Filler Masterbatch uzlabotās granulēšanas ražošanas līnijas un ekstrūzijas tehnoloģiju pielietojums

Strauji attīstoties globālajai plastmasas industrijai, pieprasījums pēc plastmasas izstrādājumiem ar katru dienu pieaug, un produkta veiktspējas prasības, arī izmaksu kontrole un vides aizsardzība kļūst arvien stingrāka. Pildvielas pamatsavienojums, kā galvenā funkcionālā piedeva plastmasas apstrādē, ir plaši izmantots dažādās plastmasas ražošanas jomās, pateicoties tās priekšrocībām samazināt ražošanas izmaksas, uzlabot produktu veiktspēju un optimizēt apstrādes efektivitāti. Mēs esam apņēmušies nodrošināt uzlabotas granulēšanas ražošanas līnijas un augstas veiktspējas ekstrūderus dažāda veida pildvielu pamatsavienojumiem, paļaujoties uz bagātīgu pieredzi ekstrūzijas tehnoloģiju izpētē, izstrādē un ražošanā, nodrošināt mērķtiecīgu, efektīvi un uzticami apstrādes risinājumi pildvielu maisījuma ražotājiem, palīdzēt uzņēmumiem uzlabot ražošanas efektivitāti, nodrošināt produktu kvalitāti, un iegūt konkurences priekšrocības sīvajā tirgus konkurencē.

Šajā rakstā galvenā uzmanība tiks pievērsta pildvielu pamatsavienojuma jomai, padziļināti izstrādājot pamatjēdzienus, klasifikācija, špakteļmasas ražošanas process, Ekstrūzijas tehnoloģijas galvenā loma granulu ražošanā, mūsu ekstrūderu sērijas priekšrocības un to mērķtiecīga pielāgošana pildvielu pamatsavienojuma apstrādei, kā arī specifiskos lietojumprogrammu laukus, lietošanas metodes un izplatītākās problēmas un risinājumi ražošanā. Tas papildinās detalizētus tehniskos parametrus, procesa detaļas un nozares sāpju punkti, lai bagātinātu saturu, atbilst vārdu skaita prasībai 3000-4000 vārdus, un nodrošināt visaptverošu un profesionālu uzziņu atbilstošiem uzņēmumiem un praktiķiem pildvielu pamatsavienojumu nozarē.

1. Pildvielu galvenā maisījuma ražošanas nozares un produktu raksturojumu pārskats

1.1 Pašreizējā situācija un attīstības tendences pildvielu maisījuma rūpniecībā

Pēdējos gados, pakārtoto nozaru, piemēram, iepakošanas, straujā attīstība, celtniecība, automobiļu rūpniecība, elektronika un ikdienas nepieciešamība, globālais pildvielu galveno maisījumu tirgus ir uzrādījis stabilu pieauguma tendenci. Pildvielas pamatmaisījums ir sava veida kompozītmateriāls, ko izgatavo, sajaucot, kušana, neorganisko pildvielu ekstrudēšana un granulēšana (piemēram, kalcija karbonāts, talks, bārija sulfāts, utt.) ar polimēru nesējiem (piemēram, polietilēns, polipropilēns, polivinilhlorīds, utt.) un atbilstošas ​​piedevas (piemēram, disperģētāji, saderības līdzekļi, smērvielas, utt.) noteiktā proporcijā. Tās galvenā funkcija ir samazināt plastmasas izstrādājumu ražošanas izmaksas, vienlaikus uzlabojot vai saglabājot plastmasas izstrādājumu pamata veiktspēju.

Saskaņā ar attiecīgo datu statistiku, globālais pildvielu pamatsavienojumu tirgus apjoms ir pārsniedzis 20 miljardu ASV dolāru, un paredzams, ka tas saglabās pieauguma tempu 6%-9% tuvākajos gados. Starp tiem, kalcija karbonāts (CaCO3) špakteļmasa ir visplašāk izmantotais produktu veids, kas veido vairāk nekā 60% no kopējā pildvielu galvenā maisījuma tirgus, kam seko talka pildvielas pamatmaisījums, bārija sulfāts (BaSO4) pildvielas pamatsajas un citas īpašas pildvielas pamatsajas. Āzijas un Klusā okeāna reģions ir pasaulē lielākais pildvielu galveno maisījumu ražošanas un patēriņa tirgus, kas veido vairāk nekā 50% no pasaules tirgus daļas, kas galvenokārt ir saistīts ar straujo plastmasas apstrādes rūpniecības attīstību Ķīnā, Indija un citas valstis, milzīgais pieprasījums pēc izmaksu samazināšanas un plastmasas izstrādājumu veiktspējas uzlabošanas, un nepārtraukta rūpnieciskās atbalsta jaudas uzlabošana.

Pildvielu maisījuma ražošanas nozares attīstības tendence galvenokārt ir atspoguļota četros aspektos: vispirms, augsta veiktspēja un funkcionalitāte. Uzlabojot pakārtotās plastmasas izstrādājumu prasības, pildvielas galvenais maisījums vairs neaprobežojas tikai ar izmaksu samazināšanu, bet pamazām attīstās uz funkcionalizāciju, piemēram, uzlabojot stingrību, stingrība, karstumizturība, plastmasas izstrādājumu laika apstākļu izturība un barjeras īpašības, un izstrādājot īpašas funkcionālas pildvielas galvenās partijas, piemēram, liesmas slāpētājus, antistatiska un antibakteriāla; otrais, augsts pildījuma daudzums un laba izkliedējamība. Saskaņā ar priekšnoteikumu nodrošināt produkta veiktspēju, palielinot neorganisko pildvielu pildījuma daudzumu, var vēl vairāk samazināt ražošanas izmaksas, kas izvirza augstākas prasības pildvielas galvenā maisījuma disperģējamībai — izcila disperģējamība var nodrošināt, ka pildviela tiek vienmērīgi sadalīta plastmasas matricā, izvairoties no baltu plankumu parādīšanās, melni plankumi vai aglomerācija galaproduktā; trešais, vides aizsardzība un zems piesārņojums. Ar globālās vides aizsardzības politikas stiprināšanu un vides aizsardzības izpratnes uzlabošanos, pildvielu galveno maisījumu ražotāji pakāpeniski ievieš videi draudzīgas piedevas un ražošanas procesus, samazinot kaitīgo vielu emisiju, un izstrādājot noārdāmu pildvielu galveno maisījumu, lai pielāgotos zaļās plastmasas attīstības tendencei; ceturtais, ražošanas iekārtu intelekts un efektivitāte. Lai apmierinātu liela mēroga, nepārtrauktas un kvalitatīvas pildvielas pamatsasijas ražošanas vajadzības, ražotāji pastāvīgi ievieš progresīvas granulēšanas ražošanas līnijas un inteliģentas vadības sistēmas, ražošanas efektivitātes uzlabošana, darbaspēka izmaksu samazināšana un produktu kvalitātes stabilitātes nodrošināšana.

Uz šī fona, Ekstrūzijas granulēšanas tehnoloģija, kā pildvielu maisījuma ražošanas pamattehnoloģiju, ir kļuvusi par atslēgu špakteļmasas kvalitātes un uzņēmumu konkurētspējas noteikšanā. Ekstrūderu veiktspēja tieši ietekmē izkliedējamību, daļiņu forma, kušanas indekss un citi galvenie pildvielas galvenā maisījuma rādītāji. Mūsu profesionālie ekstrūderi un granulēšanas ražošanas līnijas pildvielu galvenajai masai ir izstrādātas, reaģējot uz nozares īpašībām un tirgus pieprasījumu, kas var efektīvi atrisināt sāpju punktus pildvielu pamatsasijas apstrādē (piemēram, slikta izkliedējamība, nevienmērīgs daļiņu izmērs, zems pildījuma daudzums, augsts enerģijas patēriņš, utt.) un palīdzēt uzņēmumiem sasniegt kvalitatīvu un efektīvu ražošanu.

1.2 Pildvielu galvenā maisījuma klasifikācija un tās pamatīpašības

Pildvielas pamatsavienojumu var iedalīt dažādos veidos atkarībā no pildvielas veida, nesējsveķi, pieteikuma lauks un aizpildījuma daudzums. Katram pildvielas galvenā maisījuma veidam ir savas unikālās īpašības un piemērojamie scenāriji. Tālāk ir sniegts detalizēts ievads pildvielas galvenā maisījuma vispārīgajai klasifikācijai un galvenajām īpašībām:

1.2.1 Klasifikācija pēc pildvielas veida:

Šī ir visizplatītākā pildvielu galvenās maisījuma klasifikācijas metode. Atbilstoši neorganiskās pildvielas veidam, to galvenokārt var iedalīt kalcija karbonātā (CaCO3) pildvielas pamatsasija, talka pildvielas pamatmaisījums, bārija sulfāts (BaSO4) pildvielas pamatsasija, un citas speciālas pildvielas pamatsasejas (piemēram, kaolīna pildvielas pamatmaisījums, ogļmelnās pildvielas pamatmaisījums, stikla šķiedras pildvielas pamatsavienojums, utt.).

• Kalcija karbonāts (CaCO3) Pildvielas pamatmaisījums: Tā ir visplašāk izmantotā špakteļmasa ar viszemākajām izmaksām. Pildviela galvenokārt ir vieglais kalcija karbonāts vai smagais kalcija karbonāts. Vieglajam kalcija karbonātam ir smalks daļiņu izmērs, laba izkliedējamība un augsts baltums, kas ir piemērots plastmasas izstrādājumiem ar augstām prasībām attiecībā uz izskatu un smalkumu (piemēram, plastmasas plēves, iesmidzināšanas formēšanas izstrādājumi); smagajam kalcija karbonātam ir augsta cietība, laba nodilumizturība un zema cena, kas ir piemērots plastmasas izstrādājumiem ar augstām prasībām attiecībā uz stingrību un izmaksu kontroli (piemēram, austi maisiņi, iepakošanas lentes, caurules, utt.). Kalcija karbonāta pildvielas galvenais maisījums var ne tikai samazināt ražošanas izmaksas, bet arī uzlabo stingrību, plastmasas izstrādājumu karstumizturība un izmēru stabilitāte, un tam ir noteikta eļļošanas iedarbība, kas var uzlabot plastmasas apstrādes plūstamību.
• Talka pildījuma pamatmaisījums: Pildviela ir talka pulveris ar slāņainu struktūru. Talka pulverim ir labas mehāniskās īpašības, karstumizturība un ķīmiskā stabilitāte. Talka pildvielas galveno maisījumu galvenokārt izmanto polipropilēnā (PP) plastmasas izstrādājumi, kas var ievērojami uzlabot stingrību, PP izstrādājumu siltuma deformācijas temperatūra un triecienizturība, un to plaši izmanto automobiļu detaļās, sadzīves tehnikas čaulas, plastmasas caurules un citi lauki, kuriem nepieciešama augsta veiktspēja.
• Bārija sulfāts (BaSO4) Pildvielas pamatmaisījums: Pildviela ir bārija sulfāta pulveris, kam ir augsts baltums, laba pārredzamība, ķīmiskā inerce un starojuma izturība. Bārija sulfāta pildvielas pamatmaisījums ir piemērots plastmasas izstrādājumiem ar augstām prasībām attiecībā uz caurspīdīgumu, baltums un ķīmiskā stabilitāte (piemēram, plastmasas plēves, plastmasas pudeles, medicīniskās plastmasas izstrādājumi, utt.), un to var izmantot arī radiācijas necaurlaidīgos plastmasas izstrādājumos (piemēram, medicīniskie aizsardzības līdzekļi, atomelektrostaciju piederumi, utt.).

1.2.2 Klasifikācija pēc nesējsveķiem:

Atbilstoši izmantoto nesējsveķu veidam, pildvielu galveno maisījumu var iedalīt polietilēnā (PE) pildvielas pamatsasija, polipropilēns (PP) pildvielas pamatsasija, polivinilhlorīds (PVC) pildvielas pamatsasija, polietilēntereftalāts (PET) pildvielas pamatsasija, utt. Nesējsveķu izvēli galvenokārt nosaka pakārtoto plastmasas izstrādājumu veids. Piemēram, PE pildvielas pamatmaisījums ir piemērots PE plastmasas izstrādājumiem (piemēram, plastmasas plēves, somas, caurules); PP pildvielas pamatmaisījums ir piemērots PP plastmasas izstrādājumiem (piemēram, austi maisiņi, iesmidzināšanas formēšanas daļas, automobiļu daļas); PVC filler masterbatch is suitable for PVC plastic products (piemēram, PVC caurules, profili, loksnes).

1.2.3 Klasifikācija pēc lietojuma laukiem:

According to the application field of downstream plastic products, filler masterbatch can be divided into film-grade filler masterbatch, injection-grade filler masterbatch, extrusion-grade filler masterbatch, blow molding-grade filler masterbatch, utt. Film-grade filler masterbatch requires good dispersibility, high fineness and no impurities, to ensure that the blown film has no white spots, black spots or pinholes, and maintains good transparency and toughness; injection-grade filler masterbatch requires good fluidity and uniform particle size, to adapt to the rapid injection molding process and ensure the appearance and dimensional accuracy of injection products; extrusion-grade filler masterbatch requires good thermal stability and mechanical properties, pielāgoties cauruļu augstas temperatūras un augstspiediena ekstrūzijas procesam, profili un citi produkti.

1.2.4 Klasifikācija pēc uzpildes daudzuma:

Atbilstoši neorganisko pildvielu uzpildes daudzumam, pildvielas galveno maisījumu var iedalīt zemas pildījuma pamatsaukumā (uzpildes daudzums 30%-50%), vidēja pildījuma pamatmaisījums (uzpildes daudzums 50%-70%) un augstas pildījuma pamatsavienojums (uzpildes daudzums 70% un augstāk). Uzpildes daudzumu nosaka atbilstoši pakārtoto produktu veiktspējas prasībām un iekārtu apstrādes jaudai. Augstas pildījuma pamatsavienojumam ir acīmredzamāks izmaksu samazināšanas efekts, bet tai ir augstākas prasības attiecībā uz pildvielu izkliedējamību un ekstrūderu veiktspēju - tikai augstas veiktspējas ekstrūderi var nodrošināt vienmērīgu augstas pildījuma materiālu sajaukšanu un kausēšanu, izvairoties no aglomerācijas un sliktas apstrādes plūstamības.

Ir vērts atzīmēt, ka pildvielas galvenās maisījuma galvenie darbības rādītāji galvenokārt ietver izkliedējamību, daļiņu izmēra viendabīgums, kušanas indekss, baltums (gaišas krāsas izstrādājumiem) un saderība ar nesējsveķiem. Starp tiem, izkliedējamība ir vissvarīgākais rādītājs — slikta izkliedējamība izraisīs nevienmērīgu pildvielu sadalījumu plastmasas izstrādājumos, kā rezultātā rodas defekti, piemēram, balti plankumi, melni plankumi, aglomerācija un trausli produkti, kas nopietni ietekmē plastmasas izstrādājumu izskatu un veiktspēju. Tāpēc, uzlabotas ekstrūzijas iekārtas un zinātniskās apstrādes tehnoloģijas izvēle ir ļoti svarīga, lai nodrošinātu pildvielas galvenā maisījuma izkliedējamību un vispārējo kvalitāti..

2. Pildvielu maisījuma ražošanas pamattehnoloģija: Ekstrūzijas granulēšanas tehnoloģija

Ekstrūzijas granulēšanas tehnoloģija ir galvenā pildvielu maisījuma ražošanas tehnoloģija, kas integrē sajaukšanu, kušana, cirpšana, dispersija un granulēšana. Tam ir augstas ražošanas efektivitātes priekšrocības, laba produkta kvalitāte, spēcīga pielāgošanās izejvielām un plašs pielietojuma diapazons. Pildvielu galvenā maisījuma ražošanā, Ekstrūzijas granulēšanas tehnoloģija galvenokārt tiek izmantota, lai realizētu neorganisko pildvielu vienmērīgu izkliedi polimēra nesējā, izkausē un plastificē maisījumu, un pēc tam izspiediet un granulējiet, lai izveidotu vienāda izmēra granulu pildvielas pamatsavienojumu, laba plūstamība un stabila veiktspēja. Ekstrūzijas granulēšanas kvalitāte tieši nosaka pildvielas galvenā maisījuma galvenos darbības rādītājus, piemēram, izkliedējamība, daļiņu izmērs un kušanas indekss.

2.1 Pildvielu pamatmaisījumu izejvielu raksturojums un prasības ekstrūzijas iekārtām

Pildvielas galvenā maisījuma izejvielas galvenokārt ietver trīs daļas: neorganiskās pildvielas (piemēram, CaCO3, talks, BaSO4), polimēru nesēji (piemēram, PE, PP, PVC) un piedevas (piemēram, disperģētāji, saderības līdzekļi, smērvielas, antioksidanti, utt.). Šo izejvielu īpašības ir diezgan atšķirīgas, kas izvirza īpašas prasības ekstrūzijas iekārtām:

Pirmkārt, neorganiskajām pildvielām ir augsta cietība, slikta saderība ar polimēru nesējiem, un ir viegli aglomerējami. Lielākā daļa neorganisko pildvielu (piemēram, CaCO3, talks) ir hidrofīli, savukārt polimēru nesēji ir hidrofobi, kas noved pie sliktas saderības starp pildvielām un nesējiem. Ja sajaukšana un cirpšana ir nepietiekama, pildvielas aglomerēsies, kuras nevar vienmērīgi izkliedēt nesējā, kā rezultātā ir slikta pildvielas galvenā maisījuma kvalitāte. Turklāt, neorganisko pildvielu augstā cietība izraisīs nopietnu ekstrūdera skrūves un cilindra nodilumu ekstrūzijas procesa laikā, kas prasa, lai ekstrūdera skrūvei un cilindram būtu ārkārtīgi augsta nodilumizturība.

Otrkārt, pildvielas maisījumam ir augsta viskozitāte un slikta plūstamība. Liela skaita neorganisko pildvielu pievienošana ievērojami palielinās maisījuma viskozitāti, samazināt apstrādes plūstamību, un pieprasīt, lai ekstrūderim būtu spēcīga transportēšanas jauda un bīdes spēks, lai nodrošinātu vienmērīgu kušanas gaitu, sajaukšana un ekstrūzija.

Trešais, apstrādes temperatūras diapazons ir šaurs. Dažādiem nesējsveķiem ir dažādi kušanas punkti un termiskā stabilitāte. Piemēram, PE kušanas temperatūra ir 100-130 ℃, PP kušanas temperatūra ir 160-170 ℃, un PVC viegli sadalās augstā temperatūrā (virs 160 ℃). Tāpēc, ekstrūzijas iekārtai ir jābūt precīzai temperatūras kontroles spējai, lai nodrošinātu, ka maisījums ir pilnībā izkusis bez termiskās sadalīšanās, un lai izvairītos no piedevu sadalīšanās un produkta veiktspējas pasliktināšanās.

Pamatojoties uz iepriekš minētajām īpašībām, vienas skrūves ekstrūderi nav piemēroti liela mēroga un kvalitatīvai pildvielu pamatsavienojuma ražošanai. Tā kā vienas skrūves ekstrūderim ir šaurs bīdes diapazons, slikta sūknēšanas jauda un nav pašattīrīšanās efekta. Apstrādājot augstas viskozitātes un augstas pildvielas maisījumus, ir viegli izraisīt materiāla uzkrāšanos, aizsprostojums un nevienmērīga sajaukšanās ekstrūdera mucā, kā rezultātā pildvielas galvenā maisījuma disperģējamība ir slikta, nevienmērīgs daļiņu izmērs un nestabila produkta kvalitāte. Turklāt, vienas skrūves ekstrūderim ir liels enerģijas patēriņš, apstrādājot materiālus ar augstu pildvielu, un skrūve un stobra ir stipri nolietotas, kas palielina uzņēmumu ražošanas izmaksas un iekārtu uzturēšanas izmaksas.

Divskrūvju ekstrūderi, no otras puses, ir acīmredzamas priekšrocības pildvielu pamatsasijas ražošanā, un tās ir kļuvušas par galveno iekārtu pildvielu galvenās maisījuma ekstrūzijas granulēšanai. Divskrūvju ekstrūderiem ir plašāks bīdes diapazons, efektīvāks sūknēšanas efekts un pašattīrīšanās efekts, kas var efektīvi atrisināt sliktas saderības problēmas, viegla aglomerācija un slikta plūstamība pildvielas galvenās maisījuma izejvielas. Divu skrūvju savstarpēja savienošana un rotēšana var radīt spēcīgu bīdes spēku un mīcīšanas spēku, kas var pilnībā salauzt neorganisko pildvielu aglomerātus, padarīt pildvielas vienmērīgi izkliedētas polimēra nesējā, un nodrošina produkta izkliedējamību un stabilitāti. Turklāt, divu skrūvju ekstrūderim ir laba temperatūras kontroles precizitāte, spēcīga pielāgošanās spēja izejvielām, un var pielāgoties dažādu veidu apstrādei, dažādi pildvielas galvenā maisījuma uzpildes daudzumi, un tai ir augsta ražošanas efektivitāte un zems enerģijas patēriņš.

2.2 Pildvielu pamatsavienojumu ekstrūzijas granulēšanas darbības princips

The extrusion granulation process of filler masterbatch is a complex physical and chemical process, kas ietver vairāku faktoru, piemēram, temperatūras, mijiedarbību, spiedienu, bīdes spēks un laiks. Konkrētais darbības princips un procesa plūsma ir šāda:

Pirmkārt, izejvielu pirmapstrāde. The raw materials of filler masterbatch (neorganiskās pildvielas, nesējsveķi, piedevas) need to be pretreated to ensure the quality of the final product. The specific steps include: 1) Drying treatment: Inorganic fillers (piemēram, CaCO3, talks) are usually hydrophilic and contain a certain amount of moisture. Ja mitruma saturs ir pārāk augsts, it will affect the mixing effect and dispersibility of the materials, and even cause bubbles in the extruded masterbatch. Tāpēc, the fillers need to be dried in a dryer (such as a hot air dryer, a vacuum dryer) to reduce the moisture content to below 0.5%. 2) Crushing and sieving: The carrier resin (piemēram, PE, PP) is crushed into small particles or powder with a particle size of 20-40 acs, which is conducive to uniform mixing with fillers and additives. Inorganic fillers are also sieved to remove impurities and large particles, ensuring the fineness and uniformity of fillers. 3) Premixing: According to the formula ratio, the dried fillers, carrier resin particles and additives (dispersants, saderības līdzekļi, smērvielas, utt.) are put into a high-speed mixer for premixing. The mixing speed is generally 800-1200 apgr./min, and the mixing time is 5-10 minūtes. The purpose of premixing is to make the additives evenly adhere to the surface of fillers and carrier resin, improve the compatibility between fillers and carrier, and lay a foundation for subsequent extrusion mixing. The dispersant is a key additive in premixing, which can form a protective film on the surface of the filler, reduce the surface energy of the filler, prevent the filler from agglomerating, and improve the dispersibility of the filler in the carrier resin.

Otrkārt, 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.

Trešais, kušana, 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, un ekstrūzijas dobuma tilpums pakāpeniski samazinās gar ass virzienu. When the screws rotate, the materials are gradually compressed under the action of the screws and the barrel, un spiediens ekstrūzijas dobumā pakāpeniski palielinās (generally 3-15MPa). Tajā pašā laikā, the materials are subjected to strong shear force and friction force generated by the relative movement between the screws and the barrel, kā arī starp skrūvju lidojumiem.

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 temperature control sections (barošanas sadaļa, kušanas sekcija, sajaukšanas sadaļa, homogenizācijas sadaļa, utt.), and the temperature of each section is precisely controlled according to the type of carrier resin and filler. Piemēram, when processing PE carrier filler masterbatch, the temperature of the feeding section is 80-100℃, the melting section is 120-140℃, the mixing section is 140-150℃, and the homogenizing section is 130-140℃; when processing PP carrier filler masterbatch, the temperature of each section is 20-30℃ higher than that of PE carrier.

Ceturtais, extrusion and shaping. Pilnībā izkusis, jauktais un izkliedētais materiāls ar skrūvēm tiek nospiests uz ekstrūdera galviņu. 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. Preses galviņas temperatūra ir nedaudz zemāka nekā homogenizācijas sekcijas temperatūra, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the strips.

Piektais, 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 minūtes. Rapid cooling can make the strips solidify quickly, maintain the shape and size of the strips, and avoid deformation. Pēc atdzesēšanas, 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, galvenokārt ietverot izejvielu īpašības, formula ratio, premixing effect, ekstrūzijas parametri un galviņas struktūra. 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 Izejvielu raksturojums:

Veids, daļiņu izmērs, moisture content and purity of raw materials have a great impact on the granulation effect. Piemēram, the particle size of inorganic fillers directly affects the dispersibility and fineness of the masterbatch. The finer the particle size of the filler (vispār 800-2000 acs), 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 (piemēram, akmeņi, metāli, putekļi) 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. Piemēram, 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 mixing speed is generally 800-1200 apgr./min, the mixing time is 5-10 minūtes, and the mixing temperature is controlled at 40-60℃ (appropriate temperature can improve the adhesion of additives and promote uniform mixing).

2.3.4 Ekstrūzijas parametri:

Extrusion parameters are the most important factors affecting the granulation effect, galvenokārt ieskaitot skrūves ātrumu, ekstrūzijas temperatūra un ekstrūzijas spiediens.

• Skrūves ātrums: The screw speed generally ranges from 150 uz 600 apgr./min. Jo lielāks ir skrūves ātrums, 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. Tomēr, 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.
• Ekstrūzijas temperatūra: The extrusion temperature is divided into multiple sections (barošanas sadaļa, kušanas sekcija, sajaukšanas sadaļa, homogenizācijas sadaļa, mirst galvas sekcija), and the temperature of each section needs to be precisely controlled according to the type of carrier resin and filler. Barošanas sekcijas temperatūra ir zemāka (slightly higher than the melting point of the carrier resin), kas galvenokārt ir paredzēti, lai novērstu materiālu salipšanu un nodrošinātu vienmērīgu padevi; kušanas sekcijas temperatūra ir vidēja, which is mainly to promote the melting and plasticization of the carrier resin; sajaukšanas sekcijas temperatūra ir augstāka, kas galvenokārt ir paredzēts bīdes un sajaukšanas efekta uzlabošanai, and promote the uniform dispersion of the filler; homogenizācijas sekcijas temperatūra ir nedaudz zemāka nekā maisīšanas sekcijas temperatūra, kas galvenokārt ir paredzēti, lai nodrošinātu materiālu vienmērīgu temperatūru un viskozitāti, un izvairīties no termiskās sadalīšanās; presformas galviņas sekcijas temperatūra ir nedaudz zemāka nekā homogenizācijas sekcijas temperatūra, which is to ensure the shaping effect of the strips.
• Ekstrūzijas spiediens: The extrusion pressure is generally 3-15MPa. Spiedienu ekstrūzijas dobumā galvenokārt nosaka skrūves saspiešanas pakāpe, matricas cauruma izmērs un skrūves ātrums. Jo lielāks ir ekstrūzijas spiediens, the better the mixing and dispersing effect of the materials, and the denser the masterbatch particles. Tomēr, if the pressure is too high, tas palielinās iekārtas enerģijas patēriņu un nodilumu, and even cause the die head to block; ja spiediens ir pārāk zems, the materials cannot be fully compressed and mixed, the masterbatch particles are loose, and the performance is unstable.

2.3.5 Die Head struktūra:

Preses galviņas struktūra galvenokārt ietver numuru, presformu caurumu forma un izmērs. The shape of the die hole determines the cross-sectional shape of the extruded strips (piemēram, apļveida, kvadrāts), and the size of the die hole determines the initial diameter of the strips and the final particle size of the masterbatch. Jo mazāks ir matricas cauruma izmērs, jo lielāks ekstrūzijas spiediens, the better the mixing and dispersing effect, bet ražošanas jauda tiks samazināta; 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. Formēšanas caurumu skaits ietekmē ražošanas jaudu; the more the number of die holes, jo lielāka ir ražošanas jauda, bet ir jānodrošina vienmērīgs spiediena sadalījums, so as to avoid uneven thickness of the strips and uneven particle size of the masterbatch.

3. Mūsu ekstrūderi: Advantages and Product Series for Filler Masterbatch Production

Mēs jau sen esam iesaistījušies pētniecībā, 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, high 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, precīza temperatūras kontrole, stable performance and low operating cost, which can meet the processing needs of various types, dažādi pildvielas galvenā maisījuma uzpildes daudzumi (CaCO3, talks, BaSO4, utt.), 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, Ilgs kalpošanas laiks:

Aiming at the problem that inorganic fillers (piemēram, CaCO3, talks) 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. Turklāt, 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, ar saprātīgu skrūvju soli, lead and compression ratio design. Divu skrūvju savstarpēja savienošana un rotēšana var radīt spēcīgu bīdes spēku un mīcīšanas spēku, kas var pilnībā salauzt neorganisko pildvielu aglomerātus, 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 (piemēram, pārvietošanas elementi, elementu sajaukšana, bīdes elementi) 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. Piemēram, 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 Precīza temperatūras kontrole, 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. Temperatūras kontroles sistēma ir aprīkota ar reāllaika uzraudzības un trauksmes funkciju. If the temperature of any section exceeds the set range, sistēma savlaicīgi izsauks trauksmes uzvedni, un pat automātiski regulē sildīšanas jaudu vai izslēdz iekārtu, ja nepieciešams, lai izvairītos no aprīkojuma kļūmēm un produktu kvalitātes problēmām. Turklāt, 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 Plašs pielietojuma klāsts, Strong Flexibility:

Our extruder series can adapt to the processing needs of various types of filler masterbatch, including CaCO3 filler masterbatch, talka pildvielas pamatmaisījums, BaSO4 filler masterbatch, un citas speciālas pildvielas pamatsasejas. The filling amount can be adjusted from 30% uz 80%, which can meet the different cost and performance requirements of customers. The modular design of the extruder (skrūve, muca, mirst galva, utt.) 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, nenomainot visu aprīkojumu, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. Turklāt, our extruders can also be matched with different auxiliary equipment (such as high-speed mixers, žāvētāji, coolers, 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 High Production Efficiency, Low Energy Consumption:

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

3.1.6 Vienkārša darbība un apkope:

Our extruders adopt a PLC intelligent control system and a touch screen operation interface, kas ir vienkāršs un intuitīvs, viegli darbināms. Sistēma var uzglabāt vairākas produktu formulu un apstrādes parametru kopas. When customers produce different types of filler masterbatch, viņiem tikai jāizsauc atbilstošā formula un parametri, bez atkārtotas atkļūdošanas, kas ietaupa laiku un uzlabo ražošanas efektivitāti. The modular design of the equipment makes the maintenance more convenient. Skrūve, muca, 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, HTS PLUS series, 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, zems troksnis, 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, kas var palīdzēt uzņēmumiem samazināt sākotnējo ieguldījumu izmaksas.

Runājot par konstrukcijas projektēšanu, 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, automātiska temperatūras kontrole, automātiska spiediena kontrole un automātiska griešana, 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). Viena no šīs sērijas lielākajām priekšrocībām ir tā, ka tā var nodrošināt elastīgas iespējas, izmantojot dažādas konfigurācijas kombinācijas. Klienti var izvēlēties dažādus skrūvju elementus, mirst galvas, barošanas ierīces, žāvēšanas iekārtas un pēcapstrādes iekārtas atbilstoši saviem produktu veidiem, ražošanas jauda un budžets, lai izveidotu savām vajadzībām piemērotu ražošanas līniju.

3.2.2 HTS PLUS sērijas ekstrūderi: High-Performance Choice for Engineering Plastic and Filler Masterbatch.

HTS PLUS sērijas ekstrūderi izmanto mūsu neatkarīgi izstrādātas un ražotas liela griezes momenta pārnesumkārbas, 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).

HTS PLUS sērijas ekstrūderiem ir skrūves diametrs no 65 mm līdz 110 mm, kompresijas pakāpe 5–10, and a screw speed range of 200～600 rpm. Skrūve un muca izmanto bimetāla kompozītmateriālu apstrādi, kam ir augstāka nodilumizturība un izturība pret koroziju, and can adapt to the processing of high-hardness fillers (such as heavy calcium carbonate, talks) and high-filling materials. The extruder is equipped with an advanced intelligent control system, kas var realizēt precīzu ekstrūzijas parametru kontroli un ražošanas datu uzraudzību reāllaikā. The production capacity ranges from 500kg/h to 2000kg/h, which is suitable for medium and large-scale filler masterbatch enterprises that pursue high performance and high filling amount.

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

3.2.3 HTS SUPER Series Extruders: Top-End Choice for High-End Filler Masterbatch.

The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us. Aiming at the high torque and high speed characteristics of this series, 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.

HTS SUPER sērijas ekstrūderiem ir skrūves diametrs no 80 mm līdz 130 mm, kompresijas pakāpe 6–12, and a screw speed range of 250～700 rpm. Skrūve un muca izmanto importētu nodilumizturīgu leģēto tēraudu un lāzera apšuvuma tehnoloģiju, kam ir ārkārtīgi augsta nodilumizturība un izturība pret koroziju, and can adapt to the processing of various special fillers (piemēram, stikla šķiedra, ogleklis, bārija sulfāts) and high-filling materials (filling amount ≥70%). Ekstrūderis ir aprīkots ar inteliģentu PLC + mākoņa skārienekrāna vadības sistēma, kas var realizēt attālinātu parametru regulēšanu, ražošanas datu monitorings un iekārtu paredzamā apkope, realizēt inteliģentu ražošanas vadību.

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, augsta veiktspēja un intelekts. 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 sērijas ekstrūderi: 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 sērijas ekstrūderi: 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, uzpildes daudzums, 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. Piemēram, 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, liesmu slāpējošs pamatmaisījums), 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 Nosakiet ekstrudera ražošanas jaudu atbilstoši ražošanas mērogam:

Uzņēmumiem jāizvēlas ekstrūderis ar atbilstošu ražošanas jaudu atbilstoši savam ražošanas apjomam un tirgus pieprasījumam. Ja ražošanas apjoms ir mazs (dienas izlaide mazāka par 1 tonnu), the ZTE series or HTS BASIC series extruders with production capacity of 50-300kg/h are suitable; ja ražošanas apjoms ir vidējs (ikdienas produkcija 1-5 tonnas), the HTS BASIC series or HTS PLUS series extruders with production capacity of 300-1000kg/h are suitable; ja ražošanas apjoms ir liels (dienas izlaide vairāk nekā 5 tonnas), 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, talks) 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 Apsveriet aprīkojuma izmaksu efektivitāti:

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). Piemēram, 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, nodošana ekspluatācijā, apmācību, maintenance and spare parts supply services. Mums ir profesionāla pēcpārdošanas servisa komanda, which can respond to customer needs in a timely manner (provide solutions within 24 stundas) and send technicians to the site for maintenance if necessary, nodrošinot normālu ražošanas līnijas darbību.

3.3.6 Apsveriet aprīkojuma elastību un paplašināmību:

Līdz ar tirgus pieprasījuma izmaiņām, enterprises may need to adjust their product types and filling amounts. Tāpēc, izvēloties ekstrūderus, uzņēmumiem būtu jāņem vērā aprīkojuma elastība un paplašināmība. Mūsu ekstrūderi izmanto modulāru dizainu, ko var brīvi kombinēt un modernizēt atbilstoši uzņēmumu vajadzībām, aprīkojuma elastības un paplašināšanas uzlabošana, un iekārtu pārveidošanas izmaksu samazināšana.

4. Application Fields and Usage Methods of Filler Masterbatch

Pildvielas pamatsavienojums, kā galvenā funkcionālā piedeva plastmasas apstrādē, has a wide range of application fields, covering various fields such as plastic packaging, celtniecība, automobiļu rūpniecība, elektronika, 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, kas veido vairāk nekā 50% of the total application amount. Filler masterbatch is widely used in the production of plastic films, plastic bags, woven bags, iepakošanas lentes, packaging containers and other packaging products.

• Plastic Films: Including plastic thin films, thick films, stretch films, greenhouse films, utt. The filler masterbatch used for plastic films is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires good dispersibility, high fineness and no impurities, to ensure that the blown film has no white spots, black spots or 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, bet arī uzlabo stingrību, heat resistance and dimensional stability of the film, and reduce the shrinkage rate of the film. Piemēram, in the production of plastic shopping bags, pievienojot 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, utt. 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, pievienojot atbilstošu daudzumu pildvielas pamatsasijas, var arī uzlabot maisiņu stingrību un noturību pret plīsumiem, padarot tos nav viegli salauzt.
• Austi maisiņi un iepakošanas jostas: Austi maisiņi tiek plaši izmantoti graudu iepakošanā, mēslojums, cements, ķīmiskie produkti un citas preces; iepakošanas lentes tiek izmantotas preču komplektēšanai. Austiem maisiņiem un iepakošanas lentēm izmantotā pildvielas galvenā maisījums galvenokārt ir smaga kalcija karbonāta pildvielas vai talka pildvielas pamatsaja., kam nepieciešama augsta stingrība un nodilumizturība. Adding 5%-10% pildvielas pamatsasija var uzlabot stingrību, austo maisiņu un iepakošanas lentu stiepes izturība un nodilumizturība, samazināt izmaksas, un pagarināt produktu kalpošanas laiku.
• Iepakojuma konteineri: Ieskaitot plastmasas pudeles, plastmasas mucas, plastmasas kastes, utt. 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 caurules, PP pipes, utt., which are used for water supply, drenāža, 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% pildvielas pamatsasija var uzlabot stingrību, heat distortion temperature and pressure resistance of the pipes, samazināt izmaksas, and prevent the pipes from deforming under high temperature and pressure.
• Plastic Profiles: Including PVC profiles for doors and windows, plastic decorative profiles, utt. The filler masterbatch used for plastic profiles is mainly calcium carbonate filler masterbatch, which requires good weather resistance and impact strength. Adding 5%-10% pildvielas pamatsasija var uzlabot stingrību, weather resistance and impact strength of the profiles, samazināt izmaksas, and ensure the service life of the profiles in outdoor environments.
• Plastic Sheets: Including PVC sheets, PE loksnes, PP loksnes, utt., which are used for indoor decoration, iepakojums, 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, padarot tos nav viegli salauzt.
• 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, netoksicitāte, 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 (augstāk 1250 acs) 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, utt. 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. Piemēram, in the production of automotive interior parts (such as instrument panels, durvju paneļi), pievienojot 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), pievienojot 3%-5% of glass fiber reinforced filler masterbatch can improve the impact strength and dimensional accuracy of the shells, enhancing the durability of the products.

4.1.4 Automotive Plastic Industry:

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

• Automobiļu interjera daļas: Including instrument panels, durvju paneļi, seat cushions, armrests, utt. These parts have high requirements on rigidity, karstumizturība, 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) materiāliem, 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. Piemēram, pievienojot 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%.
• Automobiļu ārējās daļas: Including bumpers, spārni, durvju rokturi, utt. 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, utt. 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. Piemēram, pievienojot 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, izolācija, 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, utt.

• Wire and Cable Sheaths: The plastic sheaths of wires and cables need to have good insulation, nodilumizturība, 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, samazināt izmaksas; 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: These products need to have good transparency, stingrība, weather resistance and anti-aging properties. The filler masterbatch used is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch. Adding 1%-4% of light calcium carbonate filler masterbatch can reduce the cost of the film, improve its toughness and anti-aging properties, and extend the service life of the film; barium sulfate filler masterbatch can improve the transparency and light transmittance of the film, which is conducive to the photosynthesis of crops.
• Irrigation Pipes and Fertilizer Bags: Irrigation pipes need to have good pressure resistance and wear resistance; fertilizer bags need to have good toughness and wear resistance. The filler masterbatch used is mainly heavy calcium carbonate filler masterbatch or talc filler masterbatch. Adding 5%-10% of heavy calcium carbonate filler masterbatch can improve the pressure resistance and wear resistance of irrigation pipes, samazināt izmaksas; pievienojot 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 (piemēram, plastmasas plēves, 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 (piemēram, automobiļu daļas, 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 (augstāk 1250 acs) 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 (piemēram, PE, PP, PVC). The specific steps are: vispirms, 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 (ja nepieciešams) to mix uniformly. The mixing speed is generally 500-800 apgr./min, and the mixing time is 3-5 minūtes. Pēc sajaukšanas, the mixture can be directly sent to the extruder or injection molding machine for processing. The advantages of dry mixing are simple operation, augsta efektivitāte, 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. Tāpēc, 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 (piemēram, temperatūra, spiedienu, skrūves ātrums) 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. Piemēram, 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 (ekstrūzijas spiediens, injection pressure) needs to be appropriately increased by 10%-20%. Piemēram, 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: Pildvielas pamatsavienojums (especially calcium carbonate, talc masterbatch) is easy to absorb moisture, which will cause bubbles, pinholes and other defects in the final product. Tāpēc, the masterbatch should be stored in a dry, cool and ventilated warehouse, and should be dried before use (the drying temperature is 80-100℃, un žāvēšanas laiks ir 2-4 stundas).
• Saderība: The carrier resin of the filler masterbatch should be consistent with or compatible with the base plastic of the product. Piemēram, 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, kā rezultātā rodas defekti, piemēram, balti plankumi, 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 (vispār 6-12 mēnešus). If the storage period is exceeded, the masterbatch may absorb moisture, agglomerate or the performance of additives may degrade, affecting the use effect. Tāpēc, 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.

Risinājumi: 1) Select inorganic fillers with fine and uniform particle size (vispār 800-2000 acs), and sieve the fillers before use to remove large particles and agglomerates; 2) Increase the dosage of dispersant appropriately (within the range of 1%-3% of the filler dosage) or replace with a dispersant compatible with the filler and carrier resin; 3) Optimize the premixing process, increase the mixing speed (800-1200 apgr./min) and mixing time (5-10 minūtes), 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.

Risinājumi: 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.

Risinājumi:

• 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 (piemēram, 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 (piemēram, disperģētāji, smērvielas) 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.

Risinājumi:

• 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: burbuļi, 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.

Risinājumi:

• Extend the drying time of the filler (drying temperature 80-100℃, drying time 3-5 stundas), 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, and avoid the materials absorbing moisture from the air.

5.2 Common Production Equipment Problems and Their Solutions

5.2.1 Extruder Blockage

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

Causes:

• The moisture content of the materials is too high, and the materials caking during extrusion;
• The processing temperature is too low, and the carrier resin is not fully melted, which accumulates in the extruder barrel;
• The materials contain impurities (piemēram, akmeņi, metāli), which block the screw or die head;
• The screw speed is too low, and the materials cannot be pushed forward smoothly, resulting in accumulation;
• The die head is not cleaned regularly, and the residual materials block the die holes.

Risinājumi:

• Stop the machine immediately, 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, talks) and long-term friction with the screw and barrel;
• The materials contain impurities (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, muca;
• Skrūve un cilindrs ir izgatavoti no materiāliem ar sliktu nodilumizturību.

Risinājumi:

• 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, muca.

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.

Risinājumi:

• 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

Pildvielas pamatsavienojums, as a key functional additive in the plastic processing industry, plays an irreplaceable role in reducing production costs, uzlabot produktu veiktspēju un optimizēt apstrādes efektivitāti. 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, funkcionalizācija, high filling amount, vides aizsardzība un izlūkošana. Extrusion granulation technology, kā pildvielu maisījuma ražošanas pamattehnoloģiju, directly determines the quality and competitiveness of the masterbatch. The performance of extruders is the key to ensuring the stable production of high-quality filler masterbatch.

We have developed a full range of twin-screw extruder products (HTS BASIC series, HTS PLUS series, HTS SUPER series, ZTE sērija, HTE sērija) according to the characteristics of filler masterbatch raw materials and processing requirements. Our extruders have the advantages of high wear resistance, strong shearing and mixing capacity, precīza temperatūras kontrole, plašs pielietojuma diapazons, high production efficiency and low energy consumption, which can meet the processing needs of various types and different filling amounts of filler masterbatch. By providing targeted extruder products and professional processing solutions, we help filler masterbatch manufacturers solve production pain points, improve production efficiency, nodrošināt produktu kvalitāti, un iegūt konkurences priekšrocības sīvajā tirgus konkurencē.

Looking forward to the future, with the continuous advancement of science and technology and the increasingly strict environmental protection policies, the filler masterbatch industry will face new opportunities and challenges. On the one hand, the demand for high-performance, functional and environmental protection filler masterbatch (such as degradable filler masterbatch, flame-retardant and antistatic filler masterbatch) will continue to grow, which will put higher requirements on extrusion technology and equipment performance; no otras puses, the intelligence and automation level of production equipment will continue to improve, and intelligent granulation production lines integrating raw material pretreatment, ekstrūzijas granulēšana, 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. Tajā pašā laikā, 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.