Filler Masterbatch хатҳои пешрафтаи истеҳсоли гранулятсия ва истифодаи технологияи экструзия

Бо рушди босуръати саноати пластикии ҷаҳонӣ, талабот ба маснуоти пластмасса руз то руз меафзояд, ва талабот ба иҷрои маҳсулот, назорати ха-рочот ва мухофизати мухити зист низ беш аз пеш катъитар мегардад. Мастерbatch пуркунанда, ҳамчун иловаи асосии функсионалии коркарди пластикӣ, дар сохахои гуногуни истехсоли пластмасса ба сабаби бартарихои кам кардани харочоти истехсолот васеъ истифода бурда мешавад, баланд бардоштани самаранокии маҳсулот ва оптимизатсияи самаранокии коркард. Мо ӯҳдадор ҳастем, ки хатҳои пешрафтаи истеҳсоли гранулятсия ва экструдерҳои баландсифатро барои намудҳои гуногуни мастербатчи пуркунанда таъмин кунем, такя ба таҷрибаи бой дар таҳқиқот ва таҳия ва истеҳсоли технологияи экструзия, максаднок таъмин намояд, ҳалли самаранок ва боэътимоди коркард барои истеҳсолкунандагони masterbatch пуркунанда, ба корхонахо бехтар намудани самараи истехсолот ёрй расонанд, сифати махсулотро таъмин намоянд, ва дар рақобати шадиди бозор бартарии рақобатӣ ба даст оред.

Ин мақола ба соҳаи masterbatch пуркунанда тамаркуз хоҳад кард, мафхумхои асосиро чукур кор карда мебароянд, тасниф, раванди истеҳсоли masterbatch пуркунанда, нақши асосии технологияи extrusion дар истеҳсоли granulation он, бартариҳои силсилаи экструдерҳои мо ва мутобиқсозии мақсадноки онҳо ба коркарди пуркунандаи мастербатч, инчунин соҳаҳои мушаххаси барнома, usage methods and common problems and solutions in production. Он параметрҳои техникии муфассалро пурра мекунад, тафсилоти раванд ва нуқтаҳои дарди саноат барои ғанӣ гардонидани мундариҷа, ба талаботи шумораи калимаҳо мувофиқат кунед 3000-4000 суханони, and provide comprehensive and professional reference for relevant enterprises and practitioners in the filler masterbatch industry.

1. Overview of Filler Masterbatch Industry and Product Characteristics

1.1 Current Situation and Development Trend of Filler Masterbatch Industry

Дар солҳоӣ охир, ки бо тараккиёти босуръати сохахои поёноб ба монанди бастабандй, сохтмон, мошинсозй, электроника ва молхои рузгор, бозори ҷаҳонии masterbatch пуркунанда тамоюли афзоиши устуворро нишон дод. Masterbatch пуркунанда як намуди маводи таркибӣ мебошад, ки бо омехта сохта мешавад, об шудан, пуркунандаҳои ғайриорганикӣ экструдсия ва гранулизатсия (ба монанди карбонати калсий, талк, сулфати барий, ва ғайра.) бо интиқолдиҳандагони полимерӣ (монанди полиэтилен, полипропилен, хлориди поливинил, ва ғайра.) ва иловаҳои мувофиқ (монанди дисперсантхо, мувофиқаткунандаҳо, равганхои молиданй, ва ғайра.) дар таносуби муайян. Вазифаи асосии он кам кардани арзиши истеҳсоли маҳсулоти пластикӣ ҳангоми беҳтар ё нигоҳ доштани кори асосии маҳсулоти пластикӣ мебошад.

Мувофики маълумоти статистикии дахлдор, андозаи бозори ҷаҳонии пуркунандаи masterbatch аз ҳад зиёд шуд 20 миллиард доллари ИМА мебошад, ва дар назар аст, ки суръати афзоиши он нигоҳ дошта шавад 6%-9% дар чанд соли оянда. Дар байни онҳо, карбонати калсий (CaCO3) masterbatch пуркунанда навъи аз ҳама васеъ истифодашавандаи маҳсулот мебошад, ба хисоб гирифтани зиёда аз 60% аз бозори умумии пуркунандаи мастербатч, пас аз он masterbatch пуркунандаи талк, сулфати барий (BaSO4) filler masterbatch and other special filler masterbatches. Минтақаи Осиё ва ҳавзаи уқёнуси Ором бузургтарин бозори истеҳсол ва истеъмоли пуркунандаи мастербатч дар ҷаҳон аст, ба хисоб гирифтани зиёда аз 50% ҳиссаи бозори ҷаҳонӣ, ки ин асосан ба тараккиёти босуръати саноати коркарди пластмасса дар Хитой вобаста аст, Хиндустон ва дигар мамлакатхо, талаботи калон ба кам кардани арзиши аслй ва бехтар намудани кори махсулоти пластмасса, ва мунтазам такмил додани иктидори ёрирасони саноат.

Тамоюли рушди саноати пуркунандаи мастербатч асосан дар чор ҷиҳат инъикос ёфтааст: аввал, иҷрои баланд ва функсионалӣ. Бо такмил додани талаботи маҳсулоти пластикии поёноб, Masterbatch пуркунанда дигар бо кам кардани хароҷот маҳдуд намешавад, балки тадричан ба суи функсионализация инкишоф меёбад, ба монанди бехтар намудани устуворй, сахтгирй, муқовимати гармӣ, муқовимат ба ҳаво ва хосиятҳои монеаи маҳсулоти пластикӣ, ва таҳияи мастер-батчаҳои махсуси пуркунандаи функсионалӣ, ба монанди ретарденти оташ, антистатикӣ ва антибактериалӣ; дуюм, миқдори зиёди пуркунӣ ва паҳншавии хуб. Дар зери заминай таъмини кори махсулот, зиёд кардани миқдори пуркунии пуркунандаи ғайриорганикӣ метавонад минбаъд хароҷоти истеҳсолиро кам кунад, ки ба дисперсиатсияи masterbatch пуркунанда талаботи баландтар мегузорад - парокандагии аъло метавонад кафолат диҳад, ки пуркунанда дар матритсаи пластикӣ баробар тақсим карда шавад., пешгирӣ кардани пайдоиши доғҳои сафед, нуқтаҳои сиёҳ ё агломератсия дар маҳсулоти ниҳоӣ; сеюм, мухофизати мухити зист ва ифлосшавии кам. Бо таҳкими сиёсати глобалии ҳифзи муҳити зист ва баланд бардоштани огоҳии ҳифзи муҳити зист, истеҳсолкунандагони masterbatch пуркунанда тадриҷан иловаҳои аз ҷиҳати экологӣ тоза ва равандҳои истеҳсолиро қабул мекунанд, кам кардани партови моддахои зарарнок, ва таҳияи masterbatch пуркунандаи харобшаванда барои мутобиқ шудан ба тамоюли рушди пластикаи сабз; чорум, интеллигенция ва самаранокии тачхизоти истехсолот. Барои пешвоз гирифтани микьёси калон, эҳтиёҷоти истеҳсолии пайваста ва баландсифати masterbatch пуркунанда, истеҳсолкунандагон пайваста хатҳои пешрафтаи истеҳсоли гранулятсия ва системаҳои идоракунии интеллектуалиро ҷорӣ мекунанд, баланд бардоштани самаранокии истехсолот, кам кардани сарфи мехнат ва таъмини устувории сифати махсулот.

Дар ин замина, технологияи гранулизатсияи экструзия, ҳамчун технологияи асосии истеҳсоли masterbatch пуркунанда, калиди муайян кардани сифати устои пуркунанда ва ракобатпазирии корхонахо гардид. 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, истеъмоли энергияи баланд, ва ғайра.) 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, қатрони интиқолдиҳанда, application field and filling amount. Each type of filler masterbatch has its own unique characteristics and applicable scenarios. Дар зер муқаддимаи муфассал ба таснифоти умумӣ ва хусусиятҳои асосии masterbatch пуркунанда оварда шудааст:

1.2.1 Тасниф аз рӯи намуди пуркунанда:

Ин усули маъмултарини тасниф барои masterbatch пуркунанда аст. Аз рӯи намуди пуркунандаи ғайриорганикӣ, онро асосан ба карбонати калсий таксим кардан мумкин аст (CaCO3) masterbatch пуркунанда, masterbatch пуркунандаи тальк, сулфати барий (BaSO4) masterbatch пуркунанда, ва дигар мас-тербатхои махсуси пуркунанда (ба монанди masterbatch пуркунандаи каолин, Masterbatch пуркунандаи карбон сиёҳ, masterbatch пуркунандаи нахи шиша, ва ғайра.).

• Карбонати калсий (CaCO3) Пуркунандаи Masterbatch: Ин Masterbatch пуркунандаи васеъ истифодашаванда бо арзиши пасттарин аст. Пуркунанда асосан карбонати калсий сабук ё карбонати вазнини калсий мебошад. Карбонати калсий сабук андозаи заррачаҳои хуб дорад, парокандагии хуб ва сафедии баланд, ки ба маснуоти пластмасса мувофик аст, ки ба намуди зохир ва назокат талаботи баланд доранд (монанди плёнкахои пластикй, маҳсулоти қолаби тазриќї); карбонати вазнини калсий сахтии баланд дорад, муқовимат ба фарсудашавии хуб ва нархи паст, ки барои маснуоти пластмассй бо талаботи баланд оид ба сахтгирй ва назорати харочот мувофик аст (монанди халтахои бофташуда, тасмаҳои бастабандӣ, қубурҳо, ва ғайра.). Masterbatch пуркунандаи карбонати калсий метавонад на танҳо хароҷоти истеҳсолиро кам кунад, балки сахтгирй хам бехтар карда шавад, муқовимат ба гармӣ ва устувории андозагирии маҳсулоти пластикӣ, ва таъсири муайяни молиданй дорад, ки моеъи коркарди пластмассаро бехтар карда метавонад.
• Talc Filler Masterbatch: Пуркунанда хокаи тальк мебошад, ки сохтори қабати дорад. Хокаи талк хосиятхои хуби механикй дорад, тобоварии гармй ва устувории химиявй. Masterbatch пуркунандаи тальк асосан дар полипропилен истифода мешавад (PP) маҳсулоти пластикӣ, ки дуруштро хеле бехтар карда метавонад, ҳарорати таҳрифи гармӣ ва қувваи таъсири маҳсулоти PP, ва дар қисмҳои автомобилӣ васеъ истифода мешавад, снарядхои асбобхои рузгор, кубурхои пластмасса ва дигар сохахое, ки махорати баландро талаб мекунанд.
• Барий сулфат (BaSO4) Пуркунандаи Masterbatch: Пуркунанда хокаи сулфати барий мебошад, ки сафедии баланд дорад, шаффофияти хуб, беэътиноии химиявй ва тобоварии радиационй. Masterbatch пуркунандаи сулфати барий барои маҳсулоти пластикӣ бо талаботи баланд оид ба шаффофият мувофиқ аст, сафедй ва устувории химиявй (монанди плёнкахои пластикй, шишаҳои пластикӣ, маҳсулоти пластикии тиббӣ, ва ғайра.), ва инчунин метавонад дар маҳсулоти пластикии аз радиатсионӣ тобовар истифода бурда мешавад (монанди асбобхои мухофизати тиббй, лавозимоти станцияи электрикии атомй, ва ғайра.).

1.2.2 Тасниф аз рӯи қатрони интиқолдиҳанда:

Мувофиқи намуди қатрони интиқолдиҳанда истифода мешавад, masterbatch пуркунанда метавонад ба полиэтилен тақсим карда шавад (PE) masterbatch пуркунанда, полипропилен (PP) masterbatch пуркунанда, хлориди поливинил (PVC) masterbatch пуркунанда, полиэтилентерефталат (ПЕТ) masterbatch пуркунанда, ва ғайра. Интихоби қатрони интиқолдиҳанда асосан аз рӯи намуди маҳсулоти пластикии поёноб муайян карда мешавад. Барои намуна, Masterbatch пуркунандаи PE барои маҳсулоти пластикии PE мувофиқ аст (монанди плёнкахои пластикй, халтаҳо, қубурҳо); PP filler masterbatch is suitable for PP plastic products (монанди халтахои бофташуда, injection molding parts, қисмҳои автомобилӣ); PVC filler masterbatch is suitable for PVC plastic products (монанди қубурҳои PVC, профилҳо, варақҳо).

1.2.3 Тасниф аз рӯи майдони барнома:

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, ва ғайра. Film-grade filler masterbatch requires good dispersibility, high fineness and no impurities, to ensure that the blown film has no white spots, black spots or pinholes, and maintains good transparency and toughness; injection-grade filler masterbatch requires good fluidity and uniform particle size, to adapt to the rapid injection molding process and ensure the appearance and dimensional accuracy of injection products; Masterbatch пуркунандаи дараҷаи экструзия устувории хуби гармӣ ва хосиятҳои механикиро талаб мекунад, ки ба процесси экструзияи харорати баланд ва фишори баланди кубурхо мутобик шавад, профилхо ва дигар махсулот.

1.2.4 Тасниф аз рӯи маблағи пуркунӣ:

Мувофиқи миқдори пур кардани пуркунандаи ғайриорганикӣ, masterbatch пуркунандаро метавон ба masterbatch пуркунандаи кам тақсим кард (маблағи пур 30%-50%), мастер-батчаи миёна пур (маблағи пур 50%-70%) ва усто-батч пуркувват (маблағи пур 70% ва боло). Ҳаҷми пуркунӣ мувофиқи талаботи иҷрои маҳсулоти поёноб ва иқтидори коркарди таҷҳизот муайян карда мешавад. Мастербатчи пурбор таъсири бештари коҳиш додани хароҷот дорад, аммо он нисбат ба парокандагии пуркунандаҳо ва иҷрои экструдерҳо талаботи баландтар дорад - танҳо экструдерҳои баландсифат метавонанд омехта ва обшавии яксони маводи пурқувватро таъмин кунанд, пешгирӣ кардани агломератсия ва моеъи сусти коркард.

Қобили зикр аст, ки нишондиҳандаҳои асосии иҷрои Masterbatch пуркунанда асосан дисперсияро дар бар мегиранд, якрангии андозаи зарраҳо, индекси обшавии, сафедӣ (барои маснуоти сабуки ранга) ва мутобиқат бо қатрони интиқолдиҳанда. Дар байни онҳо, Парокандашавӣ нишондиҳандаи муҳимтарин аст - парокандагии суст ба тақсимоти нобаробари пуркунандаҳо дар маҳсулоти пластикӣ оварда мерасонад, ки дар натича доги сафед барин нуксонхо ба амал меоянд, нуқтаҳои сиёҳ, агломератсия ва маҳсулоти шикаста, ки ба намуди зоҳирӣ ва кори маҳсулоти пластикӣ таъсири ҷиддӣ мерасонанд. Бинобар ин, интихоби таҷҳизоти пешрафтаи экструзия ва технологияи коркарди илмӣ барои таъмини парокандагӣ ва сифати умумии masterbatch пуркунанда муҳим аст.

2. Технологияи асосии истеҳсоли Masterbatch Filler: Технологияи гранулизатсияи экструзия

Extrusion granulation technology is the core technology of filler masterbatch production, which integrates mixing, об шудан, тарошидан, dispersion and granulation. It has the advantages of high production efficiency, сифати хуби махсулот, мутобиқати қавӣ ба ашёи хом ва доираи васеи татбиқ. 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, ба монанди парокандашавӣ, 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, талк, BaSO4), polymer carriers (ба монанди PE, PP, PVC) ва иловахо (монанди дисперсантхо, мувофиқаткунандаҳо, равганхои молиданй, антиоксидантҳо, ва ғайра.). The characteristics of these raw materials are quite different, which puts forward special requirements for extrusion equipment:

Аввал, the inorganic fillers have high hardness, poor compatibility with polymer carriers, and are easy to agglomerate. Most inorganic fillers (such as CaCO3, талк) 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. Дар Илова, сахтии баланди пуркунандаҳои ғайриорганикӣ боиси фарсудашавии ҷиддии винт ва баррели экструдер дар ҷараёни экструзия мегардад, ки винт ва баррели экструдерро талаб мекунад, ки муқовимат ба фарсудашавӣ хеле баланд бошад.

Дуюм, омехтаи masterbatch пуркунанда дорои часпакии баланд ва моеъи суст аст. Илова кардани миқдори зиёди пуркунандаҳои ғайриорганикӣ часпакии омехтаро хеле зиёд мекунад, кам кардани моеъи коркард, ва аз экструдер талаб кунед, ки қобилияти интиқоли қавӣ ва қувваи буридан дошта бошад, то пешрафти мураттаби обшавии обро таъмин кунад., омехта ва экструзия.

Сеюм, доираи харорати коркард танг аст. Қатронҳои гуногуни интиқолдиҳанда дорои нуқтаҳои обшавии гуногун ва устувории гармӣ мебошанд. Барои намуна, нуқтаи обшавии PE 100-130 ℃ аст, нуқтаи обшавии PP 160-170 ℃ аст, ва PVC дар ҳарорати баланд ба осонӣ таҷзия мешавад (боло аз 160 ℃). Бинобар ин, таҷҳизоти экструзия бояд қобилияти дақиқи назорати ҳарорат дошта бошад, то омехта бе таҷзияи гармӣ пурра гудохта шавад, ки ба вайроншавии моддахои иловагй ва бад шудани кори махсулот рох надиханд.

Дар асоси хусусиятҳои дар боло зикршуда, экструдерҳои яквинтӣ барои истеҳсоли миқёси калон ва баландсифати мастербатчи пуркунанда мувофиқ нестанд. Чунки экструдери яквинта дорои доираи танги буриш аст, иктидори насосии суст ва таъсири худ-тозакунй. Дар вакти кор карда баромадани омехтахои часпакиаш баланд ва пуркунанда, боиси андухтани моддй осон аст, басташавӣ ва омехтаи нобаробар дар баррел экструдер, Дар натиҷа дисперсионии сусти masterbatch пуркунанда, андозаи нобаробар ва ноустувори сифати маҳсулот. Дар Илова, экструдери яквинтӣ ҳангоми коркарди масолеҳи пуркунандаи баланд истеъмоли зиёди энергия дорад, ва винт ва бочка сахт фарсуда шудаанд, ки арзиши аслии махсулот ва харочоти нигохубини тачхизо-ти корхонахоро зиёд мекунад.

Экструдерҳои дувинтӣ, аз тарафи дигар, дар истеҳсоли masterbatch пуркунанда бартариҳои ошкоро доранд ва таҷҳизоти асосӣ барои гранулизатсияи экструзияи пуркунандаи masterbatch шудаанд.. Экструдерҳои дувинтӣ доираи васеътари буриш доранд, таъсири насосии самараноктар ва таъсири худидоракунии тозакунӣ, ки пробле-махои мутобикшавии сустро самаранок хал карда метавонанд, агломератсияи осон ва моеъи сусти ашёи хоми пуркунандаи masterbatch. Ба ҳам пайвастан ва гардиши винтҳои дугона метавонад қувваи қавии буридан ва қувваи хамирро ба вуҷуд орад, ки агломератхои пуркунандаи гайриорганикиро пурра вайрон карда метавонад, пуркунандаҳоро дар интиқолдиҳандаи полимерӣ яксон пароканда кунанд, парокандашавй ва устувории махсулотро таъмин кунанд. Дар Илова, экструдери дугонаи винтӣ дорои дақиқии хуби назорати ҳарорат аст, ба ашьёи хом мутобик будани мустахкам, ва метавонад ба коркарди навъҳои гуногун мутобиқ шавад, миқдори гуногуни пуркунии masterbatch пуркунанда, ва самаранокии баланди истеҳсолот ва сарфи ками энергия дорад.

2.2 Принсипи кории Granulation Filler Masterbatch Extrusion

Раванди гранулизатсияи экструзионии masterbatch пуркунанда як раванди мураккаби физикӣ ва химиявӣ мебошад, ки таъсири мутақобилаи омилҳои гуногун ба монанди ҳароратро дар бар мегирад, фишор, қувваи буриш ва вақт. Принсипи мушаххаси кор ва ҷараёни раванд инҳоянд:

Аввал, коркарди ашёи хом. Ашёи хоми masterbatch пуркунанда (inorganic fillers, қатрони интиқолдиҳанда, иловагихо) барои таъмини сифати махсулоти нихой пешакй кор кардан лозим аст. Қадамҳои мушаххас дар бар мегиранд: 1) Табобати хушккунӣ: Пуркунандаи ғайриорганикӣ (such as CaCO3, талк) are usually hydrophilic and contain a certain amount of moisture. Агар намнокй аз хад зиёд бошад, it will affect the mixing effect and dispersibility of the materials, and even cause bubbles in the extruded masterbatch. Бинобар ин, the fillers need to be dried in a dryer (such as a hot air dryer, a vacuum dryer) to reduce the moisture content to below 0.5%. 2) Crushing and sieving: The carrier resin (ба монанди PE, PP) is crushed into small particles or powder with a particle size of 20-40 тор, which is conducive to uniform mixing with fillers and additives. Inorganic fillers are also sieved to remove impurities and large particles, ensuring the fineness and uniformity of fillers. 3) Premixing: Мувофиқи таносуби формула, the dried fillers, carrier resin particles and additives (dispersants, мувофиқаткунандаҳо, равганхои молиданй, ва ғайра.) are put into a high-speed mixer for premixing. Суръати омехта умуман аст 800-1200 чархзании, ва вақти омехта аст 5-10 дақиқа. Мақсади пеш аз омехта кардан ин аст, ки иловаҳо ба сатҳи пуркунандаҳо ва қатрони интиқолдиҳанда баробар пайваст шаванд., мутобиқати байни пуркунандаҳо ва интиқолдиҳандаро беҳтар кунед, ва барои омехтаи минбаъдаи экструзия замина гузоред. Дисперсант як иловаи калидӣ дар омехтакунӣ мебошад, ки дар сатхи пуркунанда плёнкаи мухофизаткунанда ташкил карда метавонад, кам кардани энергияи сатҳи пуркунанда, аз агломератсияи пуркунанда пешгирӣ мекунад, ва паҳншавии пуркунандаро дар қатрони интиқолдиҳанда беҳтар кунед.

Дуюм, хӯрдан ва интиқол додан. Омехтаи қаблан омехташуда ба бункери ғизодиҳии экструдери дувинтӣ тавассути фидер винт ё фидери тасма фиристода мешавад.. Суръати гизодихй бояд якхела ва устувор бошад, ки бо суръати винт ва суръати экструзияи экструдер мувофиқат мекунад, to ensure that the materials enter the extrusion cavity stably and avoid material accumulation or insufficient feeding. Дастгоҳи ғизодиҳии экструдер одатан бо функсияи танзими суръати табдили басомад муҷаҳҳаз аст, which can adjust the feeding speed according to the actual production situation.

Сеюм, об шудан, mixing and shearing. Маводҳое, ки ба холигоҳи экструзионии экструдери дугона ворид мешаванд, тавассути винтҳои даврзананда пайваста ба пеш тела дода мешаванд.. Ковокии экструзия аз винт ва баррел иборат аст, ва ҳаҷми холигии extrusion тадриҷан дар баробари самти меҳвар кам мешавад. Вақте ки винтҳо гардиш мекунанд, материалхо тадричан дар зери таъсири винтхо ва бочка фишурда мешаванд, ва фишор дар холигии экструзия тадриҷан меафзояд (generally 3-15MPa). Ҳамзамон, маводҳо ба қувваи қавии буридан ва қувваи соиш дучор мешаванд, ки дар натиҷаи ҳаракати нисбии байни винтҳо ва баррел тавлид мешаванд, инчунин дар байни парвозхои винт.

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. Қувваи соиш низ метавонад миқдори муайяни гармиро тавлид кунад, ки бо гармкунии берунии бочка якчоя карда мешавад (гармкунии электрикӣ ё гармкунии буғ) to make the carrier resin gradually melt and plasticize. Баррели экструдер одатан ба тақсим карда мешавад 3-6 қисмҳои назорати ҳарорат (бахши ғизодиҳӣ, бахши гудохта, бахши омехта, бахши гомогенизатсия, ва ғайра.), ва ҳарорати ҳар як қисм аз рӯи намуди қатрони интиқолдиҳанда ва пуркунанда дақиқ назорат карда мешавад. Барои намуна, ҳангоми коркарди Masterbatch пуркунандаи PE интиқолдиҳанда, харорати кисми гизодихй 80—100° аст, қисми обшавии 120-140 ℃ аст, қисмати омехта 140-150 ℃ аст, ва қисмати гомогенизатсия 130-140 ℃ аст; ҳангоми коркарди PP интиқолдиҳанда пуркунандаи masterbatch, ҳарорати ҳар як бахш аз 20-30 ℃ баландтар аз интиқолдиҳандаи PE аст.

Чорум, экструзия ва шакл додан. Дар пурра гудохта, маводи омехта ва пароканда ба сари матрит экструдер бо иддао тела. Сари матоъ бо сӯрохиҳои сершумор муҷаҳҳаз шудааст (шумора ва андозаи сӯрохиҳои штамп аз рӯи андозаи зарраҳои masterbatch муайян карда мешаванд), and the material is extruded from the die holes at a high speed to form continuous strips of uniform thickness. Ҳарорати сари штамп нисбат ба қисми гомогенизатсия каме пасттар аст, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the strips.

Панҷум, 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℃, ва вақти хунуккунӣ аст 2-5 дақиқа. Rapid cooling can make the strips solidify quickly, maintain the shape and size of the strips, and avoid deformation. Пас аз хунуккунӣ, 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, ки мувофики талаботи мизочон ислох кардан мумкин аст). The speed of the rotary knife is matched with the conveying speed of the strips to ensure that the particle size of the masterbatch is uniform.

Sixth, screening and packaging. The cut granular filler masterbatch is sent to a vibrating screen for screening, which can remove unqualified particles (such as too large, too small or agglomerated particles) and ensure the uniformity of the product. The qualified masterbatch is then sent to an automatic packaging machine for packaging. Мушаххасоти бастабандиро мувофиқи ниёзҳои муштарӣ танзим кардан мумкин аст (such as 25kg/bag, 50кг/халта), and the packaging should be sealed and moisture-proof to prevent the masterbatch from absorbing moisture and affecting the quality. Пас аз бастабандӣ, махсулот дар хушк нигох дошта мешавад, анбори хунук ва вентилятсияшаванда.

2.3 Key Factors Affecting Filler Masterbatch Extrusion Granulation Effect

The effect of extrusion granulation directly affects the quality of filler masterbatch. There are many factors affecting the granulation effect, mainly including raw material characteristics, formula ratio, premixing effect, extrusion parameters and die head structure. Mastering these key factors and making scientific adjustments can ensure the stability of the granulation effect and the consistency of product quality.

2.3.1 Raw Material Characteristics:

The type, particle size, moisture content and purity of raw materials have a great impact on the granulation effect. Барои намуна, the particle size of inorganic fillers directly affects the dispersibility and fineness of the masterbatch. The finer the particle size of the filler (умуман 800-2000 тор), the better the dispersibility, but the higher the cost and the easier it is to agglomerate; the coarser the particle size, the lower the cost, but the dispersibility is poor, which will affect the appearance and performance of the masterbatch. The moisture content of raw materials (especially fillers) should be controlled below 0.5%; агар намии он аз хад зиёд бошад, it will cause bubbles in the masterbatch, affect the density and mechanical properties of the product. Тоза будани ашьёи хом низ ахамияти калон дорад; ифлосиҳо дар ашёи хом (such as stones, metals, чанг) will not only affect the quality of the masterbatch, балки инчунин винт ва баррели экструдерро мепӯшанд, ва хатто боиси бастани тачхизот мегардад.

2.3.2 Таносуби формула:

The formula ratio of filler masterbatch (the ratio of filler, carrier resin and additives) is the key to determining the performance and cost of the product. The filling amount of the filler should be determined according to the performance requirements of the downstream product and the processing capacity of the equipment. Too high filling amount will lead to poor dispersibility, low toughness and poor processing fluidity of the masterbatch; too low filling amount will reduce the cost reduction effect. Навъ ва миқдори иловагиҳо низ бояд мувофиқат кунанд. Барои намуна, 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 Таъсири пешакӣ:

Premixing is the foundation of extrusion granulation. The uniformity of premixing directly affects the dispersibility of the filler in the carrier resin. Агар омехтаи пешакй нобаробар бошад, 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. Барои таъмини таъсири пеш аз омехта, суръати омехтаро назорат кардан лозим аст, вақти омехта ва ҳарорати омехта. Суръати омехта умуман аст 800-1200 чархзании, вақти омехта аст 5-10 дақиқа, ва ҳарорати омехта дар 40-60 ℃ назорат карда мешавад (ҳарорати мувофиқ метавонад часпидани иловаҳоро беҳтар кунад ва ба омехтаи якхела мусоидат кунад).

2.3.4 Параметрҳои экструзия:

Extrusion parameters are the most important factors affecting the granulation effect, асосан аз чумла суръати винт, ҳарорати extrusion ва фишори extrusion.

• Суръати винт: The screw speed generally ranges from 150 ба 600 чархзании. Суръати винт ҳамон қадар баландтар аст, қувваи буриш ва қувваи соиш, ки маводҳо мегиранд, ҳамон қадар зиёдтар аст, the better the mixing and dispersing effect of the filler, ва самараи истехсолот хар кадар баланд мешавад. Аммо, агар суръати винт хеле баланд бошад, мӯҳлати будубоши мавод дар холигоҳи экструзия хеле кӯтоҳ аст, resulting in incomplete melting of the carrier resin, insufficient mixing of the materials, and uneven particle size of the masterbatch; агар суръати винт хеле паст бошад, кувваи буриш ва соиш нокифоя аст, the filler cannot be fully dispersed, ва самараи истехсолот паст аст. 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.
• Ҳарорати экструзия: The extrusion temperature is divided into multiple sections (бахши ғизодиҳӣ, бахши гудохта, бахши омехта, бахши гомогенизатсия, қисмати сар), and the temperature of each section needs to be precisely controlled according to the type of carrier resin and filler. Харорати участкаи гизодихй пасттар аст (slightly higher than the melting point of the carrier resin), ки асосан барои пешгирй кардани пух-тани ​​масолех ва таъмин намудани гизодихй; харорати участкаи гудохта миёна аст, which is mainly to promote the melting and plasticization of the carrier resin; харорати участкаи омехта баландтар аст, ки асосан барои баланд бардоштани таъсири буридан ва омехта, and promote the uniform dispersion of the filler; ҳарорати қисмати гомогенизатсия нисбат ба қисмати омехта каме пасттар аст, ки асосан барои таъмини якхелаи харорат ва часпакии материалхо, ва аз таҷзияи гармӣ пешгирӣ кунед; ҳарорати қисмати сари штамп нисбат ба қисмати гомогенизатсия каме пасттар аст, which is to ensure the shaping effect of the strips.
• Фишори экструзия: The extrusion pressure is generally 3-15MPa. Фишор дар холигии экструзия асосан бо таносуби фишурдани винт муайян карда мешавад, андозаи сӯрохи бимирад ва суръати винт. Фишори экструзия баландтар аст, the better the mixing and dispersing effect of the materials, and the denser the masterbatch particles. Аммо, агар фишор хеле баланд бошад, сарфи энергия ва фарсудашавии тачхизотро зиёд мекунад, ва ҳатто боиси баста шудани сари матрит; агар фишор хеле паст бошад, масолехро пурра фишурда ва омехта кардан мумкин нест, the masterbatch particles are loose, and the performance is unstable.

2.3.5 Сохтори сар:

Сохтори сари бимирад асосан рақамро дар бар мегирад, шакл ва андозаи сӯрохиҳои қолаб. The shape of the die hole determines the cross-sectional shape of the extruded strips (монанди даврашакл, мураббаъ), and the size of the die hole determines the initial diameter of the strips and the final particle size of the masterbatch. Чӣ қадаре ки андозаи сӯрохи чӯб хурдтар бошад, фишори экструзия ҳамон қадар зиёдтар аст, the better the mixing and dispersing effect, вале иктидори истехсолй кам мешавад; 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. Шумораи сӯрохиҳо ба иқтидори истеҳсолӣ таъсир мерасонад; the more the number of die holes, иктидори истехсолй хар кадар зиёд мешавад, балки як хел таксим кардани фишорро таъмин кардан лозим аст, so as to avoid uneven thickness of the strips and uneven particle size of the masterbatch.

3. Экструдерхои мо: Advantages and Product Series for Filler Masterbatch Production

Мо кайхо боз бо тадкикот машгулем, 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, часпакии баланд) ва талаботи коркард (good dispersibility, uniform particle size, high filling amount), we have developed a series of twin-screw extruders specially suitable for filler masterbatch production. Our extruders have the advantages of high wear resistance, strong shearing force, назорати дақиқи ҳарорат, stable performance and low operating cost, which can meet the processing needs of various types, миқдори гуногуни пуркунии masterbatch пуркунанда (CaCO3, талк, BaSO4, ва ғайра.), and help enterprises improve production efficiency, ensure product quality and reduce production costs.

3.1 Main Advantages of Our Extruders for Filler Masterbatch Production

3.1.1 Муқовимати баланд ба фарсудашавӣ, Муҳлати хидматрасонии дароз:

Aiming at the problem that inorganic fillers (such as CaCO3, талк) have high hardness and easy to wear the screw and barrel, we adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components of the extruder. The screw and barrel are made of imported wear-resistant alloy steel (such as 38CrMoAlA), and after nitriding treatment or bimetallic composite treatment, the surface hardness can reach ≥65 HRC, which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by the friction between the high-hardness filler and the components. This greatly extends the service life of the screw and barrel, reduces the frequency of component replacement, and reduces the maintenance cost of the equipment. Дар Илова, 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, гузориши муфассали фарсудашавии, 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, бо як винти оқилона, lead and compression ratio design. Ба ҳам пайвастан ва гардиши винтҳои дугона метавонад қувваи қавии буридан ва қувваи хамирро ба вуҷуд орад, ки агломератхои пуркунандаи гайриорганикиро пурра вайрон карда метавонад, 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 (монанди унсурҳои интиқолдиҳанда, унсурҳои омехта, унсурҳои буридан) 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. Барои намуна, 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 Назорати дақиқи ҳарорат, Stable Performance:

Our extruders adopt advanced intelligent temperature control systems, which can realize precise control of the temperature of each section of the barrel and the die head. The temperature control accuracy can reach ±1℃, which can ensure that the carrier resin is fully melted without thermal decomposition, and the additives are not decomposed, ensuring the stability of the product performance. The temperature control system is equipped with a real-time monitoring and alarm function. If the temperature of any section exceeds the set range, система сари вақт огоҳии ҳушдор медиҳад, and even automatically adjust the heating power or shut down the equipment if necessary, ки аз бекористии тачхизот ва сифати махсулот рох надиханд. Дар Илова, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time. If the pressure is too high or too low, the system will adjust the screw speed or feeding speed automatically, ensuring the stability of the extrusion process.

3.1.4 Доираи васеи татбиқ, Strong Flexibility:

Our extruder series can adapt to the processing needs of various types of filler masterbatch, including CaCO3 filler masterbatch, masterbatch пуркунандаи тальк, BaSO4 filler masterbatch, ва дигар мас-тербатхои махсуси пуркунанда. The filling amount can be adjusted from 30% ба 80%, which can meet the different cost and performance requirements of customers. The modular design of the extruder (винт, баррел, сар бимирад, ва ғайра.) иваз кардани детальхоро кулайтар ва тезтар мегардонад. When customers need to adjust the product type or filling amount, ба онхо факат кисмхои дахлдорро иваз кардан лозим аст, тамоми тачхизотро иваз накарда, ки харочоти дигаргунсозии тачхизотро кам карда, кобилият ва мутобикшавии тачхизотро бехтар мекунад. Дар Илова, our extruders can also be matched with different auxiliary equipment (монанди миксерхои баландсуръат, хушккунакхо, сардкунакҳо, грануляторхо, мошинҳои скрининг, мошинҳои бастабандӣ) to form a complete automatic granulation production line, амалӣ намудани истеҳсоли муттасил аз коркарди ашёи хом то бастабандии маҳсулот.

3.1.5 Самаранокии баланди истехсолот, Low Energy Consumption:

Экструдерҳои дугонаи мо дорои самаранокии баланди истеҳсолӣ мебошанд, ки ин назар ба экструдерхои яквинтдор хеле зиёд аст. The production capacity of our extruders ranges from 100kg/h to 3000kg/h, ки эхтиёчоти истехсолии микьёси гуногуни корхонахоро конеъ гардонад (хурд, миёна ва калон). Системаи гардонандаи моменти баланд ва тарҳи винти оптимизатсияшудаи экструдер метавонад қобилияти интиқол ва самаранокии пластикии маводҳоро ба таври муассир беҳтар кунад, кам кардани вақти будубоши мавод дар холигии экструзия ва баланд бардоштани самаранокии истеҳсолот. Ҳамзамон, the extruder adopts an energy-saving design, such as a high-efficiency motor, a heat recovery device, ва ғайра., which can reduce the unit energy consumption by 15%-25% дар муқоиса бо экструдерҳои оддӣ, helping enterprises reduce production costs.

3.1.6 Истифода ва нигоҳдории осон:

Our extruders adopt a PLC intelligent control system and a touch screen operation interface, ки содда ва фахмо аст, осон кор кардан. 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, баррел, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Дастаи хидматрасонии пас аз фурӯш мо насби касбиро таъмин хоҳад кард, ба истифода додани хизматрасонй ва таълим барои муштариён, таъмин намудани он, ки харидорон аз тачхизот бемалол истифода баранд.

3.2 Our Extruder Product Series and Their Adaptation to Filler Masterbatch

Бо мақсади қонеъ гардонидани эҳтиёҷоти гуногуни истеҳсолии корхонаҳои пуркунанда аз миқёс ва намудҳои гуногуни маҳсулот, мо мачмуи пурраи маснуоти экструдерии ду-винтиро ба кор андохтаем, аз ҷумла силсилаи HTS BASIC, Силсилаи HTS PLUS, Силсилаи HTS SUPER, Силсилаи ZTE ва силсилаи HTE. Ҳар як силсила дорои хусусиятҳои худ ва сенарияҳои мутобиқсозии мақсаднок мебошад, ки онро харидорон мувофики микьёси истехсолии худ интихоб карда метавонанд, навъи маҳсулот, буҷет ва омилҳои дигар.

3.2.1 Экструдерҳои силсилаи HTS BASIC: Интихоби камхарҷ барои корхонаҳои миёна ва хурд.

Экструдерҳои силсилаи HTS BASIC як силсилаи маҳсулоти камхарҷ мебошанд, ки мустақилона аз ҷониби мо таҳия шудааст, ки махсус барои корхонаҳои коркарди пуркунанда бо миқёси истеҳсолии миёна ва хурд ё воридшавии ибтидоӣ ба саноат тарҳрезӣ шудаанд. Ин силсилаи экструдерҳо қуттиҳои редукторҳои моменти миёнаро аз истеҳсолкунандагони пешбари аврупоӣ истифода мебаранд, ки афзалияти кори устувор доранд, садои паст, самаранокии баланд ва мӯҳлати хизмати дароз. Тарҳрезии моменти миёна метавонад эҳтиёҷоти коркарди маъмултарин мастер-батчи пуркунандаро қонеъ кунад (ба монанди паст-ба миёна пур аз CaCO3 masterbatch, Мастербатчи интиқолдиҳандаи PE/PP), ва дар айни замон, он нархи муътадил дорад, ки ба корхонахо барои кам кардани арзиши аслии маблаггузорй ёрй расонда метавонад.

Аз чихати лоихакашии структурен, экструдерҳои силсилаи HTS BASIC сохтори параллели дугонаро қабул мекунанд, бо диаметри винт аз 30мм то 65мм, ва таносуби фишурдани 4～8, which can be adjusted according to the type and filling amount of filler masterbatch. Баррел аз пӯлоди хӯлаи ба фарсуда тобовар бо коркарди нитридӣ сохта шудааст, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. Экструдер бо системаи идоракунии PLC ва интерфейси экрани сенсорӣ муҷаҳҳаз шудааст, ки гизодихии автоматиро ба амал бароварда метавонад, назорати автоматии ҳарорат, назорати автоматии фишор ва буридани автоматӣ, ва содда ва осон кор кардан аст.

Иқтидори истеҳсолии экструдерҳои HTS BASIC аз 100кг / соат то 500кг / соат аст., 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). Яке аз бузургтарин бартариҳои ин силсила дар он аст, ки он метавонад тавассути комбинатсияҳои гуногуни конфигуратсия имконоти тағйирпазирро таъмин кунад. Мизоҷон метавонанд унсурҳои буриши гуногунро интихоб кунанд, сар мемиранд, асбобхои хурокдихй, дастгоххои хушккунй ва тачхизоти пстехсолй аз руи навъхои махсулоти худ, иктидори истехсолй ва бюджет, so as to form a production line suitable for their own needs.

3.2.2 HTS PLUS Series Extruders: High-Performance Choice for Engineering Plastic and Filler Masterbatch.

The HTS PLUS series extruders adopt high-torque gearboxes independently developed and manufactured by us, which have stronger torque and load-bearing capacity than the HTS BASIC series. This series of extruders is mainly used for the processing of high-performance filler masterbatch, such as high-filling CaCO3 masterbatch (filling amount ≥60%), talc masterbatch, BaSO4 masterbatch, and filler masterbatch for engineering plastics (ба монанди PP, ПА, Компютер).

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, талк) 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, which is suitable for medium and large-scale filler masterbatch enterprises that pursue high performance and high filling amount.

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

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

The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us. Aiming at the high torque and high speed characteristics of this series, тарҳи сохтории ҳар як ҷузъи асосии экструдер комилан оптимизатсия карда шудааст, ки силсилаи олитарини экструдери мост, намояндагии сатҳи пешрафтаи рушди экструдер Чин. 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.

Экструдерҳои силсилаи HTS SUPER дорои диаметри винт аз 80мм то 130мм мебошанд., таносуби фишурдасозии 6 ~ 12, and a screw speed range of 250～700 rpm. Бурд ва баррел технологияи пӯлоди хӯлаи ба фарсудашаванда тобовар ва технологияи пӯшидани лазериро қабул мекунад, which has extremely high wear resistance and corrosion resistance, and can adapt to the processing of various special fillers (монанди нахи шишагй, carbon black, сулфати барий) 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, ба амал баровардани идоракунии интеллектуалии истехсолот.

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, иҷрои баланд ва интеллектуалӣ. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end filler masterbatch.

3.2.4 Экструдерҳои силсилаи ZTE: Cost-Effective Choice for General Filler Masterbatch.

The ZTE series extruders have excellent cost performance, and their designed parameters are suitable for most filler masterbatch materials (ба монанди паст-ба миёна пур аз CaCO3 masterbatch, Мастербатчи интиқолдиҳандаи PE/PP). This series of extruders adopts a simplified and optimized structure, which reduces the production cost while ensuring the basic performance, and is suitable for small and medium-sized enterprises with limited budget and general product requirements.

The ZTE series extruders have a screw diameter ranging from 30mm to 50mm, a compression ratio of 4～7, and a screw speed range of 150～500 rpm. The production capacity ranges from 50kg/h to 300kg/h, which is suitable for small-scale production of common filler masterbatch. The extruder is easy to operate and maintain, and the after-sales service cost is low, which is a cost-effective choice for small enterprises and individual workshops.

3.2.5 Экструдерҳои Силсилаи HTE: High-Efficiency and Energy-Saving Choice for Large-Scale Production.

The HTE series extruders combine high performance and high cost performance, and are designed to reduce energy consumption with higher output. This series of extruders adopts a high-efficiency motor, an optimized screw structure and a heat recovery device, which can reduce the unit energy consumption by 20%～25% compared with ordinary extruders, and has higher production efficiency.

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

3.3 Selection Suggestions for Filler Masterbatch Extruders

When selecting extruders for filler masterbatch production, корхонахо бояд талаботи истехсолии худро хаматарафа ба назар гиранд, намудхои махсулот, маблағи пур, бючет ва дигар омилхо барои он ки тачхизоти интихобшуда эхтиёчоти хакикии истехсолиро конеъ гардонад ва фоидаи максималии иктисодй дихад. Дар зер баъзе пешниҳодҳои мушаххаси интихоб мавҷуданд:

3.3.1 Determine the Extruder Series According to Product Type and Filling Amount:

Different types and filling amounts of filler masterbatch have different requirements for extruders. Барои намуна, if the enterprise mainly produces low-to-medium filling CaCO3 masterbatch (filling amount ≤60%) and common PE/PP carrier masterbatch, the HTS BASIC series or ZTE series extruders are suitable; if the enterprise produces high-filling masterbatch (filling amount ≥60%), talc masterbatch or BaSO4 masterbatch, the HTS PLUS series extruders are recommended; if the enterprise produces high-end, special filler masterbatch (such as glass fiber reinforced masterbatch, устои ба оташ тобовар), 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 тонна), 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 тонна), 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, талк) 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 (монанди сарфи энергия, maintenance cost, spare parts cost). Барои намуна, 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, ба истифода додан, таълим, maintenance and spare parts supply services. Мо як дастаи касбии хидматрасонии пас аз фурӯш дорем, which can respond to customer needs in a timely manner (provide solutions within 24 соат) and send technicians to the site for maintenance if necessary, кори муътадили хатти нстехсолотро таъмин мекунанд.

3.3.6 Дар бораи чандирӣ ва васеъшавии таҷҳизот фикр кунед:

Бо тағирёбии талаботи бозор, enterprises may need to adjust their product types and filling amounts. Бинобар ин, ҳангоми интихоби экструдерҳо, корхонахо бояд чандон ва васеъ кардани тачхизотро ба назар гиранд. Экструдерҳои мо тарҳи модулиро қабул мекунанд, ки мувофики эхтиёчоти корхонахо озодона муттахид ва такмил додан мумкин аст, баланд бардоштани кобилият ва васеъ кардани тачхизот, ва кам кардани арзиши тачхизот табдил дода шавад.

4. Application Fields and Usage Methods of Filler Masterbatch

Мастерbatch пуркунанда, ҳамчун иловаи асосии функсионалии коркарди пластикӣ, has a wide range of application fields, covering various fields such as plastic packaging, сохтмон, мошинсозй, электроника, 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, ба хисоб гирифтани зиёда аз 50% of the total application amount. Filler masterbatch is widely used in the production of plastic films, халтаҳои пластикӣ, woven bags, тасмаҳои бастабандӣ, packaging containers and other packaging products.

• Plastic Films: Including plastic thin films, thick films, stretch films, greenhouse films, ва ғайра. The filler masterbatch used for plastic films is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires good dispersibility, high fineness and no impurities, to ensure that the blown film has no white spots, black spots or pinholes, and maintains good transparency, toughness and tensile strength. Adding an appropriate amount of filler masterbatch can not only reduce the production cost of the film, балки сахтгирй хам бехтар карда шавад, heat resistance and dimensional stability of the film, and reduce the shrinkage rate of the film. Барои намуна, in the production of plastic shopping bags, илова кардан 1%-3% of CaCO3 filler masterbatch can reduce the cost by 5%-10% without affecting the toughness and load-bearing capacity of the bags.
• Plastic Bags: Including shopping bags, vest bags, garbage bags, food packaging bags, ва ғайра. The filler masterbatch used for plastic bags is mainly heavy calcium carbonate filler masterbatch, which has low cost and good wear resistance. Adding 2%-5% of filler masterbatch can reduce the cost and improve the rigidity and wear resistance of the bags. For garbage bags, adding an appropriate amount of filler masterbatch can also improve the toughness and tear resistance of the bags, making them not easy to break.
• Woven Bags and Packaging Belts: Woven bags are widely used in the packaging of grain, fertilizer, цемент, chemical products and other goods; packaging belts are used for the bundling of goods. The filler masterbatch used for woven bags and packaging belts is mainly heavy calcium carbonate filler masterbatch or talc filler masterbatch, which requires high rigidity and wear resistance. Adding 5%-10% of filler masterbatch can improve the rigidity, tensile strength and wear resistance of woven bags and packaging belts, reduce the cost, and extend the service life of the products.
• Packaging Containers: Including plastic bottles, баррелҳои пластикӣ, plastic boxes, ва ғайра. 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, қубурҳои PE, PP pipes, ва ғайра., which are used for water supply, дренаж, gas transmission, cable protection and other fields. The filler masterbatch used for plastic pipes is mainly calcium carbonate filler masterbatch or talc filler masterbatch, which requires high rigidity, heat resistance and pressure resistance. Adding 5%-15% of filler masterbatch can improve the rigidity, heat distortion temperature and pressure resistance of the pipes, reduce the cost, and prevent the pipes from deforming under high temperature and pressure.
• Plastic Profiles: Including PVC profiles for doors and windows, plastic decorative profiles, ва ғайра. The filler masterbatch used for plastic profiles is mainly calcium carbonate filler masterbatch, which requires good weather resistance and impact strength. Adding 5%-10% of filler masterbatch can improve the rigidity, weather resistance and impact strength of the profiles, reduce the cost, and ensure the service life of the profiles in outdoor environments.
• Plastic Sheets: Including PVC sheets, варақаҳои PE, варақаҳои PP, ва ғайра., which are used for indoor decoration, бастабандӣ, waterproofing and other fields. The filler masterbatch used for plastic sheets is mainly calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires good flatness and toughness. Adding 3%-8% of filler masterbatch can reduce the cost and improve the rigidity and toughness of the sheets.

4.1.3 Plastic Injection Molding Industry:

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

• Plastic Daily Necessities: Including plastic bowls, plastic plates, plastic cups, plastic baskets, plastic buckets and other daily necessities. The filler masterbatch used for these products is mainly calcium carbonate filler masterbatch, which has low cost and good safety. Adding 2%-5% of filler masterbatch can reduce the cost and improve the rigidity and impact strength of the products, making them not easy to break.
• Plastic Toys: Including various plastic toys for children. The filler masterbatch used for plastic toys is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires high safety, заҳролуд набудан, good dispersibility and no odor, in line with international toy safety standards (such as EN 71, ASTM F963). The particle size of the filler should be fine (боло 1250 тор) to avoid scratching children’s skin and ensure the smoothness of the toy surface. Adding 1%-3% of light calcium carbonate filler masterbatch can reduce the production cost of toys without affecting the toughness and colorability of the toys; barium sulfate filler masterbatch is suitable for transparent or semi-transparent plastic toys, which can improve the transparency and surface gloss of the toys, making them more beautiful.
• Plastic Parts and Shells: Including plastic parts for home appliances, automotive interior parts, electronic product shells, ва ғайра. The filler masterbatch used for these products is mainly talc filler masterbatch or glass fiber reinforced filler masterbatch, which requires high rigidity, heat resistance and impact strength. Барои намуна, in the production of automotive interior parts (монанди панелхои асбобхо, панелҳои дари), илова кардан 5%-8% of talc filler masterbatch can improve the rigidity and heat distortion temperature of the parts, reduce the shrinkage rate, and make the parts not easy to deform under high temperature environment in the car; in the production of electronic product shells (such as mobile phone shells, router shells), илова кардан 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, панелҳои дари, seat cushions, armrests, ва ғайра. These parts have high requirements on rigidity, муқовимати гармӣ, 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) масолех, 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. Барои намуна, илова кардан 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, панҷараҳо, door handles, ва ғайра. These parts are exposed to the outdoor environment for a long time, so they have high requirements on weather resistance, impact strength and UV resistance. The filler masterbatch used for exterior parts is mainly talc filler masterbatch or barium sulfate filler masterbatch, which is usually compounded with weather-resistant additives. Adding 4%-7% of talc filler masterbatch can improve the impact strength and rigidity of the exterior parts, enhance their resistance to external impact; barium sulfate filler masterbatch can improve the weather resistance and color retention of the exterior parts, making them not easy to fade and aging under the action of sunlight and rain.
• Automotive Functional Parts: Including air intake pipes, cooling system parts, battery casings, ва ғайра. These parts have high requirements on heat resistance, chemical resistance and mechanical properties. The filler masterbatch used for functional parts is mainly glass fiber reinforced filler masterbatch or special mineral filler masterbatch. Барои намуна, илова кардан 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, изолятсия, 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, ва ғайра.

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

4.1.6 Agricultural Plastic Industry:

Agricultural plastic products (such as greenhouse films, mulch films, кубурхои обьёрй, fertilizer bags) have the characteristics of large dosage, low cost and harsh use environment. Filler masterbatch can effectively reduce the production cost of agricultural plastic products and improve their service life.

• Greenhouse Films and Mulch Films: These products need to have good transparency, сахтгирй, weather resistance and anti-aging properties. The filler masterbatch used is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch. Adding 1%-4% of light calcium carbonate filler masterbatch can reduce the cost of the film, improve its toughness and anti-aging properties, and extend the service life of the film; barium sulfate filler masterbatch can improve the transparency and light transmittance of the film, which is conducive to the photosynthesis of crops.
• Irrigation Pipes and Fertilizer Bags: Irrigation pipes need to have good pressure resistance and wear resistance; fertilizer bags need to have good toughness and wear resistance. The filler masterbatch used is mainly heavy calcium carbonate filler masterbatch or talc filler masterbatch. Adding 5%-10% of heavy calcium carbonate filler masterbatch can improve the pressure resistance and wear resistance of irrigation pipes, reduce the cost; илова кардан 3%-6% of talc filler masterbatch can improve the toughness and wear resistance of fertilizer bags, making them not easy to break during transportation and use.

4.2 Usage Methods of Filler Masterbatch

The correct use of filler masterbatch is crucial to ensure the quality of plastic products and give full play to the performance of the masterbatch. The usage methods of filler masterbatch mainly include mixing ratio, mixing method, processing parameter adjustment and precautions. The specific operation points are as follows:

4.2.1 Determination of Mixing Ratio:

The mixing ratio of filler masterbatch and base plastic (carrier resin of plastic products) is mainly determined by the filling amount of the masterbatch, the performance requirements of the final product and the processing capacity of the equipment. The general mixing ratio range is 1%-20%, and the specific ratio can be adjusted according to the following principles:

• For plastic products with low performance requirements and high cost control requirements (such as ordinary plastic bags, garbage bags), the mixing ratio can be 5%-20% (using low-to-medium filling calcium carbonate filler masterbatch);
• For plastic products with medium performance requirements (монанди плёнкахои пластикй, ordinary injection molding parts), the mixing ratio can be 2%-8% (using medium filling calcium carbonate, talc or barium sulfate filler masterbatch);
• For plastic products with high performance requirements (монанди кисмхои автомобиль, electronic product shells, high-grade films), the mixing ratio can be 1%-5% (using high-filling, high-performance talc, barium sulfate or glass fiber reinforced filler masterbatch);
• For transparent or semi-transparent plastic products (such as plastic bottles, transparent films), the mixing ratio should be controlled at 1%-3%, and barium sulfate or light calcium carbonate filler masterbatch with fine particle size (боло 1250 тор) 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 (ба монанди PE, PP, PVC). The specific steps are: аввал, 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 (агар лозим бошад) to mix uniformly. Суръати омехта умуман аст 500-800 чархзании, ва вақти омехта аст 3-5 дақиқа. Пас аз омехта, the mixture can be directly sent to the extruder or injection molding machine for processing. The advantages of dry mixing are simple operation, самаранокии баланд, 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. Бинобар ин, 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 (монанди харорат, фишор, суръати винт) 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. Барои намуна, 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 (фишори экструзия, injection pressure) needs to be appropriately increased by 10%-20%. Барои намуна, 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: Мастерbatch пуркунанда (especially calcium carbonate, talc masterbatch) is easy to absorb moisture, which will cause bubbles, pinholes and other defects in the final product. Бинобар ин, the masterbatch should be stored in a dry, анбори хунук ва вентилятсияшаванда, and should be dried before use (the drying temperature is 80-100℃, ва вақти хушккунӣ аст 2-4 соат).
• Мутобиқати: The carrier resin of the filler masterbatch should be consistent with or compatible with the base plastic of the product. Барои намуна, 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, ки дар натича доги сафед барин нуксонхо ба амал меоянд, 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 (умуман 6-12 моҳҳо). If the storage period is exceeded, the masterbatch may absorb moisture, agglomerate or the performance of additives may degrade, affecting the use effect. Бинобар ин, 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, аз таъсири ашьёи хом, формула, 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.

Сабабҳо: 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.

Ҳалли: 1) Select inorganic fillers with fine and uniform particle size (умуман 800-2000 тор), 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) Раванди омехтаро оптимизатсия кунед, суръати омехтаро зиёд кунед (800-1200 чархзании) ва вақти омехта (5-10 дақиқа), 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.

Сабабҳо: 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.

Ҳалли: 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) Раванди хунуккунӣ оптимизатсия кунед, 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.

Сабабҳо:

• 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.

Ҳалли:

• 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 (барои намуна, 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).

Сабабҳо:

• The thermal stability of the carrier resin is poor, and thermal decomposition occurs at high processing temperatures;
• The additives (монанди дисперсантхо, равганхои молиданй) 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.

Ҳалли:

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

Сабабҳо:

• 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.

Ҳалли:

• Extend the drying time of the filler (drying temperature 80-100℃, drying time 3-5 соат), 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, анбори хунук ва вентилятсияшаванда, 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.

Сабабҳо:

• 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 (such as stones, metals), which block the screw or die head;
• Суръати винт хеле паст аст, 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.

Ҳалли:

• Stop the machine immediately, кувваи электрро катъ кунед, 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.

Сабабҳо:

• The filler has high hardness (such as heavy calcium carbonate, талк) and long-term friction with the screw and barrel;
• The materials contain impurities (монанди металлхо, сангхо), 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, баррел;
• The screw and barrel are made of materials with poor wear resistance.

Ҳалли:

• 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, баррел.

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, ва сифати махсулот ноустувор аст.

Сабабҳо:

• 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.

Ҳалли:

• 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

Мастерbatch пуркунанда, as a key functional additive in the plastic processing industry, plays an irreplaceable role in reducing production costs, баланд бардоштани самаранокии маҳсулот ва оптимизатсияи самаранокии коркард. 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, функсионализатсия, high filling amount, мухофизати мухити зист ва интеллигенция. Extrusion granulation technology, ҳамчун технологияи асосии истеҳсоли masterbatch пуркунанда, 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, Силсилаи HTS PLUS, Силсилаи HTS SUPER, Силсилаи ZTE, Силсилаи HTE) according to the characteristics of filler masterbatch raw materials and processing requirements. Our extruders have the advantages of high wear resistance, strong shearing and mixing capacity, назорати дақиқи ҳарорат, доираи васеи татбиқ, 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, сифати махсулотро таъмин намоянд, ва дар рақобати шадиди бозор бартарии рақобатӣ ба даст оред.

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; аз тарафи дигар, the intelligence and automation level of production equipment will continue to improve, and intelligent granulation production lines integrating raw material pretreatment, гранулятсияи экструзия, 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. Ҳамзамон, 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.