Filler Masterbatch Napredne proizvodne linije za granulacijo in uporaba tehnologije ekstrudiranja

S hitrim razvojem svetovne plastične industrije, povpraševanje po plastičnih izdelkih narašča iz dneva v dan, in zahteve glede delovanja izdelka, tudi nadzor nad stroški in varstvo okolja postajata vse strožja. Polnilo masterbatch, kot ključni funkcionalni dodatek pri predelavi plastike, se pogosto uporablja na različnih področjih proizvodnje plastike zaradi svojih prednosti zmanjšanja proizvodnih stroškov, izboljšanje učinkovitosti izdelka in optimizacija učinkovitosti obdelave. Zavezani smo k zagotavljanju naprednih proizvodnih linij za granulacijo in visoko zmogljivih ekstrudorjev za različne vrste polnilnih masterbatchov., temelji na bogatih izkušnjah pri raziskavah in razvoju tehnologije ekstrudiranja ter proizvodnji, to provide targeted, efficient and reliable processing solutions for filler masterbatch manufacturers, helping enterprises improve production efficiency, ensure product quality, and gain a competitive advantage in the fierce market competition.

This article will focus on the field of filler masterbatch, in-depth elaborating on the basic concepts, razvrstitev, production process of filler masterbatch, the core role of extrusion technology in its granulation production, the advantages of our extruder series and their targeted adaptation to filler masterbatch processing, as well as the specific application fields, usage methods and common problems and solutions in production. It will supplement detailed technical parameters, process details and industry pain points to enrich the content, meet the word count requirement of 3000-4000 words, in zagotoviti celovito in strokovno referenco za ustrezna podjetja in praktike v industriji masterbatch polnil.

1. Pregled industrije polnilnih masterbatchov in značilnosti izdelka

1.1 Trenutno stanje in razvojni trend industrije polnilnih masterbatchov

V zadnjih letih, poganja hiter razvoj nadaljnjih industrij, kot je embalažna industrija, gradbeništvo, avtomobilski, elektronika in vsakodnevne potrebščine, svetovni trg masterbatch polnil je pokazal stalen trend rasti. Masterbatch polnila je neke vrste kompozitni material, ki je narejen z mešanjem, taljenje, ekstrudiranje in granuliranje anorganskih polnil (kot je kalcijev karbonat, smukec, barijev sulfat, itd.) s polimernimi nosilci (kot je polietilen, polipropilen, polivinil klorid, itd.) in ustreznimi dodatki (kot so disperzijska sredstva, kompatibilizatorji, maziva, itd.) v določenem razmerju. Its core function is to reduce the production cost of plastic products while improving or maintaining the basic performance of plastic products.

According to relevant data statistics, the global filler masterbatch market size has exceeded 20 billion US dollars, and it is expected to maintain a growth rate of 6%-9% in the next few years. Among them, calcium carbonate (CaCO3) filler masterbatch is the most widely used product type, accounting for more than 60% of the total filler masterbatch market, followed by talc filler masterbatch, barijev sulfat (BaSO4) filler masterbatch and other special filler masterbatches. The Asia-Pacific region is the world’s largest filler masterbatch production and consumption market, accounting for more than 50% svetovnega tržnega deleža, which is mainly due to the rapid development of the plastic processing industry in China, India and other countries, veliko povpraševanje po zmanjšanju stroškov in izboljšanju učinkovitosti plastičnih izdelkov, in nenehno izboljševanje industrijskih podpornih zmogljivosti.

Trend razvoja industrije masterbatch polnil se odraža predvsem v štirih vidikih: prvi, visoka zmogljivost in funkcionalnost. Z nadgradnjo nadaljnjih zahtev za plastične izdelke, polnilna masterbatch ni več omejena na zmanjšanje stroškov, vendar se postopoma razvija v smeri funkcionalizacije, kot je izboljšanje togosti, žilavost, toplotna odpornost, vremensko odpornost in pregradne lastnosti plastičnih izdelkov, in razvijanje posebnih funkcionalnih masterbatch polnil, kot je zaviralec gorenja, antistatičen in antibakterijski; drugo, visoka polnilna količina in dobra disperzibilnost. Pod predpostavko zagotavljanja učinkovitosti izdelka, povečanje polnilne količine anorganskih polnil lahko dodatno zmanjša proizvodne stroške, ki postavlja višje zahteve glede disperzibilnosti masterbatch polnila – odlična disperzibilnost lahko zagotovi, da je polnilo enakomerno porazdeljeno v plastični matrici, izogibanje pojavu belih lis, črne lise ali aglomeracije v končnem izdelku; tretji, varstvo okolja in nizko onesnaževanje. S krepitvijo globalnih okoljevarstvenih politik in izboljšanjem okoljske zavesti, Proizvajalci masterbatch polnil postopoma sprejemajo okolju prijazne aditive in proizvodne procese, zmanjšanje emisij škodljivih snovi, in razvoj razgradljive masterbatch polnila za prilagajanje trendu razvoja zelene plastike; četrti, intelligence and efficiency of production equipment. In order to meet the large-scale, continuous and high-quality production needs of filler masterbatch, manufacturers are constantly introducing advanced granulation production lines and intelligent control systems, izboljšanje učinkovitosti proizvodnje, reducing labor costs and ensuring product quality stability.

Against this background, extrusion granulation technology, as the core technology of filler masterbatch production, has become the key to determining the quality of filler masterbatch and the competitiveness of enterprises. The performance of extruders directly affects the dispersibility, particle shape, melting index and other key indicators of filler masterbatch. Our professional extruders and granulation production lines for filler masterbatch are developed in response to the characteristics of the industry and market demand, which can effectively solve the pain points in filler masterbatch processing (such as poor dispersibility, uneven particle size, low filling amount, high energy consumption, itd.) and help enterprises achieve high-quality and efficient production.

1.2 Classification of Filler Masterbatch and Its Core Characteristics

Filler masterbatch can be divided into different types according to the type of filler, carrier resin, application field and filling amount. Each type of filler masterbatch has its own unique characteristics and applicable scenarios. The following is a detailed introduction to the common classification and core characteristics of filler masterbatch:

1.2.1 Razvrstitev glede na vrsto polnila:

To je najpogostejša metoda razvrščanja za masterbatch polnila. Glede na vrsto anorganskega polnila, v glavnem ga lahko razdelimo na kalcijev karbonat (CaCO3) polnilo masterbatch, smukec polnilo masterbatch, barijev sulfat (BaSO4) polnilo masterbatch, in druge posebne masterbače polnil (kot je masterbatch polnila kaolin, masterbatch polnila saj, masterbatch polnila iz steklenih vlaken, itd.).

• kalcijev karbonat (CaCO3) Polnilo Masterbatch: Je najpogosteje uporabljena masterbatch polnila z najnižjimi stroški. Polnilo je predvsem lahek kalcijev karbonat ali težak kalcijev karbonat. Lahki kalcijev karbonat ima drobne delce, dobra disperzibilnost in visoka belina, ki je primeren za plastične izdelke z visokimi zahtevami glede videza in finosti (kot so plastične folije, izdelki za brizganje); težki kalcijev karbonat ima visoko trdoto, dobra odpornost proti obrabi in nizka cena, ki je primeren za plastične izdelke z visokimi zahtevami glede togosti in nadzora stroškov (kot so tkane torbe, pakirni trakovi, cevi, itd.). Masterbatch polnila iz kalcijevega karbonata ne more samo zmanjšati proizvodnih stroškov, ampak tudi izboljšati togost, toplotna odpornost in dimenzijska stabilnost plastičnih izdelkov, in ima določen mazalni učinek, ki lahko izboljša pretočnost obdelave plastike.
• Masterbatch polnilo smukec: Polnilo je smukec s slojevito strukturo. Smukec ima dobre mehanske lastnosti, toplotna odpornost in kemična stabilnost. Masterbatch smukca se uporablja predvsem v polipropilenu (PP) plastični izdelki, kar lahko bistveno izboljša togost, temperatura toplotnega popačenja in udarna trdnost PP izdelkov, in se pogosto uporablja v avtomobilskih delih, lupine gospodinjskih aparatov, plastic pipes and other fields that require high performance.
• Barium Sulfate (BaSO4) Polnilo Masterbatch: The filler is barium sulfate powder, which has high whiteness, good transparency, chemical inertness and radiation resistance. Barium sulfate filler masterbatch is suitable for plastic products with high requirements on transparency, whiteness and chemical stability (kot so plastične folije, plastic bottles, medical plastic products, itd.), and can also be used in radiation-proof plastic products (such as medical protective equipment, nuclear power plant accessories, itd.).

1.2.2 Classification by Carrier Resin:

According to the type of carrier resin used, filler masterbatch can be divided into polyethylene (PE) polnilo masterbatch, polipropilen (PP) polnilo masterbatch, polivinil klorid (PVC) polnilo masterbatch, polyethylene terephthalate (PET) polnilo masterbatch, etc. The selection of carrier resin is mainly determined by the type of downstream plastic products. Na primer, PE filler masterbatch is suitable for PE plastic products (kot so plastične folije, bags, cevi); PP filler masterbatch is suitable for PP plastic products (kot so tkane torbe, injection molding parts, automotive parts); PVC filler masterbatch is suitable for PVC plastic products (such as PVC pipes, profili, rjuhe).

1.2.3 Classification by Application Field:

According to the application field of downstream plastic products, filler masterbatch can be divided into film-grade filler masterbatch, injection-grade filler masterbatch, extrusion-grade filler masterbatch, blow molding-grade filler masterbatch, etc. Film-grade filler masterbatch requires good dispersibility, high fineness and no impurities, to ensure that the blown film has no white spots, black spots or pinholes, and maintains good transparency and toughness; injection-grade filler masterbatch requires good fluidity and uniform particle size, prilagoditi se hitremu procesu brizganja in zagotoviti videz in dimenzijsko natančnost izdelkov za brizganje; Masterbatch polnila za ekstruzijo zahteva dobro toplotno stabilnost in mehanske lastnosti, za prilagoditev visokotemperaturnemu in visokotlačnemu postopku iztiskanja cevi, profilov in drugih izdelkov.

1.2.4 Razvrstitev glede na količino polnjenja:

Glede na količino anorganskih polnil, polnilo masterbatch lahko razdelimo na nizko polnjenje masterbatch (količino polnjenja 30%-50%), srednje polnjenje masterbatch (količino polnjenja 50%-70%) in visoko polnilno masterbatch (količino polnjenja 70% in zgoraj). Količina polnjenja je določena glede na zahteve glede zmogljivosti nadaljnjih izdelkov in zmogljivosti predelave opreme. Masterbatch z visokim polnjenjem ima očitnejši učinek zmanjšanja stroškov, but it has higher requirements on the dispersibility of fillers and the performance of extruders—only high-performance extruders can ensure the uniform mixing and melting of high-filling materials, avoiding agglomeration and poor processing fluidity.

It is worth noting that the core performance indicators of filler masterbatch mainly include dispersibility, particle size uniformity, melting index, whiteness (for light-colored products) and compatibility with carrier resin. Among them, dispersibility is the most critical indicator—poor dispersibility will lead to uneven distribution of fillers in plastic products, resulting in defects such as white spots, black spots, agglomeration and brittle products, which seriously affect the appearance and performance of plastic products. Therefore, the selection of advanced extrusion equipment and scientific processing technology is crucial to ensure the dispersibility and overall quality of filler masterbatch.

2. Core Technology of Filler Masterbatch Production: Extrusion Granulation Technology

Extrusion granulation technology is the core technology of filler masterbatch production, which integrates mixing, taljenje, shearing, dispersion and granulation. It has the advantages of high production efficiency, good product quality, strong adaptability to raw materials and wide application range. In the production of filler masterbatch, extrusion granulation technology is mainly used to realize the uniform dispersion of inorganic fillers in the polymer carrier, melt and plasticize the mixture, and then extrude and granulate to form granular filler masterbatch with uniform size, good fluidity and stable performance. The quality of extrusion granulation directly determines the key performance indicators of filler masterbatch, such as dispersibility, particle size and melting index.

2.1 Characteristics of Filler Masterbatch Raw Materials and Requirements for Extrusion Equipment

The raw materials of filler masterbatch mainly include three parts: inorganic fillers (such as CaCO3, smukec, BaSO4), polymer carriers (such as PE, PP, PVC) in dodatki (kot so disperzijska sredstva, kompatibilizatorji, maziva, antioxidants, itd.). The characteristics of these raw materials are quite different, which puts forward special requirements for extrusion equipment:

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

Second, the mixture of filler masterbatch has high viscosity and poor fluidity. The addition of a large number of inorganic fillers will significantly increase the viscosity of the mixture, reduce the processing fluidity, and require the extruder to have strong conveying capacity and shearing force to ensure the smooth progress of melting, mixing and extrusion.

Third, the processing temperature range is narrow. Different carrier resins have different melting points and thermal stability. Na primer, the melting point of PE is 100-130℃, the melting point of PP is 160-170℃, and PVC is easy to decompose at high temperatures (above 160℃). Therefore, the extrusion equipment needs to have precise temperature control capacity to ensure that the mixture is fully melted without thermal decomposition, and to avoid the decomposition of additives and the deterioration of product performance.

Based on the above characteristics, single-screw extruders are not suitable for large-scale and high-quality production of filler masterbatch. Because the single-screw extruder has a narrow shear range, poor pumping capacity and no self-cleaning effect. When processing high-viscosity and high-filler mixtures, it is easy to cause material accumulation, blokada in neenakomerno mešanje v sodu ekstruderja, kar ima za posledico slabo disperzibilnost masterbatch polnila, neenakomerna velikost delcev in nestabilna kakovost izdelka. In addition, enopolžni ekstruder ima visoko porabo energije pri obdelavi materialov z visokim polnilom, in vijak in cev sta močno obrabljena, kar povečuje proizvodne stroške in stroške vzdrževanja opreme podjetij.

Ekstruderji z dvema polžema, na drugi strani, imajo očitne prednosti pri proizvodnji masterbatch polnila in so postali glavna oprema za ekstruzijsko granulacijo masterbatch polnila. Ekstruderji z dvema polžema imajo širše območje striženja, učinkovitejši učinek črpanja in samočistilni učinek, ki lahko učinkovito reši težave slabe združljivosti, enostavna aglomeracija in slaba fluidnost surovin polnilne masterbatch. Prepletanje in vrtenje dvojnih vijakov lahko povzroči močno strižno silo in silo gnetenja, ki lahko popolnoma razbijejo aglomerate anorganskih polnil, naredite polnila enakomerno razpršena v polimernem nosilcu, ter zagotoviti disperzibilnost in stabilnost izdelka. In addition, ekstruder z dvojnim polžem ima dobro natančnost nadzora temperature, močna prilagodljivost surovinam, in se lahko prilagodi obdelavi različnih vrst, različne količine polnjenja masterbatch polnila, in ima visoko proizvodno učinkovitost in nizko porabo energije.

2.2 Delovni princip ekstruzijske granulacije polnila Masterbatch

Postopek ekstruzijske granulacije masterbatch polnila je kompleksen fizikalni in kemični proces, ki vključuje interakcijo več dejavnikov, kot je temperatura, pritisk, strižna sila in čas. Posebno načelo delovanja in potek postopka sta naslednja:

First, predobdelava surovin. Surovine masterbatch polnila (inorganic fillers, carrier resin, dodatki) jih je treba predhodno obdelati, da se zagotovi kakovost končnega izdelka. Posebni koraki vključujejo: 1) Sušenje: Anorganska polnila (such as CaCO3, smukec) so običajno hidrofilne in vsebujejo določeno količino vlage. Če je vsebnost vlage previsoka, to bo vplivalo na učinek mešanja in disperzibilnost materialov, in celo povzročajo mehurčke v ekstrudirani masterbatch. Therefore, polnila je treba posušiti v sušilniku (kot je sušilnik z vročim zrakom, vakuumski sušilnik) da zmanjšate vsebnost vlage pod 0.5%. 2) Drobljenje in sejanje: Nosilna smola (such as PE, PP) je zdrobljen v majhne delce ali prah z velikostjo delcev 20-40 mreža, kar omogoča enakomerno mešanje s polnili in dodatki. Anorganska polnila se prav tako presejejo, da se odstranijo nečistoče in veliki delci, zagotavljanje drobnosti in enakomernosti polnil. 3) Predmešanje: Glede na razmerje formule, posušena polnila, delci nosilne smole in dodatki (disperzijska sredstva, kompatibilizatorji, maziva, itd.) dajo v mešalnik visoke hitrosti za predhodno mešanje. Hitrost mešanja je na splošno 800-1200 vrtljajev na minuto, in čas mešanja je 5-10 minut. Namen predmešanja je, da se aditivi enakomerno oprimejo površine polnil in nosilne smole., izboljšati združljivost med polnili in nosilcem, in postaviti temelje za naknadno ekstruzijsko mešanje. Dispergator je ključni dodatek pri predmešanju, ki lahko tvori zaščitno folijo na površini polnila, zmanjšati površinsko energijo polnila, preprečiti strjevanje polnila, in izboljša disperzibilnost polnila v nosilni smoli.

Second, feeding and conveying. The premixed mixture is sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. The feeding speed needs to be uniform and stable, which is matched with the screw speed and extrusion speed of the extruder, to ensure that the materials enter the extrusion cavity stably and avoid material accumulation or insufficient feeding. The feeding device of the extruder is usually equipped with a frequency conversion speed regulation function, which can adjust the feeding speed according to the actual production situation.

Third, taljenje, 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, and the volume of the extrusion cavity gradually decreases along the axis direction. When the screws rotate, the materials are gradually compressed under the action of the screws and the barrel, and the pressure in the extrusion cavity gradually increases (generally 3-15MPa). At the same time, the materials are subjected to strong shear force and friction force generated by the relative movement between the screws and the barrel, as well as between the screw flights.

The shear force and friction force can fully break the agglomerates of inorganic fillers, make the fillers uniformly dispersed in the melted carrier resin, and promote the fusion and compatibility between the fillers and the carrier. The friction force can also generate a certain amount of heat, which is combined with the external heating of the barrel (electric heating or steam heating) to make the carrier resin gradually melt and plasticize. The barrel of the extruder is usually divided into 3-6 temperature control sections (feeding section, melting section, mixing section, homogenizing section, itd.), and the temperature of each section is precisely controlled according to the type of carrier resin and filler. Na primer, when processing PE carrier filler masterbatch, the temperature of the feeding section is 80-100℃, the melting section is 120-140℃, the mixing section is 140-150℃, and the homogenizing section is 130-140℃; when processing PP carrier filler masterbatch, the temperature of each section is 20-30℃ higher than that of PE carrier.

Četrtič, extrusion and shaping. The fully melted, mixed and dispersed material is pushed to the die head of the extruder by the screws. The die head is equipped with multiple die holes (the number and size of die holes are determined according to the particle size of the masterbatch), and the material is extruded from the die holes at a high speed to form continuous strips of uniform thickness. The temperature of the die head is slightly lower than that of the homogenizing section, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the strips.

Fifth, cooling and cutting. The extruded strips are sent to a cooling device (such as a water tank, an air-cooled conveyor) for rapid cooling. The cooling temperature is generally 20-30℃, and the cooling time is 2-5 minut. Rapid cooling can make the strips solidify quickly, maintain the shape and size of the strips, and avoid deformation. After cooling, the strips are sent to a granulator for cutting. The granulator is equipped with a rotary knife, which can cut the strips into granular filler masterbatch with uniform size (the particle size is generally 2-5mm, which can be adjusted according to customer needs). The speed of the rotary knife is matched with the conveying speed of the strips to ensure that the particle size of the masterbatch is uniform.

Sixth, screening and packaging. The cut granular filler masterbatch is sent to a vibrating screen for screening, which can remove unqualified particles (such as too large, too small or agglomerated particles) and ensure the uniformity of the product. Kvalificirana masterbatch se nato pošlje v avtomatski pakirni stroj za pakiranje. Specifikacije embalaže je mogoče prilagoditi glede na potrebe kupca (na primer 25 kg/vrečo, 50kg/vrečo), embalaža mora biti zaprta in odporna na vlago, da se prepreči, da bi masterbatch absorbiral vlago in vplival na kakovost. Po pakiranju, izdelki so shranjeni v suhem, hladno in prezračevano skladišče.

2.3 Ključni dejavniki, ki vplivajo na učinek granulacije ekstruzije polnila Masterbatch

Učinek ekstruzijske granulacije neposredno vpliva na kakovost masterbatch polnila. Na učinek granulacije vpliva veliko dejavnikov, predvsem vključno z značilnostmi surovin, razmerje formule, učinek predmešanja, parametri iztiskanja in struktura glave matrice. Obvladovanje teh ključnih dejavnikov in izvajanje znanstvenih prilagoditev lahko zagotovita stabilnost učinka granulacije in doslednost kakovosti izdelka.

2.3.1 Značilnosti surovine:

Vrsta, velikost delcev, vsebnost vlage in čistost surovin imata velik vpliv na učinek granulacije. Na primer, velikost delcev anorganskih polnil neposredno vpliva na disperzibilnost in drobnost masterbatcha. Bolj drobna je velikost delcev polnila (na splošno 800-2000 mreža), boljša je disperzibilnost, vendar višji so stroški in lažje je aglomerirati; večja je velikost delcev, nižji so stroški, vendar je disperzibilnost slaba, kar bo vplivalo na videz in delovanje masterbatcha. Vsebnost vlage v surovinah (predvsem polnila) je treba nadzorovati spodaj 0.5%; če je vsebnost vlage previsoka, to bo povzročilo mehurčke v masterbatchu, vplivajo na gostoto in mehanske lastnosti izdelka. Zelo pomembna je tudi čistost surovin; nečistoče v surovinah (kot so kamni, kovine, prah) ne bo vplivalo le na kakovost masterbatcha, ampak tudi obrabite vijak in cev ekstruderja, in celo povzroči blokado opreme.

2.3.2 Razmerje formule:

Formula razmerja polnila masterbatch (razmerje polnila, nosilna smola in dodatki) je ključ do določanja učinkovitosti in stroškov izdelka. Količino polnila za polnilo je treba določiti glede na zahteve glede zmogljivosti izdelka na koncu proizvodne verige in zmogljivosti predelave opreme. Previsoka količina polnila bo povzročila slabo disperzibilnost, nizka žilavost in slaba procesna fluidnost masterbatcha; too low filling amount will reduce the cost reduction effect. The type and dosage of additives also need to be reasonably matched. Na primer, the dispersant dosage is generally 1%-3% of the filler dosage; too little dispersant will lead to poor dispersibility of the filler, and too much dispersant will affect the compatibility between the masterbatch and the downstream plastic products, and reduce the mechanical properties of the products. The compatibilizer is used to improve the compatibility between the filler and the carrier resin; the dosage is generally 0.5%-2%, which can significantly improve the dispersibility and mechanical properties of the masterbatch. The lubricant is used to reduce the friction between the materials and the screw, barrel and die head, improve the processing fluidity, and prevent the materials from sticking to the equipment; the dosage is generally 0.3%-1%.

2.3.3 Premixing Effect:

Premixing is the foundation of extrusion granulation. The uniformity of premixing directly affects the dispersibility of the filler in the carrier resin. If the premixing is uneven, the additives cannot be uniformly adhered to the surface of the filler and carrier, resulting in local agglomeration of the filler, uneven mixing of the materials during extrusion, and poor quality of the masterbatch. To ensure the premixing effect, it is necessary to control the mixing speed, mixing time and mixing temperature. Hitrost mešanja je na splošno 800-1200 vrtljajev na minuto, the mixing time is 5-10 minut, and the mixing temperature is controlled at 40-60℃ (appropriate temperature can improve the adhesion of additives and promote uniform mixing).

2.3.4 Extrusion Parameters:

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

• Screw Speed: The screw speed generally ranges from 150 do 600 vrtljajev na minuto. The higher the screw speed, the greater the shear force and friction force received by the materials, the better the mixing and dispersing effect of the filler, and the higher the production efficiency. Vendar, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete melting of the carrier resin, insufficient mixing of the materials, and uneven particle size of the masterbatch; if the screw speed is too low, the shear force and friction force are insufficient, the filler cannot be fully dispersed, and the production efficiency is low. The screw speed should be adjusted according to the filling amount and type of filler masterbatch—for high-filling masterbatch, a higher screw speed is needed to ensure sufficient shearing and mixing.
• Extrusion Temperature: The extrusion temperature is divided into multiple sections (feeding section, melting section, mixing section, homogenizing section, die head section), and the temperature of each section needs to be precisely controlled according to the type of carrier resin and filler. The temperature of the feeding section is lower (slightly higher than the melting point of the carrier resin), which is mainly to prevent the materials from caking and ensure smooth feeding; the temperature of the melting section is medium, which is mainly to promote the melting and plasticization of the carrier resin; the temperature of the mixing section is higher, ki je predvsem za povečanje učinka striženja in mešanja, in spodbujajo enakomerno disperzijo polnila; temperatura homogenizacijskega dela je nekoliko nižja od mešalnega dela, ki je predvsem za zagotovitev enakomerne temperature in viskoznosti materialov, in preprečiti termično razgradnjo; temperatura dela rezalne glave je nekoliko nižja od homogenizacijskega dela, ki naj zagotovi učinek oblikovanja trakov.
• Ekstruzijski tlak: Tlak ekstrudiranja je običajno 3-15MPa. Tlak v ekstruzijski votlini je v glavnem določen s kompresijskim razmerjem vijaka, velikost luknje matrice in hitrost vijaka. Višji kot je tlak iztiskanja, boljši je učinek mešanja in dispergiranja materialov, in gostejši so delci masterbatcha. Vendar, če je pritisk previsok, it will increase the energy consumption and wear of the equipment, and even cause the die head to block; if the pressure is too low, the materials cannot be fully compressed and mixed, the masterbatch particles are loose, and the performance is unstable.

2.3.5 Die Head Structure:

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

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

We have long been engaged in the research, development and production of high-performance extruders and granulation production lines, and have accumulated rich experience in the field of filler masterbatch processing. According to the characteristics of filler masterbatch raw materials (high hardness, poor compatibility, high viscosity) and processing requirements (good dispersibility, enotna velikost delcev, visoka količina polnjenja), razvili smo serijo ekstruderjev z dvema polžema, posebej primernih za proizvodnjo masterbatch polnil. Naši ekstruderji imajo prednost visoke odpornosti proti obrabi, močna strižna sila, natančen nadzor temperature, stabilno delovanje in nizki obratovalni stroški, ki lahko zadovolji potrebe obdelave različnih vrst, različne količine polnjenja masterbatch polnila (CaCO3, smukec, BaSO4, itd.), in pomaga podjetjem izboljšati učinkovitost proizvodnje, zagotoviti kakovost izdelkov in zmanjšati proizvodne stroške.

3.1 Glavne prednosti naših ekstruderjev za proizvodnjo masterbatch polnil

3.1.1 Visoka odpornost proti obrabi, Dolga življenjska doba:

Ciljanje na problem anorganskih polnil (such as CaCO3, smukec) imajo visoko trdoto in enostavno obrabo vijaka in cevi, uporabljamo visokokakovostne materiale, odporne proti obrabi, in napredno proizvodno tehnologijo, da zagotovimo odpornost proti obrabi jedrnih komponent ekstruderja. The screw and barrel are made of imported wear-resistant alloy steel (such as 38CrMoAlA), and after nitriding treatment or bimetallic composite treatment, the surface hardness can reach ≥65 HRC, which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by the friction between the high-hardness filler and the components. This greatly extends the service life of the screw and barrel, reduces the frequency of component replacement, and reduces the maintenance cost of the equipment. In addition, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, issue a detailed wear report, and put forward targeted replacement and maintenance suggestions, ensuring that customers only replace components when necessary, avoiding unnecessary waste.

3.1.2 Strong Shearing and Mixing Capacity, Excellent Dispersibility:

The key to filler masterbatch production is to ensure the uniform dispersion of fillers. Our twin-screw extruders adopt an intermeshing co-rotating twin-screw structure, with a reasonable screw pitch, lead and compression ratio design. Prepletanje in vrtenje dvojnih vijakov lahko povzroči močno strižno silo in silo gnetenja, ki lahko popolnoma razbijejo aglomerate anorganskih polnil, make the fillers uniformly dispersed in the melted carrier resin, and ensure the dispersibility of the masterbatch. The screw is designed with a modular structure, and different screw elements (such as conveying elements, mixing elements, shearing elements) can be freely combined according to the type and filling amount of filler masterbatch, so as to adjust the shear force and mixing effect, and achieve the best processing effect. Na primer, when processing high-filling CaCO3 masterbatch, we can configure more shearing elements to enhance the shearing effect and ensure the uniform dispersion of the filler; when processing talc masterbatch which requires high mixing uniformity, we can configure more mixing elements to improve the mixing effect.

3.1.3 Precise Temperature Control, Stable Performance:

Our extruders adopt advanced intelligent temperature control systems, which can realize precise control of the temperature of each section of the barrel and the die head. The temperature control accuracy can reach ±1℃, which can ensure that the carrier resin is fully melted without thermal decomposition, and the additives are not decomposed, ensuring the stability of the product performance. The temperature control system is equipped with a real-time monitoring and alarm function. Če temperatura katerega koli dela preseže nastavljeno območje, sistem bo pravočasno sprožil alarm, in celo samodejno prilagodi moč ogrevanja ali po potrebi izklopi opremo, da bi se izognili okvaram opreme in težavam s kakovostjo izdelkov. In addition, ekstruder je opremljen z visoko natančnim tlačnim senzorjem, ki lahko spremlja ekstrudijski tlak v realnem času. Če je tlak previsok ali prenizek, sistem bo samodejno prilagodil hitrost vijaka ali hitrost podajanja, zagotavljanje stabilnosti procesa ekstrudiranja.

3.1.4 Širok obseg uporabe, Močna fleksibilnost:

Naša serija ekstruderjev se lahko prilagodi potrebam obdelave različnih vrst polnilne masterbatch, vključno z masterbatch polnila CaCO3, smukec polnilo masterbatch, BaSO4 polnilo masterbatch, in druge posebne masterbače polnil. Količino polnjenja lahko prilagodite 30% do 80%, which can meet the different cost and performance requirements of customers. The modular design of the extruder (screw, barrel, die head, itd.) makes the replacement of components more convenient and quick. When customers need to adjust the product type or filling amount, they only need to replace the corresponding components, without replacing the entire equipment, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. In addition, our extruders can also be matched with different auxiliary equipment (such as high-speed mixers, dryers, coolers, granulators, screening machines, packaging machines) to form a complete automatic granulation production line, realizing continuous production from raw material pretreatment to product packaging.

3.1.5 High Production Efficiency, Low Energy Consumption:

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

3.1.6 Easy Operation and Maintenance:

Our extruders adopt a PLC intelligent control system and a touch screen operation interface, which is simple and intuitive, easy to operate. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of filler masterbatch, they only need to call the corresponding formula and parameters, without repeated debugging, which saves time and improves production efficiency. The modular design of the equipment makes the maintenance more convenient. The screw, barrel, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Our after-sales service team will provide professional installation, commissioning and training services for customers, ensuring that customers can use the equipment smoothly.

3.2 Naša serija izdelkov za ekstruderje in njihova prilagoditev glavni batch polnila

Da bi zadovoljili raznolike proizvodne potrebe podjetij za izdelavo masterbatch polnil različnih velikosti in vrst izdelkov, lansirali smo celotno paleto izdelkov za ekstruderje z dvema polžema, vključno s serijo HTS BASIC, Serija HTS PLUS, Serija HTS SUPER, Serija ZTE in serija HTE. Vsaka serija ima svoje značilnosti in ciljne scenarije prilagajanja, ki jih lahko izberejo stranke glede na lastno proizvodno lestvico, vrsto izdelka, proračun in drugi dejavniki.

3.2.1 Ekstruderji serije HTS BASIC: Stroškovno učinkovita izbira za srednja in mala podjetja.

Ekstruderji serije HTS BASIC so stroškovno učinkovita serija izdelkov, ki smo jo neodvisno razvili, ki so posebej zasnovani za podjetja za predelavo masterbatch polnil s srednjim in majhnim proizvodnim obsegom ali začetnim vstopom v industrijo. Ta serija ekstruderjev uporablja srednje navorne menjalnike vodilnih evropskih proizvajalcev, ki imajo prednost stabilnega delovanja, nizek hrup, visoka učinkovitost in dolga življenjska doba. Zasnova s ​​srednjim navorom lahko zadovolji potrebe obdelave večine običajnih polnilnih masterbatchov (kot je CaCO3 masterbatch z nizkim do srednjim polnjenjem, PE/PP nosilec masterbatch), in hkrati, ima primerno ceno, ki lahko podjetjem pomaga zmanjšati začetne investicijske stroške.

Kar zadeva konstrukcijsko zasnovo, Ekstruderji serije HTS BASIC imajo vzporedno strukturo z dvema polžema, s premerom vijaka od 30 mm do 65 mm, in kompresijsko razmerje 4～8, which can be adjusted according to the type and filling amount of filler masterbatch. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. The extruder is equipped with a PLC control system and a touch screen operation interface, which can realize automatic feeding, automatic temperature control, automatic pressure control and automatic cutting, and is simple and easy to operate.

The production capacity of the HTS BASIC series extruders ranges from 100kg/h to 500kg/h, which is suitable for medium and small-sized filler masterbatch processing enterprises that mainly produce common filler masterbatch (such as CaCO3 masterbatch for plastic films, woven bags). Ena največjih prednosti te serije je, da lahko nudi prilagodljive možnosti z različnimi kombinacijami konfiguracij. Stranke lahko izbirajo različne vijačne elemente, die heads, napajalne naprave, sušilne naprave in oprema za naknadno obdelavo glede na lastne vrste izdelkov, proizvodne zmogljivosti in proračuna, tako da oblikujejo proizvodno linijo, primerno za lastne potrebe.

3.2.2 Ekstruderji serije HTS PLUS: Visoko zmogljiva izbira za inženirsko plastiko in polnilo Masterbatch.

Ekstruderji serije HTS PLUS uporabljajo menjalnike z visokim navorom, ki smo jih neodvisno razvili in izdelali, ki imajo večji navor in večjo nosilnost kot serija HTS BASIC. Ta serija ekstruderjev se uporablja predvsem za predelavo visoko zmogljive masterbatch polnila, kot je CaCO3 masterbatch z visokim polnjenjem (količina polnjenja ≥60%), smukec masterbatch, BaSO4 masterbatch, and filler masterbatch for engineering plastics (such as PP, PA, PC).

The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～600 rpm. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance, and can adapt to the processing of high-hardness fillers (such as heavy calcium carbonate, smukec) and high-filling materials. The extruder is equipped with an advanced intelligent control system, which can realize precise control of extrusion parameters and real-time monitoring of production data. The production capacity ranges from 500kg/h to 2000kg/h, ki je primeren za srednje in velike polnilne masterbatch podjetja, ki si prizadevajo za visoko zmogljivost in visoko količino polnjenja.

In addition, Ekstruderji serije HTS PLUS imajo večjo zmogljivost mešanja in striženja, ki lahko popolnoma razprši polnila z visokim polnilom v nosilni smoli, zagotavljanje disperzibilnosti in stabilnosti masterbatcha. Posebej je primeren za proizvodnjo masterbatch polnila, ki se uporablja v avtomobilskih delih, lupine gospodinjskih aparatov, visokokakovostne plastične folije in druge visoko zmogljive plastične izdelke.

3.2.3 Ekstruderji serije HTS SUPER: Vrhunska izbira za vrhunsko polnilno masterbatch.

Ekstruderji serije HTS SUPER uporabljajo najnovejšo napravo za prenos ultravisokega navora, ki smo jo neodvisno razvili. Cilj na visok navor in visoke hitrosti te serije, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. This series of extruders is mainly used for the processing of high-end, special and high-performance filler masterbatch, such as high-filling BaSO4 masterbatch (for medical plastics, high-grade films), glass fiber reinforced filler masterbatch, flame-retardant filler masterbatch, and filler masterbatch for special engineering plastics.

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

The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for large-scale high-end filler masterbatch enterprises that pursue high efficiency, high performance and intelligence. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, ki lahko izpolnjujejo najstrožje zahteve glede obdelave vrhunskih polnilnih masterbatchov.

3.2.4 Ekstruderji serije ZTE: Stroškovno učinkovita izbira za generalno polnilno masterbatch.

Ekstruderji serije ZTE imajo odlično stroškovno učinkovitost, in njihovi zasnovani parametri so primerni za večino polnilnih materialov masterbatch (kot je CaCO3 masterbatch z nizkim do srednjim polnjenjem, PE/PP nosilec masterbatch). Ta serija ekstruderjev ima poenostavljeno in optimizirano strukturo, kar zmanjša proizvodne stroške, hkrati pa zagotavlja osnovno delovanje, in je primeren za mala in srednje velika podjetja z omejenim proračunom in splošnimi zahtevami po izdelkih.

Ekstruderji serije ZTE imajo premer polža od 30 mm do 50 mm, kompresijsko razmerje 4～7, in območje hitrosti vijaka 150～500 rpm. Proizvodna zmogljivost se giblje od 50 kg/h do 300 kg/h, ki je primeren za proizvodnjo v majhnem obsegu običajne masterbatch polnila. Ekstruder je enostaven za uporabo in vzdrževanje, in stroški poprodajnih storitev so nizki, ki je stroškovno učinkovita izbira za mala podjetja in posamezne delavnice.

3.2.5 Ekstruderji serije HTE: Visoko učinkovita in energetsko varčna izbira za obsežno proizvodnjo.

Ekstruderji serije HTE združujejo visoko zmogljivost in visoko ceno, in so zasnovani za zmanjšanje porabe energije z večjo močjo. Ta serija ekstruderjev ima visoko učinkovit motor, optimizirana vijačna struktura in naprava za rekuperacijo toplote, ki lahko zmanjša porabo energije na enoto za 20% ~ 25% v primerjavi z navadnimi ekstruderji, in ima večjo proizvodno učinkovitost.

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

3.3 Selection Suggestions for Filler Masterbatch Extruders

When selecting extruders for filler masterbatch production, enterprises need to comprehensively consider their own production needs, product types, količino polnjenja, proračuna in drugih dejavnikov za zagotovitev, da lahko izbrana oprema zadosti dejanskim proizvodnim potrebam in prinese največjo gospodarsko korist. Sledi nekaj posebnih predlogov za izbiro:

3.3.1 Določite serijo ekstruderja glede na vrsto izdelka in količino polnjenja:

Različne vrste in količine polnjenja masterbatch polnila imajo različne zahteve za ekstruderje. Na primer, če podjetje v glavnem proizvaja masterbatch CaCO3 z nizkim do srednjim polnjenjem (količina polnjenja ≤60%) in skupni nosilec PE/PP masterbatch, primerni so ekstruderji serije HTS BASIC ali serije ZTE; če podjetje proizvaja masterbatch z visokim polnjenjem (količina polnjenja ≥60%), smukec masterbatch ali BaSO4 masterbatch, priporočamo ekstruderje serije HTS PLUS; če podjetje proizvaja vrhunske, posebna polnilna masterbatch (kot je masterbatch, ojačan s steklenimi vlakni, ognjevarna masterbatch), the HTS SUPER series extruders are the best choice; if the enterprise pursues large-scale, energy-saving and high-efficiency production, the HTE series extruders are suitable.

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

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

3.3.3 Consider the Wear Resistance of the Equipment:

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

3.3.4 Consider the Cost-Effectiveness of the Equipment:

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

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

The after-sales service of the equipment is crucial for the normal operation of the production line. Enterprises should select manufacturers with perfect after-sales service systems, which can provide professional installation, zagon, usposabljanje, maintenance and spare parts supply services. We have a professional after-sales service team, ki se lahko pravočasno odzove na potrebe strank (zagotoviti rešitve znotraj 24 ure) in po potrebi pošljite tehnike na lokacijo za vzdrževanje, zagotavljanje normalnega delovanja proizvodne linije.

3.3.6 Upoštevajte prilagodljivost in razširljivost opreme:

S spremembami tržnega povpraševanja, podjetja bodo morda morala prilagoditi svoje vrste izdelkov in količine polnjenja. Therefore, pri izbiri ekstruderjev, podjetja bi morala upoštevati prilagodljivost in razširljivost opreme. Naši ekstruderji imajo modularno zasnovo, ki se lahko prosto kombinirajo in nadgrajujejo glede na potrebe podjetij, izboljšanje fleksibilnosti in razširljivosti opreme, in zmanjšanje stroškov preoblikovanja opreme.

4. Področja uporabe in metode uporabe polnila Masterbatch

Polnilo masterbatch, kot ključni funkcionalni dodatek pri predelavi plastike, ima široko paleto področij uporabe, covering various fields such as plastic packaging, gradbeništvo, avtomobilski, elektronika, daily necessities and agriculture. Its core role is to reduce the production cost of plastic products while improving or maintaining the basic performance of plastic products. The following will introduce the specific application fields and usage methods of filler masterbatch in detail:

4.1 Application Fields of Filler Masterbatch

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

4.1.1 Plastic Packaging Industry:

This is the largest application field of filler masterbatch, accounting for more than 50% of the total application amount. Filler masterbatch is widely used in the production of plastic films, plastic bags, woven bags, pakirni trakovi, packaging containers and other packaging products.

• Plastične folije: Vključno s plastičnimi tankimi folijami, debeli filmi, raztegljive folije, folije za rastlinjake, etc. Masterbatch polnila, ki se uporablja za plastične folije, je večinoma lahka masterbatch polnila iz kalcijevega karbonata ali masterbatch polnila z barijevim sulfatom, ki zahteva dobro disperzibilnost, high fineness and no impurities, to ensure that the blown film has no white spots, black spots or pinholes, in ohranja dobro preglednost, žilavost in natezno trdnost. Dodajanje ustrezne količine masterbatch polnila ne more samo zmanjšati proizvodnih stroškov filma, ampak tudi izboljšati togost, toplotna odpornost in dimenzijska stabilnost filma, in zmanjšajte stopnjo krčenja filma. Na primer, v proizvodnji plastičnih nakupovalnih vrečk, dodajanje 1%-3% CaCO3 polnilne masterbatch lahko zniža stroške za 5%-10% brez vpliva na žilavost in nosilnost vreč.
• Plastične vrečke: Vključno z nakupovalnimi vrečkami, torbe za telovnike, vreče za smeti, vrečke za pakiranje hrane, etc. Polnilna masterbatch, ki se uporablja za plastične vrečke, je v glavnem težka polnilna masterbatch kalcijevega karbonata, ki ima nizke stroške in dobro odpornost proti obrabi. Dodajanje 2%-5% polnila masterbatch lahko zmanjša stroške in izboljša togost in odpornost proti obrabi vrečk. Za vreče za smeti, dodajanje ustrezne količine masterbatch polnila lahko izboljša tudi žilavost in odpornost na trganje vrečk, zaradi česar jih ni lahko zlomiti.
• Tkane torbe in pasovi za pakiranje: Tkane vrečke se pogosto uporabljajo pri pakiranju žita, gnojilo, cement, kemičnih izdelkov in drugega blaga; pakirni trakovi se uporabljajo za povezovanje blaga. Polnilna masterbatch, ki se uporablja za tkane vrečke in embalažne pasove, je v glavnem težka polnilna masterbatch kalcijevega karbonata ali smukec polnilna masterbatch, ki zahteva visoko togost in odpornost proti obrabi. Dodajanje 5%-10% of filler masterbatch can improve the rigidity, tensile strength and wear resistance of woven bags and packaging belts, reduce the cost, and extend the service life of the products.
• Packaging Containers: Including plastic bottles, plastic barrels, plastic boxes, etc. The filler masterbatch used for packaging containers is mainly barium sulfate filler masterbatch or light calcium carbonate filler masterbatch, which requires good transparency and chemical stability. Adding an appropriate amount of filler masterbatch can reduce the cost and improve the rigidity and impact strength of the containers.

4.1.2 Plastic Construction Industry:

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

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

4.1.3 Plastic Injection Molding Industry:

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

• Plastic Daily Necessities: Including plastic bowls, plastic plates, plastic cups, plastic baskets, plastic buckets and other daily necessities. The filler masterbatch used for these products is mainly calcium carbonate filler masterbatch, which has low cost and good safety. Dodajanje 2%-5% polnila masterbatch lahko zmanjša stroške in izboljša togost in udarno trdnost izdelkov, zaradi česar jih ni lahko zlomiti.
• Plastične igrače: Vključno z različnimi plastičnimi igračami za otroke. Masterbatch polnila, ki se uporablja za plastične igrače, je večinoma lahka masterbatch polnila iz kalcijevega karbonata ali masterbatch polnila z barijevim sulfatom, ki zahteva visoko varnost, netoksičnost, dobra disperzibilnost in brez vonja, v skladu z mednarodnimi standardi varnosti igrač (kot je EN 71, ASTM F963). Velikost delcev polnila mora biti dobra (zgoraj 1250 mreža) da preprečite praskanje otroške kože in zagotovite gladkost površine igrače. Dodajanje 1%-3% lahkega kalcijevega karbonatnega polnila masterbatch lahko zmanjša proizvodne stroške igrač brez vpliva na žilavost in barvnost igrač; Masterbatch polnila barijevega sulfata je primeren za prozorne ali polprozorne plastične igrače, ki lahko izboljšajo preglednost in površinski sijaj igrač, zaradi česar so lepši.
• Plastični deli in školjke: Vključno s plastičnimi deli za gospodinjske aparate, avtomobilski notranji deli, lupine elektronskih izdelkov, etc. Masterbatch polnila, ki se uporablja za te izdelke, je v glavnem masterbatch polnila iz smukca ali masterbatch polnila, ojačanega s steklenimi vlakni., which requires high rigidity, toplotna odpornost in udarna trdnost. Na primer, v proizvodnji notranjih avtomobilskih delov (kot so instrumentne plošče, vratne plošče), dodajanje 5%-8% masterbatch polnila smukca lahko izboljša togost in temperaturo toplotnega popačenja delov, zmanjšajte stopnjo krčenja, in poskrbi, da se deli ne bodo enostavno deformirali pod visokotemperaturnim okoljem v avtomobilu; pri proizvodnji lupin elektronskih izdelkov (kot so ohišja mobilnih telefonov, lupine usmerjevalnika), dodajanje 3%-5% of glass fiber reinforced filler masterbatch can improve the impact strength and dimensional accuracy of the shells, enhancing the durability of the products.

4.1.4 Automotive Plastic Industry:

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

• Automotive Interior Parts: Including instrument panels, vratne plošče, seat cushions, armrests, etc. These parts have high requirements on rigidity, toplotna odpornost, low odor and environmental protection. Talc filler masterbatch and calcium carbonate filler masterbatch are the most commonly used products. Talc filler masterbatch can significantly improve the rigidity and heat resistance of polypropylene (PP) materialov, making the interior parts have good dimensional stability; calcium carbonate filler masterbatch has the advantages of low cost and good processing fluidity, which can reduce the production cost of interior parts. Na primer, dodajanje 6%-10% of talc filler masterbatch to PP instrument panels can improve the heat distortion temperature by 15-25℃, and reduce the production cost by 8%-12%.
• Automotive Exterior Parts: Including bumpers, fenders, door handles, etc. These parts are exposed to the outdoor environment for a long time, so they have high requirements on weather resistance, impact strength and UV resistance. Masterbatch polnila, ki se uporablja za zunanje dele, je v glavnem masterbatch polnila smukca ali masterbatch polnila barijevega sulfata, ki je običajno sestavljen z dodatki, odpornimi na vremenske vplive. Dodajanje 4%-7% masterbatch polnila iz smukca lahko izboljša udarno trdnost in togost zunanjih delov, povečati njihovo odpornost na zunanje vplive; Masterbatch polnila z barijevim sulfatom lahko izboljša odpornost na vremenske vplive in ohranitev barve zunanjih delov, zaradi česar jih ni enostavno zbledeti in starati pod vplivom sončne svetlobe in dežja.
• Avtomobilski funkcionalni deli: Vključno s cevmi za dovod zraka, deli hladilnega sistema, ohišja baterij, etc. Ti deli imajo visoke zahteve glede toplotne odpornosti, kemična odpornost in mehanske lastnosti. The filler masterbatch used for functional parts is mainly glass fiber reinforced filler masterbatch or special mineral filler masterbatch. Na primer, dodajanje 10%-15% of glass fiber reinforced filler masterbatch to the air intake pipe can improve the heat resistance and pressure resistance of the pipe, ensuring its normal operation under high temperature and high pressure; adding barium sulfate filler masterbatch to the battery casing can improve the radiation resistance and chemical stability of the casing, ensuring the safety of the battery.

4.1.5 Electronic and Electrical Plastic Industry:

Electronic and electrical products have high requirements on the flame retardancy, insulation, dimensional accuracy and heat resistance of plastic materials. Filler masterbatch is widely used in the production of plastic parts of electronic and electrical products, such as wire and cable sheaths, transformer casings, connector housings, etc.

• Wire and Cable Sheaths: The plastic sheaths of wires and cables need to have good insulation, wear resistance, flame retardancy and weather resistance. The filler masterbatch used for wire and cable sheaths is mainly calcium carbonate filler masterbatch or flame-retardant filler masterbatch. Dodajanje 3%-6% of calcium carbonate filler masterbatch can improve the wear resistance and rigidity of the sheath, reduce the cost; flame-retardant filler masterbatch (such as magnesium hydroxide, aluminum hydroxide filler masterbatch) can improve the flame retardancy of the sheath, preventing the spread of fire in case of short circuit, ensuring the safety of the circuit.
• Transformer Casings and Connector Housings: These parts need to have good insulation, heat resistance and dimensional accuracy. The filler masterbatch used is mainly talc filler masterbatch or glass fiber reinforced filler masterbatch. Dodajanje 5%-8% of talc filler masterbatch can improve the heat resistance and dimensional stability of the parts, making them not easy to deform under long-term high temperature operation; glass fiber reinforced filler masterbatch can improve the impact strength and insulation of the parts, ensuring the normal operation of electronic and electrical products.

4.1.6 Agricultural Plastic Industry:

Agricultural plastic products (such as greenhouse films, mulch films, irrigation pipes, fertilizer bags) have the characteristics of large dosage, low cost and harsh use environment. Masterbatch polnila lahko učinkovito zmanjša proizvodne stroške kmetijskih plastičnih izdelkov in izboljša njihovo življenjsko dobo.

• Filmi za rastlinjake in folije za mulčenje: Ti izdelki morajo imeti dobro preglednost, žilavost, odpornost proti vremenskim vplivom in lastnosti proti staranju. Uporabljena masterbatch polnila je predvsem lahka masterbatch polnila iz kalcijevega karbonata ali masterbatch polnila z barijevim sulfatom. Dodajanje 1%-4% lahkega kalcijevega karbonatnega polnila masterbatch lahko zmanjša stroške filma, izboljša njeno žilavost in lastnosti proti staranju, in podaljša življenjsko dobo filma; masterbatch polnila z barijevim sulfatom lahko izboljša preglednost in prepustnost svetlobe filma, kar je ugodno za fotosintezo pridelkov.
• Namakalne cevi in ​​vreče za gnojila: Namakalne cevi morajo imeti dobro tlačno odpornost in odpornost proti obrabi; vreče za gnojila morajo imeti dobro žilavost in odpornost proti obrabi. Uporabljena masterbatch polnila je v glavnem težka masterbatch polnila iz kalcijevega karbonata ali masterbatch polnila smukca. Dodajanje 5%-10% težka masterbatch polnila iz kalcijevega karbonata lahko izboljša tlačno odpornost in odpornost na obrabo namakalnih cevi, reduce the cost; dodajanje 3%-6% masterbatch polnila iz smukca lahko izboljša žilavost in odpornost proti obrabi vreč za gnojila, zaradi česar jih ni enostavno zlomiti med prevozom in uporabo.

4.2 Metode uporabe polnilne masterbatch

Pravilna uporaba masterbatch polnila je ključnega pomena za zagotavljanje kakovosti plastičnih izdelkov in polno delovanje masterbatcha.. Metode uporabe masterbatch polnila vključujejo predvsem mešalno razmerje, način mešanja, prilagoditev parametrov obdelave in previdnostni ukrepi. Posebne točke delovanja so naslednje:

4.2.1 Določitev mešalnega razmerja:

Mešalno razmerje glavne smole polnila in osnovne plastike (nosilna smola plastičnih izdelkov) je v glavnem določena s količino polnjenja masterbatcha, zahteve glede zmogljivosti končnega izdelka in zmogljivost obdelave opreme. Splošno območje mešalnega razmerja je 1%-20%, in specifično razmerje je mogoče prilagoditi v skladu z naslednjimi načeli:

• Za plastične izdelke z nizkimi zahtevami glede zmogljivosti in visokimi zahtevami glede nadzora stroškov (kot so navadne plastične vrečke, vreče za smeti), mešalno razmerje je lahko 5%-20% (z uporabo masterbatch kalcijevega karbonatnega polnila z nizkim do srednjim polnjenjem);
• Za plastične izdelke s srednje zahtevnimi zmogljivostmi (kot so plastične folije, navadni deli za brizganje), mešalno razmerje je lahko 2%-8% (z uporabo srednje polnega kalcijevega karbonata, smukec ali masterbatch polnila z barijevim sulfatom);
• Za plastične izdelke z visokimi zahtevami glede zmogljivosti (such as automotive parts, lupine elektronskih izdelkov, high-grade films), mešalno razmerje je lahko 1%-5% (using high-filling, high-performance talc, barium sulfate or glass fiber reinforced filler masterbatch);
• For transparent or semi-transparent plastic products (such as plastic bottles, transparent films), the mixing ratio should be controlled at 1%-3%, and barium sulfate or light calcium carbonate filler masterbatch with fine particle size (zgoraj 1250 mreža) should be selected to avoid affecting the transparency of the products.

4.2.2 Mixing Method:

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

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

4.2.3 Adjustment of Processing Parameters:

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

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

4.2.4 Precautions for Use:

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

• Moisture Prevention: Polnilo masterbatch (especially calcium carbonate, smukec masterbatch) is easy to absorb moisture, which will cause bubbles, pinholes and other defects in the final product. Therefore, the masterbatch should be stored in a dry, hladno in prezračevano skladišče, and should be dried before use (the drying temperature is 80-100℃, and the drying time is 2-4 ure).
• Compatibility: The carrier resin of the filler masterbatch should be consistent with or compatible with the base plastic of the product. Na primer, PE filler masterbatch should be used with PE base plastic, and PP filler masterbatch should be used with PP base plastic. If the carrier resin is incompatible with the base plastic, it will affect the compatibility between the masterbatch and the base plastic, resulting in poor dispersibility and reduced product performance.
• Uniform Mixing: The filler masterbatch and base plastic must be mixed uniformly. If the mixing is uneven, local agglomeration of the masterbatch will occur, resulting in defects such as white spots, black spots and agglomeration in the product, affecting the appearance and performance of the product.
• Dosage Control: The dosage of filler masterbatch should not exceed the maximum filling amount applicable to the equipment and product performance. Excessive dosage will lead to poor dispersibility, low toughness, poor processing fluidity and other problems of the product; insufficient dosage will not achieve the effect of cost reduction and performance improvement.
• Storage Period: The filler masterbatch has a certain storage period (na splošno 6-12 mesecih). If the storage period is exceeded, the masterbatch may absorb moisture, agglomerate or the performance of additives may degrade, affecting the use effect. Therefore, the masterbatch should be used within the storage period.

5. Common Problems and Solutions in Filler Masterbatch Production

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

5.1 Common Quality Problems of Filler Masterbatch and Their Solutions

5.1.1 Poor Dispersibility of Filler Masterbatch:

This is the most common quality problem in filler masterbatch production. The main manifestations are: the masterbatch has agglomeration, and after mixing with the base plastic, white spots, black spots or agglomeration appear in the final product, which affects the appearance and performance of the product.

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

Solutions: 1) Select inorganic fillers with fine and uniform particle size (na splošno 800-2000 mreža), and sieve the fillers before use to remove large particles and agglomerates; 2) Increase the dosage of dispersant appropriately (within the range of 1%-3% of the filler dosage) or replace with a dispersant compatible with the filler and carrier resin; 3) Optimize the premixing process, increase the mixing speed (800-1200 vrtljajev na minuto) and mixing time (5-10 minut), and control the mixing temperature at 40-60℃ to improve the premixing uniformity; 4) Adjust the screw structure of the extruder, increase the number of shearing elements, or increase the screw speed to enhance the shear force; 5) Appropriately increase the processing temperature of the extruder to ensure that the carrier resin is fully melted, which is conducive to the dispersion of the filler.

5.1.2 Uneven Particle Size of Filler Masterbatch:

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

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

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

5.1.3 Low Melting Index of Filler Masterbatch

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

Causes:

• The filling amount of the filler is too high, which increases the viscosity of the masterbatch and reduces the fluidity;
• The type of carrier resin is inappropriate (the melting index of the carrier resin is too low);
• The processing temperature is too low, and the carrier resin is not fully melted;
• The dosage of lubricant is insufficient, which increases the friction between the materials and affects the fluidity.

Solutions:

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

5.1.4 Yellowing of Filler Masterbatch

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

Causes:

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

Solutions:

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

5.1.5 High Moisture Content of Filler Masterbatch

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

Causes:

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

Solutions:

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

5.2 Common Production Equipment Problems and Their Solutions

5.2.1 Extruder Blockage

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

Causes:

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

Solutions:

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

5.2.2 Severe Wear of Extruder Screw and Barrel

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

Causes:

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

Solutions:

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

5.2.4 Unstable Temperature Control of Extruder

The main manifestations are: the temperature of each section of the extruder fluctuates greatly (exceeding ±1℃), resulting in uneven melting of the materials, poor dispersibility of the masterbatch, and unstable product quality.

Causes:

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

Solutions:

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

6. Conclusion and Outlook

Polnilo masterbatch, as a key functional additive in the plastic processing industry, plays an irreplaceable role in reducing production costs, izboljšanje učinkovitosti izdelka in optimizacija učinkovitosti obdelave. With the rapid development of the global plastic industry and the continuous upgrading of downstream product requirements, the filler masterbatch industry is moving towards high performance, functionalization, visoka količina polnjenja, environmental protection and intelligence. Extrusion granulation technology, as the core technology of filler masterbatch production, directly determines the quality and competitiveness of the masterbatch. The performance of extruders is the key to ensuring the stable production of high-quality filler masterbatch.

We have developed a full range of twin-screw extruder products (HTS BASIC series, Serija HTS PLUS, Serija HTS SUPER, ZTE series, HTE series) according to the characteristics of filler masterbatch raw materials and processing requirements. Naši ekstruderji imajo prednost visoke odpornosti proti obrabi, strong shearing and mixing capacity, natančen nadzor temperature, wide application range, high production efficiency and low energy consumption, which can meet the processing needs of various types and different filling amounts of filler masterbatch. By providing targeted extruder products and professional processing solutions, we help filler masterbatch manufacturers solve production pain points, improve production efficiency, ensure product quality, and gain a competitive advantage in the fierce market competition.

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

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