rapid heating and cooling, and improving temperature response speed. The die head is equipped with an independent temperature control device, ensuring stable shaping of the masterbatch strip.
4.1.3 High Wear Resistance and Corrosion Resistance.
Some TPE masterbatches (such as TPA, TPC) contain high-hardness pigments or additives, which can wear the screw and barrel. Zhuoyue’s extruders use high-quality wear-resistant materials and advanced manufacturing technologies: HTS PLUS/SUPER/HTE series screws and barrels are made of imported wear-resistant alloy steel, undergoing bimetallic composite or laser cladding treatment, atose lumahing ≥65 HRC (HTS SUPER series ≥70 HRC), service life 2-3 kaping extruders biasa; HTS BASIC/ZTE series screws and barrels are nitrided, surface hardness ≥60 HRC, meeting the needs of ordinary TPE masterbatch processing.
4.1.4 Vacuum Exhaust and Moisture Removal Capabilities.
TPEs such as TPU and TPA have high water absorption, and moisture can cause bubbles and defects in the masterbatch. All Zhuoyue’s mid-to-high-end extruders (HTS PLUS/SUPER/HTE) are equipped with a vacuum exhaust device, which can effectively remove moisture, volatile substances, and air in the material, ensuring the density and quality of the masterbatch. The vacuum degree is adjustable (0.06-0.09MPa), adapting to different moisture content requirements.
4.1.5 High Production Efficiency and Energy Saving.
Zhuoyue’s extruders adopt high-torque gearboxes and optimized screw structures, with strong conveying capacity and high production efficiency. Compared with ordinary extruders, production efficiency is increased by 20%-50%, and energy consumption is reduced by 15%-25%. Contone, HTS SUPER series production capacity reaches 1000-3000kg/h, suitable for large-scale mass production; ZTE series production capacity is 50-400kg/h, suitable for small-batch production.
4.1.6 Intelligent Control and Easy Operation.
All extruders adopt a PLC intelligent control system and touch screen operation interface, which can store up to 100 sets of formula and processing parameters. When switching between different TPE masterbatches, mung paramèter sing cocog kudu diarani, ngindhari debugging bola-bali. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, monitoring data produksi, lan pangopènan prediktif, mujudake manajemen produksi sing cerdas.
4.1.7 Adaptasi Wide.
Zhuoyue’s full series of extruders can adapt to the processing of all TPE categories (TPS/SBS/TPU/TPR/TPV/TPC/TPA) and masterbatch types (werna masterbatch, masterbatch tahan api, masterbatch antistatik), with pigment content ranging from 10% kanggo 70%. They can also be matched with auxiliary equipment (high-speed mixers, pengering, coolers, granulator) kanggo mbentuk baris produksi otomatis lengkap.
4.2 Detailed Introduction of Zhuoyue’s Extruder Series for TPE Masterbatch Processing
Each series of Zhuoyue’s extruders has unique performance characteristics and targeted adaptation scenarios, and manufacturers can select the appropriate series according to their TPE type, skala produksi, lan syarat aplikasi.
4.2.1 HTS BASIC Series: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, kontrol suhu otomatis, lan dipakani, simple to operate. The modular screw design allows flexible configuration according to TPS/TPO masterbatch requirements. The HTS BASIC series is an ideal choice for small and medium-sized manufacturers with limited budget, focusing on ordinary TPE masterbatch production (such as household goods, ordinary wires and cables).
4.2.2 HTS PLUS Series: High-Torque for Engineering TPE and High-Concentration Masterbatch.
The HTS PLUS series is positioned as a mid-to-high-end product, specially designed for high-demand TPE masterbatch processing (PPN, TPU, high-concentration TPE masterbatch, masterbatch tahan api). It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 13-16Nm/cm³, screw diameter 40-75mm, production capacity 300-1200kg/h.
The series uses bimetallic composite screws and barrels (atose lumahing ≥65 HRC), with excellent wear resistance and corrosion resistance, suitable for TPV/TPC masterbatch processing (viskositas dhuwur, high-hardness pigments). It is equipped with a 5-6 section precise temperature control system and vacuum exhaust device, avoiding TPU hydrolysis and TPC degradation. The enhanced mixing elements ensure uniform dispersion of high-concentration pigments (50%-70%) and functional additives (flame retardants, agen antistatik). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (such as automotive seals, high-grade wires and cables, piranti medis).
4.2.3 HTS SUPER Series: Ultra-High Performance for High-End TPE Masterbatch.
The HTS SUPER series is Zhuoyue’s highest-end extruder series, representing the advanced level of China’s twin-screw extruders, designed for high-end, high-demand TPE masterbatch processing (TPA, TPC, ultra-high-concentration masterbatch, masterbatch for new energy vehicles/aerospace).
It adopts Zhuoyue’s latest ultra-high torque transmission device, specific torque 17-20Nm/cm³, screw diameter 50-95mm, production capacity 1000-3000kg/h. The screws are made of new wear-resistant alloy steel, undergoing laser cladding treatment (atose lumahing ≥70 HRC), service life 3-4 kaping extruders biasa. The barrel adopts a double-layer jacket + forced cooling structure, presisi kontrol suhu ± 1 ℃, suitable for high-temperature TPE processing (220-290℃). The multi-stage mixing screw combination ensures ultra-high mixing uniformity (≥98%), suitable for ultra-high-concentration masterbatch (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, lan pangopènan prediktif. It is suitable for large-scale, high-standard manufacturers producing high-end TPE masterbatch (such as automotive high-temperature hoses, precision electrical connectors, aerospace components).
4.2.4 Seri ZTE: Cost-Effective for Universal TPE Masterbatch.
The ZTE series is positioned as a cost-effective product, designed for manufacturers balancing processing quality and cost, producing universal ordinary TPE masterbatch (low-concentration TPS/TPO/TPU masterbatch). It adopts a twin-screw parallel co-rotating structure, specific torque 8-11Nm/cm³, screw diameter 25-65mm, production capacity 50-400kg/h.
The series uses nitrided screws and barrels (surface hardness ≥60 HRC), meeting the needs of ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a 4-section temperature control system, simple touch screen operation, easy to learn and master. The ZTE series has a simple structure, konsumsi energi kurang, and low maintenance cost, suitable for small manufacturers, small workshops, and enterprises producing small-batch, multi-variety TPE masterbatch (such as small toys, local household goods).
4.2.5 HTE Series: High Performance and Cost-Effective Integrated Solution.
The HTE series integrates high performance and cost-effectiveness, designed for medium-sized manufacturers upgrading product quality and expanding production scale. It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 12-14Nm/cm³, screw diameter 35-70mm, production capacity 200-800kg/h.
The series uses bimetallic composite screws and barrels (atose lumahing ≥65 HRC), with good wear resistance, suitable for TPU/TPO masterbatch processing. It adopts an optimized screw structure and high-efficiency energy-saving motor, energy consumption reduced by 18%-25% dibandhingake karo extruders biasa. The 5-section precise temperature control system and vacuum exhaust device ensure product quality, and the enhanced mixing elements ensure uniform dispersion. The HTE series balances performance and cost, suitable for medium-sized manufacturers producing medium-grade TPE masterbatch (such as automotive interior components, ordinary medical devices, mid-grade wires and cables).
5. Common Problems and Solutions in TPE Masterbatch Twin-Screw Extrusion Processing
In TPE masterbatch processing, amarga sifat unik saka TPEs (temperature sensitivity, moisture absorption, viskositas dhuwur), macem-macem masalah asring kedadeyan, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Masalah 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Nimbulaké: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Premixing: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) prabotan: Worn screw mixing elements; blocked die head.
Solusi: (1) Optimize raw materials: Select fine-particle pigments (20-40 bolong), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 rpm, extend mixing time to 5-10 menit. (3) Nyetel paramèter ekstrusi: Increase screw speed (500-800 rpm for high-viscosity TPEs); increase extrusion temperature to ensure complete melting of TPE. (4) Njaga peralatan: Replace worn screw elements; clean die head regularly.
5.2 Masalah 2: TPE Degradation and Masterbatch Discoloration
Manifestation: Masterbatch discolors (yellowing, peteng ndhedhet), generates peculiar smell; TPE products have reduced elasticity and mechanical strength, even brittle fracture.
Nimbulaké: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (luwih saka 3 menit) in the extruder. (3) Poor equipment cooling, local overheating of the barrel. (4) Raw materials: TPE has poor heat resistance; moisture content is too high (causing TPU hydrolysis).
Solusi: (1) Adjust temperature: Reduce mixing/homogenizing section temperature, control within TPE processing range; check temperature sensor accuracy. (2) Shorten residence time: Increase screw speed, reduce screw compression ratio. (3) Maintain cooling system: Clean cooling pipes, replace faulty cooling elements. (4) Optimize raw materials: Select high-temperature resistant TPE; dry raw materials thoroughly (moisture content ≤0.05% for TPU/TPA); add heat stabilizers.
5.3 Masalah 3: High Wear of Screw and Barrel
Manifestation: Rapid wear of screw and barrel, reduced shear force and mixing capacity; masterbatch dispersibility decreases, equipment maintenance cost increases.
Nimbulaké: (1) Raw materials: High-hardness pigments/additives (such as carbon black, titanium dioxide); large particle size. (2) Extrusion parameters: High screw speed, excessive shear force; high extrusion pressure. (3) prabotan: Screw/barrel material has poor wear resistance.
Solusi: (1) Optimize raw materials: Select small-particle, low-hardness pigments; crush and sieve raw materials; add lubricants to reduce friction. (2) Adjust parameters: Reduce screw speed and extrusion pressure appropriately. (3) Select high-wear-resistant equipment: Choose Zhuoyue’s HTS PLUS/SUPER/HTE series with bimetallic composite or laser-clad screws/barrels.
5.4 Masalah 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Nimbulaké: (1) Raw materials: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Premixing: Air mixed into the mixture during premixing.
Solusi: (1) Dry raw materials thoroughly: Extend drying time, increase drying temperature. (2) Nyetel paramèter ekstrusi: Increase extrusion temperature; improve vacuum exhaust (vacuum degree ≥0.08MPa). (3) Optimize premixing: Reduce mixing speed appropriately to avoid air mixing; use a closed mixer.
5.5 Masalah 5: Poor Processing Fluidity, Equipment Blockage
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Nimbulaké: (1) Raw materials: High TPE viscosity (TPV/TPC); kandungan pigmen sing dhuwur (luwih saka 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) prabotan: Worn conveying elements; blocked die head.
Solusi: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Adjust parameters: Increase extrusion temperature; increase screw speed; replace die head with larger holes. (3) Njaga peralatan: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Practical Application Cases of Zhuoyue Extruders in TPE Masterbatch Processing
To verify the performance advantages of Zhuoyue’s extruders in TPE masterbatch processing, this section introduces several practical cases, covering different TPE categories, production scales, and application fields, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Kasus 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Latar mburi Pelanggan: A large automotive component manufacturer in Shanghai, Cina, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (kandungan pigmen 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), tahan panas (260℃), and batch stability. The original equipment had problems of insufficient torque, kontrol suhu ora stabil, and poor dispersibility, which could not meet the requirements.
Solusi: Zhuoyue recommended the HTS SUPER series extruders (diameteripun meneng 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, mixer kacepetan dhuwur, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Pisanan, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Kapindho, the barrel is equipped with a double-layer jacket + forced cooling structure, karo 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Katelu, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Kajaba iku, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect: Sawise 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 wulan, reducing maintenance costs by more than 50%. Selang TPC pelanggan sing digawe saka masterbatch iki wis lulus sertifikasi kualitas industri otomotif, karo resistance suhu dhuwur banget lan kekuatan mechanical, lan wis kasil diwenehake menyang manufaktur kendaraan energi anyar utama. Customer Highly dikenali solusi extrusion Zhuoyue kang, lan banjur nandatangani perjanjian kerjasama jangka panjang, tuku 5 liyane set HTS SUPER seri extruders kanggo nggedhekake ukuran produksi.
6.1 Kasus 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Latar mburi Pelanggan:
A large automotive component manufacturer in Shanghai, Cina, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (kandungan pigmen 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), tahan panas (260℃), and batch stability. The original equipment had problems of insufficient torque, kontrol suhu ora stabil, and poor dispersibility, which could not meet the requirements.
Solusi:
Zhuoyue recommended the HTS SUPER series extruders (diameteripun meneng 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, mixer kacepetan dhuwur, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Pisanan, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Kapindho, the barrel is equipped with a double-layer jacket + forced cooling structure, karo 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Katelu, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Kajaba iku, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect:
Sawise 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 wulan, reducing maintenance costs by more than 50%. Selang TPC pelanggan sing digawe saka masterbatch iki wis lulus sertifikasi kualitas industri otomotif, karo resistance suhu dhuwur banget lan kekuatan mechanical, lan wis kasil diwenehake menyang manufaktur kendaraan energi anyar utama. Customer Highly dikenali solusi extrusion Zhuoyue kang, lan banjur nandatangani perjanjian kerjasama jangka panjang, tuku 5 liyane set HTS SUPER seri extruders kanggo nggedhekake ukuran produksi.