Masterbatch uzlabotas divu skrūvju ekstrūzijas tehnoloģiju lietojumprogrammas un visaptveroši apstrādes risinājumi

1. Pārskats par galveno maisījumu rūpniecību un pamatzināšanām

1.1 Galvenās maisījumu rūpniecības pašreizējā situācija un attīstības tendences

Galvenais maisījums, pazīstams arī kā krāsu galvenais maisījums vai krāsu koncentrāts, ir jauna veida plastmasas krāsojošs materiāls ar augstu koncentrāciju, augsta izkliedējamība un ērta lietošana. Tas ir izgatavots, vienmērīgi izkliedējot pigmentus vai krāsvielas, nesējvielas un piedevas noteiktā proporcijā, izmantojot profesionālu sajaukšanas un ekstrūzijas granulēšanas tehnoloģiju. Salīdzinājumā ar tradicionālo tiešās krāsošanas metodi (tieši pievienojot pigmentus plastmasas izejvielām), masterbatch ir ērtas lietošanas priekšrocības, viendabīga krāsošana, stabilu sniegumu, vides aizsardzība un enerģijas taupīšana, kas pakāpeniski ir aizstājis tradicionālo krāsošanas metodi un kļuvis par galveno krāsošanas risinājumu plastmasas rūpniecībā.

Pēdējos gados, pakārtoto nozaru, piemēram, iepakošanas, straujā attīstība, automobiļu rūpniecība, tekstilizstrādājumi, elektronika, celtniecības un sadzīves tehnika, globālais galveno maisījumu tirgus ir uzrādījis stabilu un strauju izaugsmes tendenci. Saskaņā ar attiecīgajiem nozares datiem, globālais pamatsavienojumu tirgus apjoms ir pārsniedzis 30 miljardu ASV dolāru, un sagaidāms, ka tas saglabās salikto gada pieauguma tempu 6%-8% nākamajos piecos gados. Starp tiem, Āzijas un Klusā okeāna reģiona valstis ir pasaulē lielākais galveno maisījumu ražošanas un patēriņa tirgus, kas veido vairāk nekā 60% no pasaules tirgus daļas, galvenokārt pateicoties straujajai plastmasas rūpniecības attīstībai Ķīnā, Indija un citas valstis, nepārtraukta rūpnieciskās atbalsta jaudas uzlabošana, un pieaugošais pieprasījums pēc augstas kvalitātes, funkcionāli un videi draudzīgi pamatprodukti.

Ķīna, kā pasaulē lielākais maisījuma ražotājs un patērētājs, ir milzīgs tirgus pieprasījums un pilnīga rūpnieciskā ķēde. Gada galvenā maisījuma izlaide un patēriņš pieaug ar divciparu ātrumu, jo īpaši jaunu enerģijas transportlīdzekļu jomā, zaļš iepakojums, augstas klases tekstilizstrādājumi un medicīnas ierīces, pieprasījums pēc augstas veiktspējas galvenā maisījuma (piemēram, augstas temperatūras izturīgs galvenais maisījums, liesmu slāpējošs pamatmaisījums, vides aizsardzības pamatmaisījums) uzrāda strauju pieauguma tendenci. Ar nepārtrauktu globālās vides aizsardzības politikas uzlabošanu (piemēram, toksisko un kaitīgo pigmentu aizliegums) un patērētāju pieprasījuma palielināšana pēc augstas kvalitātes plastmasas izstrādājumiem, galveno maisījumu rūpniecība pakāpeniski attīstās uz augstu koncentrāciju, augsta izkliedējamība, funkcionalizācija, vides aizsardzība un izlūkošana.

Galvenās maisījuma ražošanas nozares attīstības tendences ir atspoguļotas četros aspektos: vispirms, vides aizsardzība un zema toksicitāte. Ar vides aizsardzības apziņas stiprināšanu un vides aizsardzības politikas stingrību, nav toksisks, nekaitīgs, zemas gaistošās un noārdāmās vides aizsardzības pamatsavienojumi kļūs par galveno tirgus daļu, un toksiski un kaitīgi pigmenti (piemēram, smago metālu pigmenti) pakāpeniski tiks likvidēta; otrais, funkcionalizācija. Papildus krāsošanai, masterbatch arī attīstās uz funkcionālu integrāciju, piemēram, liesmu slāpējošs pamatmaisījums, antistatiska galvenā maisījuma masa, antibakteriāls pamatmaisījums, UV izturīgs pamatmaisījums, kas var atbilst pakārtoto produktu īpašajām lietošanas prasībām; trešais, augsta koncentrācija un augsta izkliedējamība. Augstas koncentrācijas galvenais maisījums var samazināt pievienošanas daudzumu, samazināt ražošanas izmaksas, un augsta izkliedējamība var nodrošināt vienmērīgu plastmasas izstrādājumu krāsojumu, izvairieties no krāsu plankumiem un krāsu atšķirībām, kas ir produkta kvalitātes uzlabošanas atslēga; ceturtais, izlūkošana un apstrādes automatizācija. Galvenā maisījuma apstrāde prasa stingru sajaukšanas viendabīguma kontroli, temperatūra un citi parametri. Inteliģents, automātiskās divu skrūvju ekstrūzijas ražošanas līnijas kļūs par galveno, realizējot reāllaika uzraudzību, automātiska parametru regulēšana un masveida ražošana, ražošanas efektivitātes un produktu konsekvences uzlabošana.

Kā galvenā maisījuma apstrādes galvenā iekārta, divu skrūvju ekstrūderiem ir izšķiroša loma galvenā maisījuma ražošanas nozares attīstībā. Galvenā maisījuma sajaukšanai ir stingras prasības sajaukšanas un izkliedēšanas efektam, temperatūras kontrole un ekstrūderu ražošanas efektivitāte. Zhuoyue pilna ekstrūderu sērija (HTS BASIC/PLUS/SUPER, ZTE, HTE) ir īpaši izstrādāti pamatsavienojumu apstrādei, ar mērķtiecīgām veiktspējas priekšrocībām, kas var efektīvi apmierināt dažādu veidu galveno maisījumu apstrādes vajadzības un palīdzēt ražotājiem uzlabot produktu kvalitāti un ražošanas efektivitāti.

1.2 Galvenās maisījuma sastāvs un darbības princips

Masterbatch sastāv no trim pamatelementiem: pigmenti vai krāsvielas, nesēji un piedevas. Katra elementa proporcija un veiktspēja tieši nosaka galvenā maisījuma kvalitāti un lietošanas efektu. Pamatsastāva un galvenā maisījuma darbības principa izpratne ir pamats, lai apgūtu tā apstrādes tehnoloģiju un izvēlētos atbilstošu ekstrūzijas iekārtu.

1.2.1 Pigmenti vai krāsvielas: Krāsošanas pamatkomponents

Pigmenti vai krāsvielas ir galvenie komponenti, kas nodrošina galveno krāsojuma veiktspēju, uzskaite 10%-80% no galvenā maisījuma sastāva (konkrētā proporcija ir atkarīga no pigmenta veida, krāsošanas prasības un galvenā maisījuma koncentrācija). Pigmentus iedala organiskajos pigmentos un neorganiskajos pigmentos: organiskajiem pigmentiem ir spilgtas krāsas, augsta tonēšanas izturība, laba pārredzamība, bet slikta karstumizturība un laika apstākļu izturība, galvenokārt izmanto zemas temperatūras plastmasas apstrādē (piemēram, PE, PP) un produkti ar augstām krāsu prasībām (piemēram, tekstilizstrādājumi, iepakojuma plēves); neorganiskajiem pigmentiem ir laba karstumizturība, laika apstākļu izturība un ķīmiskā stabilitāte, bet zema tonēšanas izturība un slikta caurspīdīgums, galvenokārt izmanto augstas temperatūras plastmasas apstrādē (piemēram, inženiertehniskā plastmasa) un āra izstrādājumi (piemēram, celtniecības materiāli, automobiļu ārējās daļas).

Krāsvielas atšķiras no pigmentiem. Krāsvielām ir laba šķīdība plastmasas izejvielās, spilgtas krāsas un augsta caurspīdīgums, bet slikta karstumizturība un gaismas izturība, galvenokārt izmanto caurspīdīgos plastmasas izstrādājumos (such as PET bottles, PC loksnes). Pigmentu vai krāsvielu izvēlei jābūt balstītai uz plastmasas izejvielu veidu (apstrādes temperatūra), produkta lietošanas vide (indoor/outdoor), krāsošanas prasības (krāsu spilgtums, caurspīdīgums) un vides aizsardzības prasības, lai nodrošinātu, ka galvenajam maisījumam ir stabila krāsojuma veiktspēja un tā atbilst pakārtoto produktu lietošanas prasībām.

1.2.2 Pārvadātāji: Dispersijas un adhēzijas komponents

Nesēji ir galvenā maisījuma matrica, uzskaite 10%-80% no galvenā maisījuma sastāva, galvenokārt pilda pigmentu/krāsu izkliedēšanas un plastmasas izejvielu pielipšanas lomu. Nesējvielai jābūt labi saderīgai gan ar pigmentiem/krāsvielām, gan ar mērķa plastmasas izejvielām (krāsojamās plastmasas izejvielas), pretējā gadījumā tas ietekmēs pigmentu izkliedējamību un produktu krāsojošo efektu. Parastie nesējmateriāli ir polietilēns (PE), polipropilēns (PP), polivinilhlorīds (PVC), poliamīds (PA), polietilēntereftalāts (PET), utt., kuras izvēlas atbilstoši mērķa plastmasas izejvielu veidam: piemēram, PE nesējs tiek izmantots PE plastmasas krāsošanai, PP nesējs tiek izmantots PP plastmasas krāsošanai, un PA nesējs tiek izmantots inženierplastmasas PA krāsošanai.

Nesējam jābūt arī labai apstrādes plūstamībai, kas veicina vienmērīgu pigmentu izkliedi ekstrūzijas apstrādes laikā un pamatsajaukšanu ar mērķa plastmasas izejvielām. Turklāt, nesēja kušanas temperatūrai un apstrādes temperatūrai jāatbilst mērķa plastmasas izejvielu kušanas temperatūrai vai nedaudz zemākai par to, lai izvairītos no nesēja vai mērķa plastmasas sadalīšanās apstrādes laikā.

1.2.3 Piedevas: Funkcionālais palīgkomponents

Piedevas ir palīgkomponenti, kas pievienoti, lai uzlabotu apstrādes veiktspēju, galvenā maisījuma izkliedējamība un lietošanas veiktspēja, uzskaite 1%-10% no galvenā maisījuma sastāva. Piedevu veids un devas tiek noteiktas atkarībā no galvenā maisījuma veida un apstrādes prasībām. Kopējās piedevas ietver:

• Dispersanti: Vissvarīgākā piedeva galvenajā maisījumā, kas var samazināt pigmentu virsmas spraigumu, novērst pigmenta aglomerāciju, un padarīt pigmentus vienmērīgi izkliedētu nesējā. Parastie disperģētāji ietver polietilēna vasku, polipropilēna vasks, stearīnskābe, kalcija stearāts, utt. Disperģējošu vielu pievienošana var ievērojami uzlabot galvenā maisījuma disperģējamību, nodrošināt vienmērīgu produktu krāsojumu, un samazināt ekstrūzijas iekārtu nodilumu.
• Saderības līdzekļi: Izmanto, lai uzlabotu saderību starp pigmentiem un nesējiem, un starp galveno maisījumu un mērķa plastmasas izejvielām. Piemēram, kad nesējai un mērķa plastmasai ir slikta savietojamība (piemēram, PE nesējs un PA plastmasa), saderības līdzekļi (piemēram, ar maleīnskābes anhidrīdu potēts polietilēns) var pievienot, lai uzlabotu savienojuma spēku starp tiem, apstrādes laikā izvairieties no galvenā maisījuma un mērķa plastmasas atdalīšanas, un uzlabot produktu mehāniskās īpašības.
• Heat Stabilizers: Lieto, lai novērstu pigmentu sadalīšanos, nesēji un mērķa plastmasa augstas temperatūras ekstrūzijas apstrādes laikā. Parastie siltuma stabilizatori ietver svina sāļus, calcium-zinc stabilizers, organic tin stabilizers, utt., kuras izvēlas atbilstoši apstrādes temperatūrai un vides aizsardzības prasībām.
• Gaismas stabilizatori un antioksidanti: Izmanto, lai uzlabotu galveno maisījumu un krāsaino plastmasas izstrādājumu izturību pret laikapstākļiem un novecošanos, novērstu krāsas izbalēšanu un produktu veiktspējas pasliktināšanos saules gaismas un skābekļa ietekmē, un pagarināt produktu kalpošanas laiku.
• Smērvielas: Izmanto, lai samazinātu berzi starp materiāliem un ekstrūzijas iekārtām (skrūve, muca, mirst galva), uzlabot apstrādes plūstamību, samazināt enerģijas patēriņu, un izvairieties no materiāla pielipšanas aprīkojumam, kas veicina vienmērīgu ekstrūzijas apstrādes gaitu.

1.2.4 Masterbatch darbības princips

Galvenās maisījuma darbības princips ir balstīts uz augstas koncentrācijas pigmentu vienmērīgu izkliedi nesējā. Plastmasas izstrādājumu apstrādes laikā, neliels daudzums galvenā maisījuma (parasti 1%-5%) ir sajaukts ar nekrāsotām plastmasas izejvielām. Augstas temperatūras un bīdes spēka iedarbībā ekstrūzijas vai injekcijas formēšanas laikā, galvenā maisījuma nesējs kūst un sajaucas ar mērķa plastmasas izejvielām, un vienmērīgi izkliedētie pigmenti tiek atbrīvoti un vienmērīgi sadalīti mērķa plastmasas matricā, tādējādi sasniedzot plastmasas izstrādājumu krāsošanas mērķi. Šī procesa atslēga ir tāda, ka pigmentiem galvenajā maisījumā jābūt vienmērīgi izkliedētiem bez aglomerācijas, pretējā gadījumā tas radīs krāsu plankumus, krāsu atšķirības un citi krāsaino izstrādājumu defekti.

1.3 Kopējā galvenā maisījuma klasifikācija

Masterbatch var iedalīt dažādos veidos atbilstoši dažādiem klasifikācijas standartiem, piemēram, krāsošanas veids, pārvadātāja veids, pielietojuma lauks, funkcionālais tips, utt. Pareiza klasifikācija palīdz labāk izprast galvenā maisījuma veiktspējas raksturlielumus un apstrādes prasības, un izvēlēties piemērotas ekstrūzijas iekārtas un apstrādes metodes.

1.3.1 Klasifikācija pēc krāsošanas veida

Atbilstoši krāsojamās sastāvdaļas veidam, galveno maisījumu var iedalīt krāsu pamatsavienībā, balts pamatmaisījums un melns galvenais maisījums.

• Krāsu galvenais maisījums: Visizplatītākais galvenais maisījuma veids, kurā izmantoti dažādu krāsu organiskie vai neorganiskie pigmenti (piemēram, sarkans, dzeltens, zils, zaļš, oranža) kā krāsvielas, un tiek izmantots dažādu krāsu plastmasas izstrādājumu krāsošanai. Tonēšanas spēks, krāsu spilgtums un galvenās krāsas maisījuma izkliedējamība ir galvenie rādītāji, lai novērtētu tā kvalitāti.
• Balts pamatmaisījums: Izmantojot titāna dioksīdu (TiO2) kā galveno krāsvielu sastāvdaļu, to izmanto plastmasas izstrādājumu balināšanai vai kā pamatkrāsu gaišas krāsas pamatmaisījumam. Baltums, Segšanas jauda un baltās galvenās maisījuma izkliedējamība ir galvenie rādītāji. Titāna dioksīdam ir augsta cietība, kam ir augstas prasības ekstrūzijas iekārtu nodilumizturībai.
• Melns pamatmaisījums: Izmantojot oglekli kā galveno krāsvielu, to izmanto plastmasas izstrādājumu melnai krāsošanai. Ogleklim ir laba UV izturība un laika apstākļu izturība, un var arī uzlabot plastmasas izstrādājumu mehāniskās īpašības. Oglekļa izkliedējamība ir melnās galvenās maisījuma kvalitātes atslēga. Slikta izkliedējamība izstrādājumos radīs melnus plankumus un svītras.

1.3.2 Klasifikācija pēc pārvadātāja veida

Atbilstoši pārvadātāja veidam, galveno maisījumu var iedalīt PE galvenajā maisījumā, PP galvenais maisījums, PVC galvenais maisījums, PA galvenais maisījums, PET pamatmaisījums, utt.

• PE galvenais maisījums: Izmantojot PE kā nesēju, tas ir piemērots PE plastmasas izstrādājumu krāsošanai (piemēram, PE plēves, PE caurules, PE iesmidzināšanas formas detaļas). Tam ir laba saderība ar PE izejvielām, laba apstrādes plūstamība un vienmērīga krāsa.
• PP galvenais maisījums: Izmantojot PP kā nesēju, tas ir piemērots PP plastmasas izstrādājumu krāsošanai (piemēram, PP šķiedras, PP iesmidzināšanas formas detaļas, PP loksnes). Tam ir laba karstumizturība un tas ir piemērots PP apstrādei augstā temperatūrā.
• PVC galvenais maisījums: Izmantojot PVC kā nesēju, tas ir piemērots PVC plastmasas izstrādājumu krāsošanai (piemēram, PVC caurules, PVC profili, PVC plēves). Tam jābūt saskaņotam ar PVC siltuma stabilizatoriem, lai izvairītos no PVC sadalīšanās apstrādes laikā.
• Inženierplastmasas galvenais maisījums: Izmantojot inženierplastmasu (PA, PC, PBT, utt.) kā nesēji, tas ir piemērots inženiertehnisko plastmasas izstrādājumu krāsošanai (piemēram, automobiļu daļas, elektriskās sastāvdaļas). Tam ir laba karstumizturība un saderība ar inženiertehniskajām plastmasām, un tai ir augstas prasības ekstrūzijas apstrādes iekārtām.

1.3.3 Klasifikācija pēc lietojuma laukiem

Saskaņā ar galvenā maisījuma pielietojuma jomu, to var iedalīt šķiedru galvenajā maisījumā, film masterbatch, blow molding masterbatch, extrusion masterbatch, iesmidzināšanas formēšanas pamatsavienojums, utt., kas atbilst piecām galvenajām maisījuma pielietojuma jomām.

• Fiber Masterbatch: Izmanto ķīmisko šķiedru krāsošanai (such as polyester fiber, nylon fiber), which is used in carpets, tekstilizstrādājumi, spilveni un citi izstrādājumi. Tam nepieciešama augsta izkliedējamība un krāsas noturība, un krāsa neizbalē vērpšanas un aušanas laikā.
• Filmu pamatsavienojums: Izmanto plastmasas plēvju krāsošanai (piemēram, iepirkumu maisiņi, filmu liešana, daudzslāņu plēves), kas prasa augstu caurspīdīgumu un viendabīgu krāsojumu, un uz plēves virsmas nav krāsu plankumu vai svītru.
• Pūšanas formēšanas pamatsavienojums: Izmanto pūšanas formēšanas izstrādājumu krāsošanai (piemēram, medicīnas un kosmētikas konteineri, lubricating oil and paint containers), which requires good processing fluidity and uniform coloring, and no deformation or color difference of the container.
• Extrusion Masterbatch: Used for coloring extrusion products (such as sheets, caurules, wires and cables), which requires good dimensional stability and uniform coloring, and no color difference on the product surface.
• Injection Molding Masterbatch: Used for coloring injection molding products (piemēram, automobiļu daļas, elektroniskie izstrādājumi, celtniecības materiāli, home appliances, furniture, rotaļlietas), which requires high dispersibility and stable performance, and no color difference between batches of products.

1.3.4 Classification by Functional Type

According to the additional functions of masterbatch, it can be divided into ordinary masterbatch (only coloring function) and functional masterbatch (krāsošana + additional functions). Functional masterbatch is the development trend of the industry, and common types include flame-retardant masterbatch, antistatiska galvenā maisījuma masa, antibakteriāls pamatmaisījums, UV izturīgs pamatmaisījums, toughening masterbatch, utt. Functional masterbatch requires adding corresponding functional additives on the basis of ordinary masterbatch, which has higher requirements on the mixing and dispersing effect of extrusion equipment.

2. Core Processing Technology of Masterbatch: Divu skrūvju ekstrūzijas tehnoloģija

Masterbatch processing mainly includes mixing, ekstrūzija, dzesēšana, granulation and other processes, among which twin-screw extrusion technology is the core technology of masterbatch mixing and granulation. Compared with single-screw extrusion technology, twin-screw extrusion technology has the advantages of strong mixing and dispersing capacity, precīza temperatūras kontrole, īss uzturēšanās laiks, high production efficiency and strong adaptability to raw materials, which can effectively solve the key problems of masterbatch processing (such as pigment agglomeration, uneven mixing, low production efficiency) and ensure the quality of masterbatch products.

Masterbatch mixing is one of the main applications of twin-screw extruders. The quality of masterbatch is directly determined by the performance of the twin-screw extruder and the rationality of the processing process. The key requirements of masterbatch processing for twin-screw extruders are: strong mixing and dispersing effect (to ensure uniform dispersion of pigments), precīza temperatūras kontrole (to avoid pigment decomposition and carrier degradation), appropriate shear force (to break pigment agglomerates without damaging pigment particles), augsta ražošanas efektivitāte (to meet mass production needs) and good wear resistance (to adapt to the wear of high-hardness pigments such as titanium dioxide and carbon black).

2.1 Processing Difficulties of Masterbatch and Requirements for Extrusion Equipment

Although twin-screw extrusion technology is suitable for masterbatch processing, due to the particularity of masterbatch composition (high pigment content, easy agglomeration of pigments) and processing requirements (vienmērīga dispersija, stabilu sniegumu), there are still many difficulties in actual processing. The main processing difficulties and corresponding requirements for extrusion equipment are as follows:

2.1.1 Pigment Agglomeration and Poor Dispersibility

Pigments (especially inorganic pigments such as titanium dioxide and carbon black) have strong polarity and large specific surface area, which are easy to agglomerate into large particles during storage and mixing. If the agglomerates cannot be fully broken and dispersed during extrusion processing, the masterbatch will have poor dispersibility, un krāsainajiem plastmasas izstrādājumiem būs krāsu plankumi, krāsu svītras un nevienmērīga krāsošana, kas nopietni ietekmēs produkta kvalitāti. Šī ir visizplatītākā un galvenā problēma pamatsavienojumu apstrādē.

Tas prasa, lai ekstrūzijas iekārtai būtu spēcīga sajaukšanas un izkliedēšanas spēja un atbilstošs bīdes spēks. Divskrūvju ekstrūderim ir jāpieņem savstarpēja kopā rotējoša struktūra, un skrūvei jābūt aprīkotai ar pietiekamiem maisīšanas elementiem un bīdes elementiem, lai rotācijas laikā radītu spēcīgu bīdes spēku un mīcīšanas spēku, kas var pilnībā sadalīt pigmenta aglomerātus un padarīt pigmentus vienmērīgi izkliedētu nesējā. Turklāt, skrūves ātrumam un ekstrūzijas spiedienam jābūt regulējamam, lai pielāgotos dažāda veida pigmentiem un galvenās maisījuma koncentrācijai.

2.1.2 Pigment Decomposition and Carrier Degradation Caused by Overheating

Most pigments (especially organic pigments) have poor heat resistance, and the carrier (piemēram, PE, PP) also has a certain temperature resistance limit. If the extrusion temperature is too high or the residence time of the material in the extruder is too long, the pigment will decompose (resulting in color fading, discoloration), and the carrier will degrade (resulting in reduced mechanical properties of the masterbatch). This is another key difficulty in masterbatch processing.

This requires the extrusion equipment to have precise temperature control capacity and short residence time. The barrel of the extruder should be divided into multiple temperature control sections, and the temperature of each section should be precisely controlled within the optimal range (usually 150-220℃ for ordinary masterbatch, 200-280℃ for engineering plastic masterbatch), with a temperature control precision of ±1℃. The screw structure should be optimized to shorten the residence time of the material in the extruder (parasti 1-3 minūtes), avoiding long-term contact between the material and high temperature.

2.1.3 Wear of Screw and Barrel Caused by High-Hardness Pigments

Inorganic pigments such as titanium dioxide and carbon black have high hardness (Mohs hardness 5-7), which will cause serious wear to the screw and barrel of the extruder during extrusion processing. Ja skrūvei un mucai ir slikta nodilumizturība, tie tiks ātri nolietoti, resulting in reduced shear force and mixing capacity of the extruder, affecting the dispersibility of the masterbatch and reducing the service life of the equipment.

Tas prasa, lai ekstrūdera skrūve un cilindrs būtu izgatavoti no augstas kvalitātes nodilumizturīgiem materiāliem un apstrādāti ar progresīvu ražošanas tehnoloģiju. Piemēram, the screw and barrel can be made of imported wear-resistant alloy steel, un pakļauti bimetāla kompozītmateriālu apstrādei vai lāzera apšuvuma apstrādei, which can greatly improve the wear resistance and corrosion resistance of the screw and barrel, and adapt to the processing of masterbatch with high-hardness pigments.

2.1.4 Instability of Product Quality Between Batches

Masterbatch processing requires strict control of various parameters (such as formula ratio, maisīšanas laiks, extrusion temperature, skrūves ātrums, barošanas ātrums). If the parameters fluctuate, the quality of the masterbatch (such as concentration, dispersibility, tinting strength) will be unstable, resulting in color difference between batches of colored products, which will affect the reputation of the manufacturer.

This requires the extrusion equipment to have intelligent control capacity and stable performance. The extruder should be equipped with a PLC intelligent control system, which can realize precise control of feeding speed, skrūves ātrums, extrusion temperature and other parameters, and store multiple sets of formula parameters. When producing different batches of masterbatch, only the corresponding parameters need to be called, avoiding repeated debugging, ensuring the stability of product quality between batches.

2.1.5 High Requirements on Processing Fluidity

Masterbatch has high pigment content, which will reduce the processing fluidity of the material. If the processing fluidity is too poor, the material will be difficult to convey and extrude, resulting in low production efficiency, unstable extrusion pressure and even equipment blockage.

This requires the extrusion equipment to have strong conveying capacity and adjustable shear force. The twin-screw extruder should adopt a reasonable screw pitch, lead and compression ratio design, and the screw should be equipped with sufficient conveying elements to ensure the smooth conveying of materials. Turklāt, the extrusion temperature can be appropriately adjusted to improve the processing fluidity of the material, and lubricants can be added to reduce the friction between materials.

2.2 Working Principle and Process Flow of Masterbatch Twin-Screw Extrusion

The twin-screw extrusion process of masterbatch is a complex physical mixing process, which mainly includes raw material pretreatment, premixing, barošana, kušana, mixing and shearing, ekstrūzija, dzesēšana, granulēšana, screening and packaging. The core purpose is to uniformly disperse pigments, carriers and additives to form high-quality masterbatch granules. Konkrētais darbības princips un procesa plūsma ir šāda:

2.2.1 Izejvielu pirmapstrāde

Raw material pretreatment is the foundation of masterbatch extrusion processing, which directly affects the mixing effect and product quality. The raw materials of masterbatch mainly include pigments/dyes, carriers, piedevas (dispersants, saderības līdzekļi, heat stabilizers, utt.). Iepriekšējās apstrādes darbības ir šādas:

• Žāvēšanas apstrāde: Some pigments (such as organic pigments) and carriers (piemēram, PA, PET) ir augsta ūdens absorbcija. Ja mitruma saturs ir pārāk augsts, it will cause bubbles, agglomeration and other defects in the masterbatch during extrusion processing, and even cause hydrolytic degradation of the carrier. Tāpēc, the raw materials must be dried before processing. The drying temperature and time are determined according to the type of raw material: piemēram, organic pigments are dried at 60-80℃ for 2-4 stundas, PE/PP carriers are dried at 80-100℃ for 3-5 stundas, and PA carriers are dried at 100-120℃ for 6-8 stundas. The moisture content of the dried raw materials should be controlled below 0.1%.
• Crushing and Sieving: For pigments with large particle size (such as titanium dioxide agglomerates) and carriers with uneven particle size, crushing and sieving treatment should be carried out to ensure the uniformity of raw materials. The particle size of the crushed raw materials should be controlled at 20-40 acs, which is conducive to the uniform mixing of raw materials and the breaking of pigment agglomerates during extrusion.
• Piemaisījumu noņemšana: The raw materials may contain impurities (such as metal particles, stones, putekļi) during production and transportation. Impurities not only affect the quality of the masterbatch, but also wear the screw and barrel of the extruder, and even cause equipment blockage. Tāpēc, the raw materials must be filtered and removed before use, using a filter screen with appropriate mesh size to remove impurities.

2.2.2 Premixing

Premixing is the key step to improve the mixing and dispersing effect of masterbatch. According to the formula ratio, the dried, crushed and impurity-removed pigments, carriers and additives are put into a high-speed mixer for premixing. The purpose of premixing is to make the pigments and additives uniformly adhere to the surface of the carrier particles, form a preliminary mixture, and lay a foundation for the uniform dispersion during extrusion.

The key parameters of premixing are 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℃. The appropriate mixing temperature can improve the adhesion of additives (piemēram, disperģētāji) to the carrier and pigments, promoting uniform mixing. For masterbatch with high pigment content (piemēram, 50% augstāk), the premixing time can be appropriately extended, and a small amount of dispersant can be added first to improve the dispersibility of pigments. After premixing, the mixture should be uniform in color, without obvious pigment agglomerates and additive particles.

2.2.3 Barošana un transportēšana

The premixed mixture is sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. 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 screw speed and extrusion speed to ensure that the materials enter the extrusion cavity stably and uniformly, avoiding material accumulation or insufficient feeding.

The feeding hopper is also equipped with a drying device (such as an electric heating jacket) to prevent the raw materials from absorbing moisture again during feeding. For masterbatch with high pigment content and poor fluidity, a forced feeding device can be selected to ensure the smooth feeding of materials. Turklāt, the feeding port of the extruder should be smooth, without dead corners, to avoid material sticking and accumulation.

2.2.4 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 5-12MPa).

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 pigments, make the pigments uniformly dispersed in the melted carrier, and promote the fusion and compatibility between the pigment, carrier and additives. 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 gradually melt and plasticize.

The barrel of the extruder is usually divided into 4-6 temperature control sections (barošanas sadaļa, kušanas sekcija, sajaukšanas sadaļa, homogenizācijas sadaļa, mirst galvas sekcija), and the temperature of each section is precisely controlled according to the type of masterbatch (pārvadātāja veids, pigment type). Piemēram, when processing PE masterbatch, the temperature of the feeding section is 100-120℃, the melting section is 160-180℃, the mixing section is 170-190℃, the homogenizing section is 160-180℃, and the die head section is 150-170℃. The precise temperature control can ensure that the carrier is fully melted without thermal decomposition, and the pigments are not decomposed or discolored.

The screw of the twin-screw extruder adopts a modular design, which can freely combine different screw elements (piemēram, pārvietošanas elementi, elementu sajaukšana, bīdes elementi) according to the type of masterbatch. Piemēram, when processing masterbatch with high pigment content and easy agglomeration, more mixing elements and shearing elements can be configured to enhance the mixing and dispersing effect; when processing masterbatch with good fluidity, more conveying elements can be configured to improve production efficiency.

2.2.5 Ekstrūzija un formēšana

Pilnībā izkusis, jauktais un izkliedētais materiāls ar skrūvēm tiek nospiests uz ekstrūdera galviņu. The die head of the masterbatch extruder is usually equipped with multiple circular die holes (the number and size of die holes are determined according to the particle size of the masterbatch). The material is extruded from the die head at a high speed to form continuous strip-shaped semi-finished products (the diameter of the strip is usually 2-5mm, which can be adjusted according to customer needs).

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 strip. The extrusion speed is controlled according to the type of masterbatch and the particle size requirement, generally ranging from 1-3m/min. The extrusion pressure should be kept stable (fluctuation within ±0.5MPa), which can ensure the uniform diameter of the strip and the consistency of the masterbatch quality.

2.2.6 Cooling and Solidification

The extruded strip-shaped semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method for masterbatch is usually water tank cooling, and the cooling water temperature is controlled at 20-30℃. The length of the cooling water tank is 3-5 metri, and the cooling time is 2-4 minūtes. Rapid cooling can make the strip solidify quickly, maintain the shape and size of the strip, and avoid deformation and adhesion.

It should be noted that the cooling speed should be uniform. If the cooling speed is too fast, the internal stress of the strip will be too large, and the strip will be brittle and easy to break during granulation; if the cooling speed is too slow, the strip will be soft and easy to adhere, affecting the granulation effect. Pēc atdzesēšanas, the surface of the strip should be dry, smooth and free of bubbles and cracks.

2.2.7 Cutting and Granulation

After cooling and solidification, the strip is sent to a granulator for cutting to form granular masterbatch products. The granulator is equipped with a rotary knife and a fixed knife, and the cutting speed is adjustable (vispār 500-1000 apgr./min). The particle size of the masterbatch is controlled by adjusting the cutting speed and the speed of the strip conveying. The common particle size of masterbatch is 2-5mm (length and diameter are basically the same), which is convenient for mixing with plastic raw materials during later use.

The granulator should be equipped with a screening device to remove unqualified particles (such as too large, too small, agglomerated or broken particles). The qualified particles enter the next process, and the unqualified particles are crushed and recycled (after drying and premixing, they are re-extruded and granulated).

2.2.8 Skrīnings, Inspection and Packaging

The granulated masterbatch is sent to a vibrating screen for screening to further remove unqualified particles and impurities. The vibrating screen is equipped with a multi-layer screen (different mesh sizes), which can screen out masterbatch particles of different specifications according to customer needs.

After screening, the masterbatch needs to undergo quality inspection. The inspection items mainly include: krāsa (uniformity, consistency with the standard sample), dispersibility (observed by microscope or test piece coloring), koncentrācija (tinting strength test), mitruma saturs, particle size distribution, utt. Only the masterbatch that meets the quality standards can be packaged.

The packaging of masterbatch adopts sealed and moisture-proof packaging (such as plastic woven bags with inner plastic film, aluminum foil bags), and the packaging weight is usually 25kg/bag or 50kg/bag. The packaging bag is marked with the product name, modelis, krāsa, koncentrācija, pārvadātāja veids, ražošanas datums, shelf life, manufacturer and other information. The packaged masterbatch should be stored in a dry, cool and ventilated warehouse, avoiding direct sunlight and moisture, and the shelf life is generally 6-12 mēnešus.

2.3 Key Factors Affecting Masterbatch Twin-Screw Extrusion Effect

The effect of twin-screw extrusion directly affects the quality of masterbatch (dispersibility, tinting strength, stability). There are many factors affecting the extrusion effect, galvenokārt ietverot izejvielu īpašības, formula ratio, premixing effect, extrusion parameters and equipment performance. Mastering these key factors and making scientific adjustments can ensure the stability of the extrusion 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 extrusion effect. For pigments, the particle size should be uniform and fine (20-40 acs), and the agglomeration degree should be low; organic pigments have poor heat resistance, so the extrusion temperature should be strictly controlled; inorganic pigments have high hardness, so the extruder should have good wear resistance. For carriers, the melting point and processing temperature should be consistent with the target plastic raw materials, and the compatibility with pigments should be good. For additives, the type and dosage should be reasonable, and the compatibility with carriers and pigments should be good.

Turklāt, the moisture content of raw materials must be strictly controlled below 0.1%; if the moisture content is too high, it will cause bubbles and agglomeration in the masterbatch. The purity of raw materials is also very important; impurities in raw materials will not only affect the product quality, but also wear the screw and barrel of the extruder.

2.3.2 Formula Ratio

The formula ratio of masterbatch (the ratio of pigment, carrier and additive) is the key to determining the quality of the product. The pigment content should be determined according to the coloring requirements and the type of pigment: high-concentration masterbatch (pigment content 50%-80%) can reduce the addition amount and production cost, but requires better dispersibility; low-concentration masterbatch (pigment content 10%-30%) has better dispersibility, but the addition amount is large and the production cost is high.

The dosage of dispersants is generally 1%-5% of the pigment dosage; too little dispersant will lead to poor dispersibility of pigments, and too much dispersant will affect the mechanical properties of the masterbatch and the colored products. The dosage of other additives (saderības līdzekļi, heat stabilizers, smērvielas) is generally 0.5%-3%, which should be adjusted according to the type of masterbatch and processing requirements. The formula ratio should be strictly controlled, and the error should be within ±1%, to ensure the consistency of product quality between batches.

2.3.3 Premixing Effect

Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of pigments during extrusion. If the premixing is uneven, the pigments cannot be uniformly adhered to the surface of the carrier, resulting in local agglomeration of pigments, uneven mixing of materials during extrusion, and reduced product dispersibility.

To ensure the premixing effect, it is necessary to control the mixing speed (800-1200 apgr./min), maisīšanas laiks (5-10 minūtes) and mixing temperature (40-60℃). For masterbatch with high pigment content, the premixing time can be appropriately extended, and the dispersant can be added first and mixed with the pigment, then mixed with the carrier and other additives. Turklāt, the premixed mixture should be inspected; if there are obvious pigment agglomerates, it should be crushed and remixed.

2.3.4 Ekstrūzijas parametri

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

• Skrūves ātrums: The screw speed of twin-screw extruders for masterbatch processing generally ranges from 200 uz 800 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 pigments, 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, insufficient mixing of materials, and uneven dispersibility; if the screw speed is too low, the shear force and friction force are insufficient, the pigment agglomerates cannot be fully broken, and the production efficiency is low.
• The screw speed should be adjusted according to the type of masterbatch: for masterbatch with high pigment content and easy agglomeration (such as black masterbatch, white masterbatch), a higher screw speed (500-800 apgr./min) is needed to ensure the uniform dispersion of pigments; for masterbatch with organic pigments (poor heat resistance), a moderate screw speed (300-500 apgr./min) is needed to avoid overheating and pigment decomposition.
• Ekstrūzijas temperatūra: The extrusion temperature is the key to ensuring the melting of the carrier and the stability of the pigment. The temperature of each section of the barrel and die head must be precisely controlled according to the type of masterbatch (pārvadātāja veids, pigment type). Barošanas sekcijas temperatūra ir zemāka (nedaudz augstāka par izejvielu žāvēšanas temperatūru), 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; sajaukšanas sekcijas temperatūra ir augstāka, kas galvenokārt ir paredzēts bīdes un sajaukšanas efekta uzlabošanai, and promote the uniform dispersion of pigments; 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 strip.
• The temperature control precision should reach ±1℃. Piemēram, when processing PP masterbatch with organic pigments, the temperature of each section is: feeding section 110-130℃, melting section 170-190℃, mixing section 180-200℃, homogenizing section 170-190℃, die head section 160-180℃. If the temperature is too high, the pigment will decompose and the carrier will degrade; if the temperature is too low, the carrier will not be fully melted, and the pigment cannot be uniformly dispersed.
• Ekstrūzijas spiediens: The extrusion pressure of masterbatch twin-screw extrusion generally ranges from 5 to 12MPa. Spiedienu ekstrūzijas dobumā galvenokārt nosaka skrūves saspiešanas pakāpe, matricas cauruma izmērs un skrūves ātrums. Jo lielāks ir ekstrūzijas spiediens, jo labāka ir materiālu sajaukšanas un izkliedēšanas iedarbība, and the denser the strip. 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 strip is loose, and the dispersibility is poor.
• The extrusion pressure should be adjusted according to the type of masterbatch and the die head size: for masterbatch with high pigment content and poor fluidity, a higher extrusion pressure is needed; for masterbatch with good fluidity, a moderate extrusion pressure is sufficient. The extrusion pressure should be kept stable, and the fluctuation should be within ±0.5MPa, to ensure the uniform diameter of the strip and the consistency of the masterbatch quality.

2.3.5 Equipment Performance

The performance of the twin-screw extruder directly determines the extrusion effect. The key performance indicators of the extruder include mixing and dispersing capacity, temperatūras kontroles precizitāte, nodilumizturība, conveying capacity and intelligent control capacity. Zhuoyue pilna ekstrūderu sērija (HTS BASIC/PLUS/SUPER, ZTE, HTE) ir īpaši izstrādāti pamatsavienojumu apstrādei, with excellent performance in these aspects, which can effectively meet the processing needs of different types of masterbatch.

3. Zhuoyue’s Full Series Extruders: Professional Solutions for Masterbatch Processing

Zhuoyue has long been engaged in the research, augstas veiktspējas divu skrūvju ekstrūderu izstrāde un ražošana, and has accumulated rich experience in the field of masterbatch processing. According to the processing characteristics of masterbatch (high pigment content, easy agglomeration of pigments, strict temperature control requirements, high wear resistance requirements) and the diverse needs of manufacturers (different production scales, dažādi pamatsavienojumu veidi, different application fields), Zhuoyue has launched a full series of extruders suitable for masterbatch processing, including HTS BASIC series, HTS PLUS series, HTS SUPER series, ZTE series and HTE series. Each series has its own performance characteristics and targeted adaptation scenarios, which can provide personalized and efficient processing solutions for masterbatch manufacturers of different scales.

3.1 Core Advantages of Zhuoyue’s Extruders for Masterbatch Processing

Whether it is the high-end HTS SUPER series or the cost-effective ZTE series, all Zhuoyue’s extruders have the following core advantages, which are specially optimized for masterbatch processing, ensuring high-quality, efektīva un stabila ražošana:

3.1.1 Excellent Mixing and Dispersing Effect

Galvenās maisījuma apstrādes pamatprasība ir vienmērīga pigmentu izkliede. Visi Zhuoyue divu skrūvju ekstrūderi izmanto savstarpēji rotējošu struktūru, ar saprātīgu skrūvju soli, lead and compression ratio design. Divu skrūvju savstarpēja savienošana un rotēšana var radīt spēcīgu bīdes spēku un mīcīšanas spēku, kas spēj pilnībā salauzt pigmentu aglomerātus (pat mazi aglomerāti, kuru izmērs pārsniedz 100 μm), un padarīt pigmentus vienmērīgi izkliedētu nesējā. Ekstrūderu sajaukšanas viendabīgums var sasniegt vairāk nekā 95%, kas ir daudz augstāks nekā parastajiem divskrūves ekstrūderiem (85%-90%).

Turklāt, visu ekstrūderu sēriju skrūvēm ir modulāra konstrukcija, kurā var brīvi kombinēt dažāda veida skrūves elementus (pārvades elementi, elementu sajaukšana, bīdes elementi) according to the type of masterbatch (piemēram, krāsu pamatsavienojums, white masterbatch, black masterbatch) un pigmenta īpašības. Piemēram, apstrādājot melno galveno maisījumu ar ogli (easy agglomeration), more mixing elements and shearing elements can be configured to enhance the mixing and dispersing effect; when processing color masterbatch with organic pigments (poor heat resistance), more conveying elements and fewer shearing elements can be configured to shorten the residence time and avoid pigment decomposition.

3.1.2 Precīza temperatūras kontrole, Avoiding Pigment Decomposition

Masterbatch processing has strict requirements on temperature control, and the temperature fluctuation must be controlled within ±1℃ to avoid pigment decomposition and carrier degradation. All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, which is composed of high-precision temperature sensors, heating elements and cooling elements. The barrel is divided into 4-6 independent temperature control sections, and the temperature of each section can be precisely adjusted and controlled in real time.

Temperatūras kontroles sistēma ir aprīkota ar reāllaika uzraudzības un trauksmes funkciju: ja kādas sekcijas temperatūra pārsniedz iestatīto diapazonu, sistēma savlaicīgi izsauks trauksmes uzvedni, and automatically adjust the heating power or start the cooling system to return the temperature to the set range. Turklāt, the barrel of the extruder adopts a double-layer jacket design, kas var nodrošināt ātru sildīšanu un dzesēšanu, un uzlabot temperatūras kontroles reakcijas ātrumu. Preses galva ir aprīkota arī ar neatkarīgu temperatūras kontroles ierīci, which ensures the uniform temperature of the die head and the stable shaping of the strip.

3.1.3 High Wear Resistance, Ilgs kalpošanas laiks

Inorganic pigments such as titanium dioxide and carbon black have high hardness, which will cause serious wear to the screw and barrel of the extruder during processing. Zhuoyue’s extruders adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components.

The screws and barrels of HTS PLUS series, HTS SUPER series and HTE series are made of imported wear-resistant alloy steel (such as 38CrMoAlA), un pakļauti bimetāla kompozītmateriālu apstrādei vai lāzera apšuvuma apstrādei. The surface hardness of the screws and barrels can reach ≥65 HRC (HTS PLUS series, HTE sērija) and ≥70 HRC (HTS SUPER series), which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by high-hardness pigments. The service life of the screws and barrels is 2-3 times that of ordinary extruders, reducing the frequency of component replacement and the maintenance cost of the equipment.

The screws and barrels of HTS BASIC series and ZTE series are made of high-quality wear-resistant alloy steel with nitriding treatment, and the surface hardness can reach ≥60 HRC, which can meet the processing needs of ordinary masterbatch (pigment content ≤50%) and has a reasonable cost performance.

3.1.4 High Production Efficiency, Energy Saving and Environmental Protection

Zhuoyue’s extruders adopt a high-torque gearbox and an optimized screw structure, which have strong conveying capacity and high production efficiency. Compared with ordinary twin-screw extruders, the production efficiency of Zhuoyue’s extruders can be increased by 20%-50%. Piemēram, the production capacity of HTS SUPER series extruders can reach 1000-3000kg/h, which is suitable for large-scale mass production; the production capacity of ZTE series extruders is 100-500kg/h, which is suitable for small and medium-sized batch production.

Turklāt, all Zhuoyue’s extruders adopt high-efficiency motors and energy-saving heating elements, which can reduce energy consumption by 15%-20% compared with ordinary extruders. The extruders are equipped with a closed structure, which can reduce the emission of dust and volatile substances during processing, meeting the environmental protection requirements of the masterbatch industry.

3.1.5 Intelligent Control, Vienkārša darbība un apkope

All Zhuoyue’s 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 (līdz 100 sets), and when producing different types of masterbatch, only the corresponding formula and parameters need to be called, bez atkārtotas atkļūdošanas, kas ietaupa laiku un uzlabo ražošanas efektivitāti.

Sistēma ir aprīkota arī ar reāllaika uzraudzības funkciju, kas var uzraudzīt ekstrūzijas procesa galvenos parametrus (piemēram, temperatūra, spiedienu, skrūves ātrums, barošanas ātrums) reālajā laikā, un reģistrēt ražošanas datus (piemēram, izvade, apstrādes laiks) vēlākiem vaicājumiem un analīzei. HTS SUPER sērijas ekstrūderiem, mēs nodrošinām arī mākoņa kontroles funkciju, kas var realizēt attālinātu parametru regulēšanu, ražošanas datu monitorings un iekārtu paredzamā apkope, realizēt inteliģentu ražošanas vadību.

Turklāt, the extruders adopt a reasonable structural design, which makes the maintenance more convenient. Skrūves, barrels and die heads can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Zhuoyue’s after-sales service team will provide professional installation, commissioning and training services for customers, ensuring that customers can use the equipment smoothly.

3.1.6 Plašs pielietojuma klāsts, Strong Adaptability

Zhuoyue’s full series of extruders have a wide application range, which can adapt to the processing needs of various types of masterbatch, including color masterbatch, white masterbatch, black masterbatch, ordinary masterbatch, functional masterbatch (liesmu slāpējošs pamatmaisījums, antistatiska galvenā maisījuma masa), and masterbatch with different carriers (PE, PP, PVC, PA, PET, utt.). The extruders can also adapt to the processing of masterbatch with different pigment contents (10%-80%), and can meet the processing needs of different application fields (fibers, filmas, pūšamformēšana, ekstrūzija, iesmidzināšanas formēšana).

Whether it is a small and medium-sized manufacturer producing ordinary masterbatch, or a large-scale manufacturer producing high-end functional masterbatch, Zhuoyue can provide suitable extruder solutions. Turklāt, the extruders can be matched with different auxiliary equipment (such as high-speed mixers, žāvētāji, coolers, granulators, screening machines, packaging machines) to form a complete automatic production line, realizing continuous production from raw material pretreatment to product packaging.

3.2 Detailed Introduction of Zhuoyue’s Extruder Series and Their Adaptation to Masterbatch Processing

Zhuoyue’s extruder series for masterbatch processing include HTS BASIC, HTS PLUS, HTS SUPER, ZTE and HTE, each series has its own unique performance characteristics and targeted adaptation scenarios. Manufacturers can select the appropriate extruder series according to their own production scale, product type, masterbatch concentration, application field and budget.

3.2.1 HTS BASIC Series Extruders: Flexible and Cost-Effective Choice for Ordinary Masterbatch

The HTS BASIC series extruders are a cost-effective product series designed for small and medium-sized masterbatch manufacturers or manufacturers that mainly produce ordinary masterbatch. 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 specific torque of the extruders is 10-12Nm/cm³, which can meet the processing needs of ordinary masterbatch (pigment content ≤50%), such as PE/PP color masterbatch, low-concentration white masterbatch and black masterbatch.

Runājot par konstrukcijas projektēšanu, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating 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 of 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 small and medium-sized masterbatch manufacturers that mainly produce ordinary masterbatch for films, injection molding and extrusion products. 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, feeding devices and post-processing equipment according to their own product types and production needs, lai izveidotu savām vajadzībām piemērotu ražošanas līniju. HTS BASIC sērijas ekstrūderiem ir saprātīga cena, which can help small and medium-sized manufacturers reduce the initial investment cost while ensuring the basic processing quality of masterbatch. It is an ideal choice for enterprises that are just entering the masterbatch industry or have limited production scale and budget. Turklāt, this series of extruders has simple operation and low maintenance cost, and its after-sales service support is consistent with other high-end series, which can fully meet the daily production needs of small and medium-sized manufacturers.

3.2.2 HTS PLUS sērijas ekstrūderi: High-Torque Solution for Engineering Plastics and Filler Masterbatch

The HTS PLUS series extruders are positioned as mid-to-high-end products, specially developed for masterbatch processing scenarios with higher requirements, such as engineering plastic masterbatch and filler masterbatch. Different from the HTS BASIC series, this series adopts high-torque gearboxes independently developed and manufactured by Zhuoyue, with a specific torque of 13-16Nm/cm³, which can provide stronger shear force and kneading force, effectively solving the processing difficulties of high-viscosity, high-hardness masterbatch materials.

In terms of core components, the screws and barrels of the HTS PLUS series are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment. The surface hardness reaches ≥65 HRC, which has excellent wear resistance and corrosion resistance, and can easily cope with the wear caused by filler masterbatch (piemēram, kalcija karbonāts, talcum powder filled masterbatch) and engineering plastic masterbatch (piemēram, PA, PC masterbatch). The screw adopts a modular design, and is equipped with enhanced mixing elements and shearing elements, which can fully disperse the fillers and pigments in the carrier, ensuring the uniformity and stability of the masterbatch. The barrel is divided into 5-6 temperature control sections, with a temperature control precision of ±1℃, which can accurately control the processing temperature of engineering plastics (200-280℃) and avoid material decomposition.

The production capacity of the HTS PLUS series extruders ranges from 300kg/h to 1200kg/h, which is suitable for medium-sized and large-scale masterbatch manufacturers that produce engineering plastic masterbatch, pildvielas pamatsasija, high-concentration color masterbatch (pigment content 50%-70%) un citi produkti. Piemēram, in the processing of PA engineering plastic masterbatch, the HTS PLUS series can rely on its high torque and precise temperature control to ensure that the PA carrier is fully melted, and the pigments and functional additives are uniformly dispersed, avoiding the problems of color spots, streaks and poor mechanical properties of the masterbatch. In the processing of filler masterbatch, its strong shear force can fully disperse the filler particles (which are easy to agglomerate) in the carrier, improving the compatibility between the filler and the carrier, and ensuring the processing performance of the masterbatch when mixed with downstream plastic raw materials.

Turklāt, the HTS PLUS series extruders are equipped with an upgraded PLC intelligent control system, which can realize more precise parameter control and data monitoring. The system can automatically adjust the screw speed, feeding speed and extrusion pressure according to the material viscosity and processing effect, ensuring the stability of product quality between batches. The extruder is also equipped with a forced feeding device and a vacuum exhaust device: the forced feeding device can ensure the smooth feeding of high-viscosity materials; the vacuum exhaust device can effectively remove moisture, volatile substances and air in the materials, avoiding bubbles and pores in the masterbatch, and improving the density and quality of the masterbatch. This series of extruders balances performance and cost, and is suitable for manufacturers that need to improve product quality and expand production scale.

3.2.3 HTS SUPER Series Extruders: The Pinnacle of Zhuoyue’s Technology for High-End Masterbatch

As Zhuoyue’s highest-end extruder series, the HTS SUPER series represents the advanced level of China’s twin-screw extruder development, specially designed for high-end, high-demand masterbatch processing scenarios, such as high-concentration functional masterbatch, special engineering plastic masterbatch (such as PBT, POM, LCP), and masterbatch for high-end downstream fields (new energy vehicles, medicīniskās ierīces, high-end electronics).

The core highlight of the HTS SUPER series is the adoption of Zhuoyue’s latest independently developed ultra-high torque transmission device, with a specific torque of 17-20Nm/cm³, which is far higher than that of the HTS PLUS series. This ultra-high torque design enables the extruder to cope with the processing of ultra-high viscosity, ultra-high hardness masterbatch materials, such as masterbatch with high filler content (filler content above 60%) and special engineering plastic masterbatch with high melting point and high viscosity. Tajā pašā laikā, aiming at the high torque and high speed characteristics of this series, Zhuoyue has carried out a comprehensive optimization of the structural design of all key components of the extruder: the screw adopts a new type of wear-resistant alloy steel and undergoes laser cladding treatment, with a surface hardness of ≥70 HRC, which has extremely strong wear resistance and service life (3-4 times that of ordinary extruders); the barrel adopts a double-layer jacket + forced cooling structure, which can realize rapid temperature adjustment and precise control, avoiding local overheating of materials during high-speed, high-torque processing; the gearbox adopts a precision planetary gear structure, with low noise, high efficiency and stable operation, which can withstand long-term high-load work.

In terms of mixing and dispersing effect, the HTS SUPER series is equipped with a new type of multi-stage mixing screw combination, including high-shear mixing elements, kneading blocks and dispersing elements, which can generate multi-directional shear force and kneading force, fully breaking the agglomerates of pigments and fillers (even agglomerates below 50μm), and making the pigments, fillers and carriers uniformly mixed. The mixing uniformity of the masterbatch can reach more than 98%, which is suitable for the processing of high-concentration, high-dispersibility masterbatch (pigment content 70%-80%). Turklāt, this series of extruders adopts a variable frequency speed regulation system with high precision, and the screw speed can be adjusted in the range of 300-1000 apgr./min, which can be flexibly adjusted according to the type of masterbatch and processing requirements, ensuring the best processing effect.

The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for large-scale, high-standard masterbatch manufacturers that focus on high-end markets. Piemēram, in the processing of masterbatch for new energy vehicle parts (such as automotive interior and exterior parts, battery shell masterbatch), the HTS SUPER series can ensure that the masterbatch has excellent weather resistance, high temperature resistance and dispersibility, meeting the strict quality requirements of automotive manufacturers; in the processing of medical grade masterbatch (such as masterbatch for medical catheters, medicīnas konteineri), it can realize clean production, avoid material pollution, and ensure that the masterbatch meets the medical grade environmental protection standards. This series of extruders is also equipped with an intelligent cloud control system, kas var realizēt attālinātu parametru regulēšanu, ražošanas datu uzraudzība, fault early warning and predictive maintenance. Manufacturers can monitor the production status of the equipment in real time through mobile phones or computers, realize intelligent production management, and greatly improve production efficiency and management level.

3.2.4 ZTE sērijas ekstrūderi: Cost-Effective Choice for Universal Masterbatch Processing

The ZTE series extruders are positioned as cost-effective products, specially designed for manufacturers that need to balance processing quality and cost, and mainly produce universal ordinary masterbatch. This series of extruders has excellent cost performance, and its designed parameters can meet the processing needs of most common masterbatch materials (PE, PP, PVC galvenais maisījums, low-concentration color masterbatch, black masterbatch and white masterbatch with pigment content ≤50%).

Runājot par konstrukcijas projektēšanu, the ZTE series adopts a twin-screw parallel co-rotating structure, with a screw diameter ranging from 25mm to 65mm, and a specific torque of 8-11Nm/cm³, which can provide sufficient shear force and conveying capacity for ordinary masterbatch processing. The screws and barrels are made of high-quality wear-resistant alloy steel with nitriding treatment, and the surface hardness reaches ≥60 HRC, which can meet the wear requirements of ordinary pigments (such as organic pigments, low-hardness inorganic pigments) and has a long service life. The barrel is divided into 4 temperature control sections, with a temperature control precision of ±2℃, which can accurately control the processing temperature of ordinary masterbatch (150-220℃), avoiding pigment decomposition and carrier degradation.

The production capacity of the ZTE series extruders ranges from 50kg/h to 400kg/h, which is suitable for small and medium-sized masterbatch manufacturers, small workshops and enterprises that need to produce small batches of multi-variety masterbatch. This series of extruders has the advantages of simple structure, viegla darbība, low energy consumption and low maintenance cost. The operation interface adopts a simple touch screen design, which is easy to learn and master, and is suitable for operators with little experience. Turklāt, the ZTE series can also be flexibly configured according to customer needs, such as adding a forced feeding device, a vacuum exhaust device or a special die head, to meet the personalized processing needs of different customers. Although the ZTE series is cost-effective, its core performance indicators (such as mixing uniformity, temperatūras kontroles precizitāte) are far higher than those of ordinary extruders on the market, which can ensure that the produced masterbatch has uniform coloring, stable performance and meets the basic use requirements of downstream customers. It is an ideal choice for enterprises with limited budget and mainly producing ordinary masterbatch.

3.2.5 HTE sērijas ekstrūderi: High-Performance and Cost-Effective Integrated Solution

The HTE series extruders integrate the advantages of high performance and cost-effectiveness, aiming at medium-sized masterbatch manufacturers that need to improve production efficiency and product quality while controlling costs. This series of extruders is designed to balance performance, efficiency and cost, and is suitable for a variety of masterbatch processing scenarios, including high-concentration color masterbatch (pigment content 50%-60%), ordinary functional masterbatch (liesmu slāpējošs pamatmaisījums, antistatiska galvenā maisījuma masa) and masterbatch for films, blow molding and injection molding products.

In terms of core performance, the HTE series adopts a high-torque gearbox independently developed by Zhuoyue, with a specific torque of 12-14Nm/cm³, which is higher than that of the HTS BASIC and ZTE series, and can provide stronger shear force and kneading force, ensuring the uniform dispersion of pigments and additives. The screws adopt a modular design, and are equipped with a combination of conveying elements, mixing elements and shearing elements, which can be flexibly adjusted according to the type of masterbatch, improving the adaptability of the extruder. The screws and barrels are made of imported wear-resistant alloy steel with bimetallic composite treatment, and the surface hardness reaches ≥65 HRC, which has excellent wear resistance and can cope with the processing of high-hardness pigments (such as titanium dioxide, ogleklis) and low-content filler masterbatch.

The biggest advantage of the HTE series is that it can reduce energy consumption while improving production efficiency. This series of extruders adopts an optimized screw structure and a high-efficiency energy-saving motor, which can reduce energy consumption by 18%-25% compared with ordinary extruders of the same type. Tajā pašā laikā, its production capacity ranges from 200kg/h to 800kg/h, which is 15%-20% higher than that of the HTS BASIC series of the same specification. The barrel is divided into 5 temperature control sections, with a temperature control precision of ±1℃, which can accurately control the processing temperature, avoid material waste caused by overheating or insufficient melting, and further reduce production costs. Turklāt, the HTE series is equipped with a PLC intelligent control system, which can realize automatic parameter control, data monitoring and formula storage, ensuring the stability of product quality between batches. The extruder is also equipped with a vacuum exhaust device and a forced feeding device, which can improve the quality of masterbatch and ensure the smooth progress of production.

The HTE series is suitable for medium-sized masterbatch manufacturers that are in the stage of expanding production scale and upgrading product quality. It can not only meet the processing needs of high-quality masterbatch, but also control the production cost effectively, helping enterprises improve their market competitiveness. Compared with the HTS PLUS series, the HTE series has a more reasonable price; compared with the ZTE series, it has better performance and higher production efficiency, which is a cost-effective choice between mid-range and high-end products.

4. Wide Application Fields of Masterbatch and Matching Zhuoyue Extruder Solutions

As an indispensable core material in the plastics industry, masterbatch is widely used in fibers, filmas, pūšamformēšana, extrusion molding, injection molding and other fields. Different application fields have different requirements on the performance of masterbatch (piemēram, izkliedējamība, temperatūras izturība, color fastness) and production efficiency, which also determines the selection of twin-screw extruders. Zhuoyue’s full series of extruders can provide targeted solutions for different application fields, ensuring that the produced masterbatch meets the specific requirements of downstream products. The following is a detailed introduction to the application fields of masterbatch and the matching Zhuoyue extruder series.

4.1 Fiber Field: High-Dispersibility and Color Fastness Requirements

Masterbatch in the fiber field is mainly used for coloring chemical fibers, such as polyester fiber, nylon fiber, polypropylene fiber, utt., and the final products include carpets, tekstilizstrādājumi, cushions, non-woven fabrics, utt. This field has extremely high requirements on masterbatch: vispirms, augsta izkliedējamība. The fiber diameter is very small (usually a few microns to dozens of microns), and if the pigments in the masterbatch are not uniformly dispersed, it will cause color spots, streaks and uneven fineness of the fiber, affecting the appearance and quality of the fiber product; otrais, high color fastness. The fiber products need to go through spinning, weaving, dyeing and finishing and other processes, and the masterbatch must have good washing fastness, light fastness and friction fastness, avoiding color fading and discoloration; trešais, low impurity content. Impurities in the masterbatch will cause breakage of the fiber during spinning, reducing the yield of the fiber.

According to the requirements of the fiber field, the suitable Zhuoyue extruder series are HTS PLUS series, HTS SUPER series and HTE series. For high-end fiber masterbatch (such as high-grade textile fiber, carpet fiber), the HTS SUPER series is recommended. Its ultra-high mixing uniformity (≥98%) can ensure that the pigments are uniformly dispersed in the carrier, avoiding color spots and streaks of the fiber; the high-torque and precise temperature control can ensure the stability of the masterbatch performance, improving the color fastness of the fiber. For medium-grade fiber masterbatch (such as ordinary textile fiber, non-woven fabric), the HTS PLUS series and HTE series are recommended. Their high mixing and dispersing effect can meet the basic requirements of fiber masterbatch, and the cost performance is higher. For small-batch, low-cost fiber masterbatch, the HTS BASIC series can also be selected, which can ensure the basic dispersibility and color fastness.

4.2 Film Field: High Transparency and Uniform Coloring Requirements

Masterbatch in the film field is mainly used for coloring plastic films, piemēram, iepirkumu maisiņi, filmu liešana, daudzslāņu plēves, iepakojuma plēves, lauksaimniecības plēves, utt. The key requirements of this field for masterbatch are: vispirms, high transparency. For transparent or translucent films (piemēram, pārtikas iepakojuma plēves, agricultural mulch films), the masterbatch must have good transparency, avoiding affecting the appearance and visibility of the packaged products; otrais, viendabīga krāsošana. The film surface must be uniform in color, without color spots, color streaks and color difference, ensuring the aesthetic property of the film; trešais, good processing fluidity. The film extrusion speed is fast, and the masterbatch must have good fluidity, which is conducive to the uniform mixing of the masterbatch and the film base material, and avoiding affecting the film forming efficiency.

For the film field, the suitable Zhuoyue extruder series are HTS BASIC series, HTE series and HTS PLUS series. For ordinary film masterbatch (piemēram, iepirkumu maisiņi, ordinary packaging films), the HTS BASIC series and HTE series are recommended. Their good mixing and dispersing effect can ensure uniform coloring of the film, and the good processing fluidity can match the high-speed extrusion of the film. For high-end film masterbatch (piemēram, pārtikas iepakojuma plēves, multi-layer composite films), the HTS PLUS series is recommended. Its precise temperature control can avoid the decomposition of pigments and carriers, ensuring the transparency and safety of the film; the enhanced mixing elements can further improve the dispersibility of the masterbatch, making the film surface more smooth and uniform. For ultra-high transparent film masterbatch (such as PET packaging films), the HTS SUPER series can be selected, which can achieve ultra-high dispersibility of pigments, ensuring the transparency and clarity of the film.

4.3 Blow Molding Field: Good Fluidity and Dimensional Stability Requirements

Masterbatch in the blow molding field is mainly used for coloring blow molding products, piemēram, medicīnas un kosmētikas konteineri, lubricating oil and paint containers, dzērienu pudeles, plastmasas mucas, utt. The requirements of this field for masterbatch are: vispirms, good processing fluidity. Blow molding products need to be formed by high-temperature blow molding, and the masterbatch must have good fluidity, which is conducive to the uniform distribution of the masterbatch in the parison, avoiding uneven wall thickness and color difference of the product; otrais, good dimensional stability. The blow molding products have strict requirements on dimensional accuracy, and the masterbatch must have stable performance, avoiding the deformation of the product due to uneven shrinkage; trešais, vides aizsardzība. Especially for medical and cosmetic containers, the masterbatch must meet environmental protection standards, non-toxic and harmless, without volatile substances.

For the blow molding field, the suitable Zhuoyue extruder series are ZTE series, HTS BASIC series and HTE series. For ordinary blow molding masterbatch (such as lubricating oil containers, plastmasas mucas), the ZTE series and HTS BASIC series are recommended. Their reasonable screw structure and temperature control system can ensure the good fluidity and stability of the masterbatch, meeting the basic requirements of blow molding products. For medium-grade blow molding masterbatch (such as cosmetic containers, dzērienu pudeles), the HTE series is recommended. Its high production efficiency and energy-saving advantages can reduce production costs, and the good mixing and dispersing effect can ensure uniform coloring and dimensional stability of the product. For high-end blow molding masterbatch (such as medical containers), the HTS PLUS series and HTS SUPER series are recommended. Their high-precision temperature control and clean production design can ensure that the masterbatch meets medical grade standards, and the stable performance can ensure the dimensional accuracy and safety of the product.

4.4 Extrusion Molding Field: High Dimensional Stability and Wear Resistance Requirements

Masterbatch in the extrusion molding field is mainly used for coloring extrusion products, such as sheets, caurules, wires and cables, profili, utt. The key requirements of this field for masterbatch are: vispirms, high dimensional stability. Extrusion products (piemēram, caurules, profili) have strict requirements on dimensional accuracy, and the masterbatch must have stable performance, avoiding the deformation and color difference of the product due to uneven shrinkage; otrais, good wear resistance. For products such as pipes and wires and cables that need to withstand friction and extrusion, the masterbatch must have good wear resistance, ensuring the service life of the product; trešais, good weather resistance. For outdoor extrusion products (such as building profiles, outdoor pipes), the masterbatch must have good weather resistance, avoiding color fading and performance degradation under sunlight and rain.

For the extrusion molding field, the suitable Zhuoyue extruder series are HTS PLUS series, HTE series and HTS SUPER series. For ordinary extrusion masterbatch (such as indoor sheets, ordinary pipes), the HTE series and HTS BASIC series are recommended. Their good mixing and dispersing effect can ensure uniform coloring of the product, and the stable performance can ensure the dimensional accuracy of the product. For medium-grade extrusion masterbatch (such as wires and cables, building profiles), the HTS PLUS series is recommended. Its high-torque gearbox and wear-resistant screw/barrel can cope with the processing of high-hardness, high-viscosity masterbatch, ensuring the wear resistance and weather resistance of the product. For high-end extrusion masterbatch (such as high-temperature resistant pipes, outdoor high-grade profiles), the HTS SUPER series is recommended. Its ultra-high torque and precise temperature control can ensure the stable performance of the masterbatch, and the enhanced wear resistance can further extend the service life of the product.

4.5 Injection Molding Field: High Dispersibility and Batch Stability Requirements

Masterbatch in the injection molding field is the most widely used, mainly used for coloring injection molding products, piemēram, automobiļu daļas, elektroniskie izstrādājumi, celtniecības materiāli, home appliances, furniture, rotaļlietas, utt. The requirements of this field for masterbatch are diverse, but the core requirements are: vispirms, augsta izkliedējamība. Injection molding products have complex shapes and small sizes, and the masterbatch must have high dispersibility, avoiding color spots, color streaks and uneven coloring of the product; otrais, good batch stability. Injection molding products are usually produced in large batches, and the masterbatch must have stable performance, ensuring no color difference between batches of products; trešais, targeted functional requirements. Piemēram, automotive parts require masterbatch with high temperature resistance and flame retardancy, electronic products require masterbatch with antistatic performance, and toys require masterbatch with non-toxic and environmental protection performance.

For the injection molding field, Zhuoyue’s full series of extruders can provide corresponding solutions according to different product levels. For ordinary injection molding masterbatch (such as toys, ordinary home appliances), the ZTE series and HTS BASIC series are recommended. Their cost-effective advantages can reduce production costs, and the basic mixing and dispersing effect can meet the requirements of ordinary products. For medium-grade injection molding masterbatch (such as electronic products, ordinary automotive parts), the HTE series and HTS PLUS series are recommended. Their high mixing and dispersing effect and batch stability can ensure the quality of the product, and the targeted functional masterbatch processing capacity can meet the special requirements of the product. For high-end injection molding masterbatch (such as high-grade automotive parts, precision electronic products), the HTS SUPER series is recommended. Its ultra-high dispersibility, batch stability and high-temperature resistance can meet the strict quality requirements of high-end products, and the intelligent control system can ensure the efficiency and stability of large-scale production.

5. Common Problems and Solutions in Masterbatch Twin-Screw Extrusion Processing

In the actual production process of masterbatch, due to the influence of raw materials, formula, processing parameters and equipment performance, various problems often occur, which affect the quality of masterbatch and production efficiency. Based on years of industry experience, Zhuoyue summarizes the common problems in masterbatch twin-screw extrusion processing, analyzes the causes in detail, and provides corresponding solutions, which can help manufacturers quickly solve production problems and improve production efficiency and product quality.

5.1 Common Problem 1: Poor Dispersibility of Masterbatch, Color Spots and Streaks in Products

This is the most common problem in masterbatch processing, which is mainly manifested in uneven coloring of the masterbatch, obvious pigment agglomerates, and color spots and streaks in the colored plastic products. The main causes and solutions are as follows:

5.1.1 Main Causes:

• (1) Raw material problems: The pigment particle size is too large, the agglomeration degree is high, and the drying is insufficient; the compatibility between the pigment and the carrier is poor; the dispersant dosage is insufficient or the type is improper.
• (2) Premixing problems: The mixing speed is too low, the mixing time is too short, the mixing temperature is improper, resulting in uneven premixing of raw materials.
• (3) Extrusion parameter problems: The screw speed is too low, the shear force is insufficient, and the pigment agglomerates cannot be fully broken; the extrusion temperature is too low, the carrier is not fully melted, and the pigment cannot be uniformly dispersed.
• (4) Equipment problems: The screw mixing elements are insufficient or worn; the barrel and screw are worn, resulting in reduced shear force; the die head is blocked, affecting the uniform extrusion of materials.

5.1.2 Risinājumi:

• (1) Optimize raw materials: Select pigments with small particle size and low agglomeration degree, and dry them thoroughly (moisture content ≤0.1%); select carriers compatible with pigments; replace appropriate dispersants and increase the dosage appropriately (ietvaros 1%-5% of the pigment dosage).
• (2) Improve premixing effect: Increase the mixing speed to 800-1200 apgr./min, extend the mixing time to 5-10 minūtes, and control the mixing temperature at 40-60℃; for high-concentration masterbatch, add dispersant first and mix with pigment, then mix with carrier and other additives.
• (3) Adjust extrusion parameters: Increase the screw speed appropriately (500-800 rpm for high-concentration masterbatch), improve the shear force; increase the extrusion temperature appropriately to ensure that the carrier is fully melted (adjust according to the carrier type).
• (4) Maintain equipment: Replace worn screw mixing elements, barrel and screw; clean the die head regularly to avoid blockage; check the equipment regularly to ensure that the screw and barrel are properly matched.

5.2 Common Problem 2: Pigment Decomposition and Discoloration of Masterbatch

This problem is mainly manifested in the discoloration of the masterbatch (such as yellowing, darkening), the color is inconsistent with the standard sample, and even peculiar smell is generated. It is mostly caused by overheating of the material during extrusion processing, which is common in organic pigment masterbatch and engineering plastic masterbatch. The main causes and solutions are as follows:

5.2.1 Main Causes:

• (1) Extrusion temperature is too high: The temperature of the mixing section, homogenizing section or die head is too high, exceeding the heat resistance limit of the pigment or carrier.
• (2) The residence time of the material is too long: The screw speed is too low, the compression ratio is too large, resulting in the material staying in the extrusion cavity for too long (vairāk nekā 3 minūtes), and thermal decomposition occurs.
• (3) Poor heat dissipation of the equipment: The cooling system of the barrel fails, resulting in local overheating of the barrel.
• (4) Raw material problems: The heat resistance of the pigment is poor, or the carrier is easy to degrade at high temperature.

5.2.2 Risinājumi:

• (1) Adjust extrusion temperature: Reduce the temperature of the mixing section, homogenizing section and die head appropriately, and control it within the heat resistance range of the pigment and carrier (150-220℃ for ordinary masterbatch, 200-280℃ for engineering plastic masterbatch); check the temperature sensor regularly to ensure accurate temperature control.
• (2) Shorten the residence time: Increase the screw speed appropriately, reduce the compression ratio of the screw, and ensure that the residence time of the material in the extrusion cavity is 1-3 minūtes.
• (3) Maintain the cooling system: Check the cooling water circulation system regularly, clean the cooling pipe, and ensure that the barrel can dissipate heat normally; replace the faulty cooling element in time.
• (4) Optimize raw materials: Select pigments with good heat resistance (such as inorganic pigments for high-temperature processing); select carriers with stable performance and not easy to degrade; add appropriate heat stabilizers (0.5%-3%) to prevent pigment decomposition and carrier degradation.

5.3 Common Problem 3: High Wear of Screw and Barrel, Short Service Life

This problem is common in the processing of white masterbatch, black masterbatch and filler masterbatch, which is mainly manifested in the rapid wear of the screw and barrel, reduced shear force and mixing capacity of the extruder, and increased maintenance cost. The main causes and solutions are as follows:

5.3.1 Main Causes:

• (1) Raw material problems: The pigment or filler has high hardness (such as titanium dioxide, ogleklis, kalcija karbonāts), and the particle size is too large, which causes severe wear to the screw and barrel.
• (2) Extrusion parameter problems: The screw speed is too high, the shear force is too large, and the friction between the material and the screw/barrel is increased; the extrusion pressure is too high, which increases the wear of the screw and barrel.
• (3) Equipment problems: Skrūve un cilindrs ir izgatavoti no materiāliem ar sliktu nodilumizturību, vai apstrādes tehnoloģija ir nepareiza; skrūve un cilindrs nav pareizi saskaņoti, kā rezultātā rodas nevienmērīgs spriegums un palielinās nodilums.

5.3.2 Risinājumi:

• (1) Optimize raw materials: Izvēlieties pigmentus vai pildvielas ar mazu daļiņu izmēru (20-40 acs) un zema cietība; sasmalciniet un izsijājiet izejvielas, lai noņemtu lielas daļiņas; pievienojiet atbilstošas ​​smērvielas (0.5%-2%) lai samazinātu berzi starp materiālu un skrūvi/mucu.
• (2) Adjust extrusion parameters: Atbilstoši samaziniet skrūves ātrumu un ekstrūzijas spiedienu, un kontrolēt bīdes spēku saprātīgā diapazonā; izvairieties no iekārtas ilgstošas ​​liela ātruma un augsta spiediena darbības.
• (3) Izvēlieties augstas nodilumizturības aprīkojumu: Izvēlieties ekstrūderus ar nodilumizturīgām skrūvēm un mucām, piemēram, Zhuoyue HTS PLUS, HTS SUPER un HTE sērijas, whose screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite or laser cladding treatment, which can greatly improve the service life; regularly check the wear of the screw and barrel, and replace them in time when the wear is serious.

5.4 Common Problem 4: Instability of Product Quality Between Batches, Color Difference

This problem is mainly manifested in the inconsistency of masterbatch quality (such as concentration, dispersibility, krāsa) between different batches, resulting in color difference of downstream products, which affects the reputation of the manufacturer. The main causes and solutions are as follows:

5.4.1 Main Causes:

• (1) Formula problem: The formula ratio is not strictly controlled, and the dosage of pigment, dispersant and other additives fluctuates (error exceeds ±1%).
• (2) Raw material problem: The performance of raw materials (such as pigment tinting strength, carrier melting point) of different batches is inconsistent.
• (3) Processing parameter problem: The extrusion temperature, skrūves ātrums, feeding speed and other parameters fluctuate between different batches, resulting in inconsistent processing effect.
• (4) Equipment problem: The equipment has poor stability, and the parameters (piemēram, temperatūra, spiedienu) cannot be kept stable for a long time.

5.4.2 Risinājumi:

• (1) Strictly control the formula ratio: Use high-precision weighing equipment to weigh raw materials, and the error is controlled within ±1%; establish a formula management system, and record the dosage of each raw material in detail.
• (2) Standardize raw material procurement and inspection: Select raw material suppliers with stable quality, and inspect the performance of raw materials (such as tinting strength, daļiņu izmērs, mitruma saturs) before use; for raw materials of different batches, conduct trial production first to ensure consistent performance.
• (3) Standardize processing parameters: Use an intelligent control system (such as Zhuoyue’s PLC control system) to store the processing parameters of different masterbatch, and call the corresponding parameters when producing different batches, avoiding repeated debugging; regularly check the equipment parameters to ensure stable operation.
• (4) Establish quality inspection system: Conduct strict quality inspection on each batch of masterbatch, ieskaitot krāsu, dispersibility, concentration and other indicators, and only deliver the products that meet the standards.

5.5 Common Problem 5: Poor Processing Fluidity of Masterbatch, Difficult Extrusion, Equipment Blockage

This problem is mainly manifested in the difficulty of material conveying and extrusion, low production efficiency, unstable extrusion pressure, and even blockage of the die head and extrusion cavity, which affects the normal production. The main causes and solutions are as follows:

5.5.1 Main Causes:

• (1) Raw material problem: The carrier has poor fluidity, or the pigment content is too high (vairāk nekā 80%), resulting in poor fluidity of the mixture; the raw material has high moisture content, which causes the material to agglomerate and block the feeding port.
• (2) Premixing problem: The premixing is uneven, and the dispersant is not fully mixed, resulting in poor fluidity of the material.
• (3) Extrusion parameter problem: The extrusion temperature is too low, the carrier is not fully melted, and the fluidity is poor; the screw speed is too low, the conveying capacity is insufficient; the die head hole is too small, and the extrusion resistance is too large.
• (4) Equipment problem: The screw conveying elements are worn, the conveying capacity is reduced; the feeding device fails, resulting in uneven feeding.

5.5.2 Risinājumi:

• (1) Optimize raw materials: Select carriers with good fluidity; reduce the pigment content appropriately (control within 80%); dry the raw materials thoroughly to control the moisture content below 0.1%.
• (2) Improve premixing effect: Extend the premixing time, increase the mixing speed, ensure that the dispersant is fully mixed with the pigment and carrier, and improve the fluidity of the mixture.
• (3) Adjust extrusion parameters: Increase the extrusion temperature appropriately to ensure that the carrier is fully melted; increase the screw speed to improve the conveying capacity; replace the die head with larger die holes to reduce extrusion resistance.
• (4) Maintain equipment: Replace worn screw conveying elements; check the feeding device regularly, and repair or replace the faulty parts in time; clean the feeding port and extrusion cavity regularly to avoid material accumulation and blockage.

6. Practical Application Cases of Zhuoyue Extruders in Masterbatch Processing

To further verify the performance advantages and application effects of Zhuoyue’s full series of extruders in masterbatch processing, this section will introduce several practical application cases, covering different masterbatch types, production scales and application fields. These cases fully demonstrate that Zhuoyue’s extruders can provide targeted and efficient processing solutions for different manufacturers, helping manufacturers improve production efficiency, product quality and market competitiveness.

6.1 Lieta 1: Application of HTS SUPER Series in High-Concentration Black Masterbatch Processing for New Energy Vehicles

Customer Background: A large-scale masterbatch manufacturer in Jiangsu, Ķīna, mainly produces high-end functional masterbatch, focusing on the new energy vehicle field. The customer needs to produce high-concentration black masterbatch (carbon black content 70%) for automotive battery shell parts. The masterbatch requires ultra-high dispersibility (produktā nav melnu plankumu un svītru), augsta temperatūras izturība (var izturēt 200 ℃ augstu temperatūru bez krāsas maiņas), un laba partijas stabilitāte. Klienta oriģinālajam aprīkojumam ir tādas problēmas kā nepietiekams sajaukšanas un izkliedēšanas efekts, nestabila temperatūras kontrole, un zema ražošanas efektivitāte, kas nevar izpildīt ražošanas prasības.

Risinājums: Zhuoyue iesaka HTS SUPER sērijas divu skrūvju ekstrūderus (skrūves diametrs 75 mm) klientam. Šī sērija izmanto īpaši augsta griezes momenta pārnesumkārbas un ar lāzeru pārklātas nodilumizturīgas skrūves / mucas, kas var nodrošināt spēcīgu bīdes spēku un nodilumizturību, efektīvi risinot ogļu aglomerācijas problēmu; 6 sekciju precīza temperatūras kontroles sistēma (temperatūras kontroles precizitāte ±1 ℃) var precīzi kontrolēt ekstrūzijas temperatūru, avoiding carbon black decomposition; the multi-stage mixing screw combination ensures that the carbon black is uniformly dispersed in the PE carrier; the intelligent cloud control system can realize remote parameter adjustment and data monitoring, ensuring batch stability.

Application Effect: After using the HTS SUPER series extruders, the customer’s high-concentration black masterbatch has achieved ultra-high dispersibility, and the colored battery shell parts have no black spots and streaks, which meets the strict requirements of new energy vehicle manufacturers; the high temperature resistance of the masterbatch has been significantly improved, and no discoloration occurs at 200℃; the production efficiency has increased from 500kg/h to 1200kg/h, and the energy consumption has decreased by 22%; the batch stability of the masterbatch has been greatly improved, and the color difference between batches is less than 0.5, which has won high recognition from downstream customers. The customer has successively purchased 8 sets of HTS SUPER series extruders, forming a large-scale production line.

6.2 Lieta 2: Application of HTS PLUS Series in Engineering Plastic PA Masterbatch Processing

Customer Background: A medium-sized masterbatch manufacturer in Guangdong, Ķīna, mainly produces engineering plastic masterbatch, focusing on the automotive and electronic fields. The customer needs to produce PA66 masterbatch (pigment content 50%) for automotive connector parts. The masterbatch requires good dispersibility, augsta temperatūras izturība (260℃), and good compatibility with PA66 raw materials. The customer’s original equipment has problems such as poor wear resistance of the screw/barrel, insufficient torque, and easy decomposition of PA66 carrier, which affects the product quality.

Risinājums: Zhuoyue recommends the HTS PLUS series twin-screw extruders (screw diameter 65mm) klientam. This series adopts high-torque gearboxes independently developed by Zhuoyue, which can provide sufficient torque for PA66 masterbatch processing; the bimetallic composite screw/barrel has excellent wear resistance and corrosion resistance, which can cope with the wear of high-hardness pigments; the 5-section precise temperature control system and vacuum exhaust device can avoid PA66 carrier decomposition and remove moisture and volatile substances, ensuring the quality of the masterbatch; the modular screw design can be flexibly configured according to the PA66 masterbatch processing characteristics, improving the mixing and dispersing effect.

Application Effect: After using the HTS PLUS series extruders, the customer’s PA66 masterbatch has good dispersibility, and the automotive connector parts have uniform coloring and no color spots; the masterbatch can withstand 260℃ high temperature without decomposition and discoloration, and has good compatibility with PA66 raw materials; the service life of the screw/barrel has increased from 6 mēnešus līdz 18 mēnešus, reducing the maintenance cost by 60%; the production efficiency has increased from 300kg/h to 800kg/h, and the product qualification rate has increased from 92% uz 99%. The customer’s PA66 masterbatch has successfully entered the supply chain of a well-known automotive parts manufacturer.

6.3 Lieta 3: Application of HTE Series in Cost-Effective Film Masterbatch Processing

Customer Background: A small and medium-sized masterbatch manufacturer in Zhejiang, Ķīna, mainly produces film masterbatch, focusing on the packaging film field. The customer needs to produce PE film masterbatch (pigment content 40%) for food packaging films. The masterbatch requires good transparency, viendabīga krāsošana, un zemas ražošanas izmaksas. The customer’s original equipment has problems such as high energy consumption, unstable product quality, un zema ražošanas efektivitāte, which cannot meet the market competition needs.

Risinājums: Zhuoyue recommends the HTE series twin-screw extruders (screw diameter 50mm) klientam. This series integrates high performance and cost-effectiveness, adopts high-efficiency energy-saving motors and optimized screw structures, which can reduce energy consumption by 18%-25%; the precise temperature control system ensures that the PE carrier is fully melted, avoiding affecting the transparency of the masterbatch; the enhanced mixing elements ensure uniform coloring of the masterbatch, and the stable performance ensures batch consistency; the reasonable price and low maintenance cost can help the customer reduce production costs.

Application Effect: After using the HTE series extruders, the customer’s PE film masterbatch has good transparency and uniform coloring, and the food packaging films produced have smooth surface and no color spots, which meets the food packaging standards; the energy consumption per ton of masterbatch has decreased by 20%, and the production efficiency has increased from 150kg/h to 400kg/h; the product qualification rate has increased from 90% uz 98%, and the production cost has decreased by 15%. The customer’s market competitiveness has been significantly improved, and the order volume has increased by 40% within half a year. The customer has purchased 4 sets of HTE series extruders to expand production scale.

6.4 Lieta 4: Application of ZTE Series in Small-Batch Multi-Variety Ordinary Masterbatch Processing

Customer Background: A small masterbatch manufacturer in Shandong, Ķīna, mainly produces small-batch multi-variety ordinary masterbatch (PE/PP color masterbatch, black masterbatch, white masterbatch), focusing on the local plastic product processing market. The customer has limited budget, small production scale, and needs to produce multiple types of masterbatch with small batches (50-100kg per batch). The customer’s requirements for the equipment are simple operation, zemas uzturēšanas izmaksas, and strong adaptability.

Risinājums: Zhuoyue recommends the ZTE series twin-screw extruders (screw diameter 35mm) klientam. This series has excellent cost performance, simple structure and easy operation, which is suitable for operators with little experience; the modular screw design can be flexibly adjusted according to different types of masterbatch, with strong adaptability; the wear-resistant screw/barrel and stable temperature control system can meet the basic processing requirements of ordinary masterbatch; the low energy consumption and low maintenance cost can help the customer reduce the initial investment and daily operation costs.

Application Effect: After using the ZTE series extruders, the customer can flexibly produce multiple types of ordinary masterbatch, and the product quality meets the basic requirements of local plastic product manufacturers; the equipment operation is simple, and the operator can master it quickly; the maintenance cost is low, and the annual maintenance cost is less than 5000 yuan; the production efficiency can meet the small-batch production needs (50-200kg/h). The ZTE series extruders have helped the customer stabilize the local market and lay a foundation for future expansion.

7. Future Development Trend of Masterbatch and Twin-Screw Extrusion Technology

With the continuous development of the global plastics industry, the upgrading of environmental protection policies and the diversification of downstream market demand, the masterbatch industry and twin-screw extrusion technology are facing new development opportunities and challenges. The future development trend will focus on environmental protection, funkcionalizācija, intelligence and high efficiency, and Zhuoyue will continue to focus on technological innovation, keep up with the industry trend, and provide more advanced and efficient processing solutions for masterbatch manufacturers.

7.1 Development Trend of Masterbatch Industry

7.1.1 In-depth Development of Environmental Protection and Low Toxicity.

With the strengthening of global environmental protection awareness and the strictness of environmental protection policies (such as the European Union’s REACH directive, China’s “double carbon” goal), environmental protection masterbatch will become the mainstream of the market. The future environmental protection masterbatch will focus on non-toxic, nekaitīgs, low-volatile, degradable and recyclable, un toksiski un kaitīgi pigmenti (piemēram, smago metālu pigmenti) and additives will be completely eliminated. Piemēram, water-based masterbatch, bio-based masterbatch and recyclable masterbatch will have broad market prospects. Tajā pašā laikā, the recycling of masterbatch waste will also become an important development direction, which can reduce resource waste and environmental pollution.

7.1.2 Functional Integration and High Performance.

With the diversification of downstream product requirements, masterbatch will develop towards functional integration, that is, integrating multiple functions (such as coloring, liesmas slāpētājs, antistatiska, antibakteriāls, UV-resistant) into one masterbatch, which can reduce the addition amount of masterbatch, simplify the processing process, and reduce production costs. Piemēram, new energy vehicle masterbatch will integrate high temperature resistance, liesmas slāpētājs, antistatic and other functions; medical masterbatch will integrate non-toxic, antibakteriāls, high transparency and other functions. Turklāt, high-performance masterbatch (such as high-concentration, high-dispersibility, high-temperature resistant, corrosion-resistant masterbatch) will be more widely used in high-end fields such as aerospace, precision electronics and new energy.

7.1.3 Customization and Personalization.

With the upgrading of downstream market demand, the customization and personalization of masterbatch will become more and more prominent. Different downstream manufacturers have different requirements on masterbatch (such as color, koncentrācija, funkciju, pārvadātāja veids), and masterbatch manufacturers need to provide personalized customization solutions according to the specific needs of customers. Piemēram, according to the color sample provided by the customer, customize the masterbatch with matching color; according to the special use environment of the product, customize the masterbatch with targeted functions. This requires masterbatch manufacturers to have strong R&D capabilities and flexible production capacity.

7.2 Development Trend of Twin-Screw Extrusion Technology

7.2.1 Intelligence and Automation Upgrading.

The future twin-screw extruders will develop towards higher intelligence and automation. The intelligent control system will integrate AI, big data, Internet of Things and other technologies, which can realize real-time monitoring, automatic parameter adjustment, fault early warning, predictive maintenance and production data analysis of the extrusion process. Piemēram, the AI system can automatically adjust the screw speed, extrusion temperature and feeding speed according to the raw material performance and processing effect, ensuring the stability of product quality; the Internet of Things technology can realize the interconnection of multiple extruders, realizing centralized management and intelligent scheduling of the production line; the big data system can analyze the production data, optimize the processing parameters and formula, and improve production efficiency and product quality.

7.2.2 Augsta Efektivitāte, Energy Saving and Environmental Protection.

High efficiency, energy saving and environmental protection will continue to be the key development direction of twin-screw extrusion technology. The future extruders will adopt more advanced screw structures, high-efficiency energy-saving motors and heating/cooling systems, which can further reduce energy consumption and improve production efficiency. Piemēram, the optimized screw structure can reduce the shear loss and improve the conveying efficiency; the high-efficiency energy-saving motor can reduce the energy consumption by 25%以上 compared with the traditional motor; the closed structure and waste gas treatment system can reduce the emission of dust and volatile substances, meeting the higher environmental protection requirements.

7.2.3 High Performance and Wear Resistance.

With the development of high-concentration, high-hardness masterbatch (such as filler masterbatch, engineering plastic masterbatch), the requirements for the performance and wear resistance of twin-screw extruders will be higher. The future extruders will adopt more high-performance wear-resistant materials (such as new alloy steel, ceramic materials) and advanced manufacturing technologies (such as laser cladding, bimetāla kompozīts), which can greatly improve the wear resistance and corrosion resistance of the screw and barrel, extend the service life of the equipment. Tajā pašā laikā, the extruders will be equipped with higher torque gearboxes and more advanced mixing elements, which can provide stronger shear force and kneading force, meeting the processing needs of high-performance masterbatch.

7.2.4 Modularization and Flexibility.

Modularization and flexibility will become an important development trend of twin-screw extruders. The future extruders will adopt a more perfect modular design, and the screw, muca, die head and other components can be freely combined and replaced according to the type of masterbatch and processing requirements, which can improve the adaptability of the equipment and reduce the investment cost of the customer. Piemēram, when producing different types of masterbatch, only the corresponding screw elements and die head need to be replaced, without replacing the entire extruder. Turklāt, the small and medium-sized modular extruders will be more popular, which can meet the small-batch and multi-variety production needs of small and medium-sized manufacturers.

7.3 Zhuoyue’s Layout in the Future Development Trend

Facing the future development trend of the masterbatch industry and twin-screw extrusion technology, Zhuoyue will focus on technological innovation and product upgrading, and make layout in the following aspects: vispirms, strengthen the R&D of intelligent extrusion technology, integrate AI, big data and Internet of Things technologies into the extruder design, launch more intelligent and automatic extruders, and help customers realize intelligent production; otrais, increase the R&D investment in high-performance wear-resistant materials and energy-saving technologies, develop more efficient, energy-saving and wear-resistant extruders, reduce the production cost and environmental impact of customers; trešais, strengthen the R&D of customized solutions, according to the personalized needs of different customers, provide targeted extruder configuration and processing solutions, and improve customer satisfaction; ceturtais, expand the R&D of environmental protection masterbatch processing technology, launch extruders suitable for water-based masterbatch, bio-based masterbatch and recyclable masterbatch processing, and help the masterbatch industry achieve green development.

8. Secinājums

Galvenais maisījums, as the core material of plastic coloring and functional modification, plays an indispensable role in the global plastics industry. Twin-screw extrusion technology, as the key processing technology of masterbatch, directly determines the quality, production efficiency and market competitiveness of masterbatch products. With the continuous development of the masterbatch industry towards environmental protection, funkcionalizācija, high concentration and intelligence, the requirements for twin-screw extruders are becoming higher and higher.

Zhuoyue, as a professional manufacturer of twin-screw extruders, has launched a full series of extruders (HTS BASIC/PLUS/SUPER, ZTE, HTE) specially designed for masterbatch processing, each series has its own unique performance characteristics and targeted adaptation scenarios, which can provide personalized and efficient processing solutions for masterbatch manufacturers of different scales and fields. These extruders have the advantages of excellent mixing and dispersing effect, precīza temperatūras kontrole, augsta nodilumizturība, augsta ražošanas efektivitāte, energy saving and environmental protection, intelligent control and wide application range, which have been fully verified in many practical application cases.

This article comprehensively elaborates on the core knowledge of masterbatch, the principle and process of twin-screw extrusion technology, the performance advantages of Zhuoyue’s full series of extruders, the application fields of masterbatch, common problems and solutions in processing, practical application cases, and the future development trend. It is hoped that this article can provide comprehensive and professional reference for masterbatch manufacturers, processing technicians, industry practitioners and relevant researchers.

In the future, Zhuoyue turpinās ievērot tehnoloģisko inovāciju un uz klientu orientētu koncepciju, sekot līdzi nozares attīstības tendencēm, pastāvīgi atjaunināt produktus un tehnoloģijas, nodrošināt progresīvāku, efektīvi un videi draudzīgi divu skrūvju ekstrūzijas risinājumi, un strādāt kopā ar galveno maisījumu ražotājiem visā pasaulē, lai veicinātu kvalitatīvu galveno maisījumu ražošanas nozares attīstību.