Masterbatch ilg'or ikki vintli ekstruziya texnologiyasi ilovalari va kompleks qayta ishlash echimlari

1. Masterbatch sanoati va asosiy bilimlarga umumiy nuqtai

1.1 Current Situation and Development Trend of Masterbatch Industry

Masterbatch, rangli masterbatch yoki rangli konsentrat sifatida ham tanilgan, yuqori konsentratsiyali yangi turdagi plastik rang beruvchi materialdir, yuqori disperslik va qulay foydalanish. U pigmentlarni yoki bo'yoqlarni bir xilda tarqatish orqali amalga oshiriladi, carriers and additives in a specific proportion through professional mixing and extrusion granulation technology. Compared with the traditional direct coloring method (directly adding pigments to plastic raw materials), masterbatch has the advantages of convenient use, uniform coloring, stable performance, environmental protection and energy saving, which has gradually replaced the traditional coloring method and become the mainstream coloring solution in the plastics industry.

In recent years, driven by the rapid development of downstream industries such as packaging, avtomobilsozlik, textiles, electronics, construction and home appliances, the global masterbatch market has shown a steady and rapid growth trend. According to relevant industry data, the global masterbatch market size has exceeded 30 billion US dollars, and it is expected to maintain a compound annual growth rate of 6%-8% in the next five years. Among them, Asia-Pacific is the world’s largest masterbatch production and consumption market, accounting for more than 60% of the global market share, mainly due to the rapid development of the plastics industry in China, India and other countries, the continuous improvement of industrial supporting capacity, and the increasing demand for high-quality, functional and environmentally friendly masterbatch products.

Xitoy, as the world’s largest masterbatch producer and consumer, has a huge market demand and a complete industrial chain. The annual output and consumption of masterbatch are growing at a double-digit rate, especially in the fields of new energy vehicles, green packaging, high-end textiles and medical devices, the demand for high-performance masterbatch (such as high-temperature resistant masterbatch, olovga chidamli masterbatch, environmental protection masterbatch) is showing an explosive growth trend. With the continuous improvement of global environmental protection policies (such as the ban on toxic and harmful pigments) and the upgrading of consumer demand for high-quality plastic products, the masterbatch industry is gradually developing towards high concentration, high dispersibility, functionalization, environmental protection and intelligence.

The main development trends of the masterbatch industry are reflected in four aspects: first, environmental protection and low toxicity. With the strengthening of environmental protection awareness and the strictness of environmental protection policies, non-toxic, harmless, low-volatile and degradable environmental protection masterbatch will become the mainstream of the market, and toxic and harmful pigments (such as heavy metal pigments) will be gradually eliminated; second, functionalization. In addition to coloring, masterbatch is also developing towards functional integration, such as flame-retardant masterbatch, antistatik masterbatch, antibacterial masterbatch, UV-resistant masterbatch, which can meet the special use requirements of downstream products; third, high concentration and high dispersibility. High-concentration masterbatch can reduce the addition amount, reduce production costs, and high dispersibility can ensure uniform coloring of plastic products, avoid color spots and color difference, which is the key to improving product quality; fourth, intelligence and automation of processing. Masterbatch processing requires strict control of mixing uniformity, harorat va boshqa parametrlar. Aqlli, avtomatik ikkita vintli ekstruziya ishlab chiqarish liniyalari asosiy oqimga aylanadi, real vaqt rejimida monitoringni amalga oshirish, avtomatik parametrlarni sozlash va ommaviy ishlab chiqarish, ishlab chiqarish samaradorligini va mahsulot izchilligini oshirish.

Masterbatchning asosiy ishlov berish uskunasi sifatida, ikki vintli ekstruderlar masterbatch sanoatini rivojlantirishda hal qiluvchi rol o'ynaydi. Masterbatch aralashtirish aralashtirish va tarqatish ta'siri bo'yicha qat'iy talablarga ega, haroratni nazorat qilish va ekstruderlarning ishlab chiqarish samaradorligi. Zhuoyue ekstruderlarining to'liq seriyasi (HTS BASIC/PLUS/SUPER, ZTE, HTE) masterbatch qayta ishlash uchun maxsus mo'ljallangan, maqsadli ishlash afzalliklari bilan, har xil turdagi masterbatchlarni qayta ishlash ehtiyojlarini samarali qondira oladigan va ishlab chiqaruvchilarga mahsulot sifati va ishlab chiqarish samaradorligini oshirishga yordam beradi.

1.2 Masterbatch ning asosiy tarkibi va ishlash printsipi

Masterbatch uchta asosiy elementdan iborat: pigmentlar yoki bo'yoqlar, tashuvchilar va qo'shimchalar. Har bir elementning nisbati va ishlashi masterbatchning sifati va foydalanish samarasini bevosita aniqlaydi. Masterbatchning asosiy tarkibi va ishlash printsipini tushunish uni qayta ishlash texnologiyasini o'zlashtirish va tegishli ekstruziya uskunalarini tanlash uchun asosdir..

1.2.1 Pigmentlar yoki bo'yoqlar: Asosiy rang berish komponenti

Pigmentlar yoki bo'yoqlar masterbatch rang berish samaradorligini beruvchi asosiy komponentlardir, buxgalteriya hisobi 10%-80% masterbatch tarkibi (o'ziga xos nisbat pigment turiga bog'liq, rang berish talablari va masterbatch konsentratsiyasi). Pigmentlar organik va noorganik pigmentlarga bo'linadi: organik pigmentlar yorqin ranglarga ega, yuqori rang berish kuchi, good transparency, but poor heat resistance and weather resistance, mainly used in low-temperature processing plastics (such as PE, PP) and products with high color requirements (such as textiles, packaging films); inorganic pigments have good heat resistance, weather resistance and chemical stability, but low tinting strength and poor transparency, mainly used in high-temperature processing plastics (such as engineering plastics) and outdoor products (such as building materials, automotive exterior parts).

Dyes are different from pigments. Dyes have good solubility in plastic raw materials, bright colors and high transparency, but poor heat resistance and light resistance, mainly used in transparent plastic products (such as PET bottles, PC sheets). The selection of pigments or dyes should be based on the type of plastic raw materials (ishlov berish harorati), product use environment (ichki/tashqi), rang berish talablari (rang yorqinligi, shaffoflik) va atrof-muhitni muhofaza qilish talablari, masterbatchning barqaror rang berish ko'rsatkichiga ega bo'lishini va quyi oqim mahsulotlaridan foydalanish talablariga javob berishini ta'minlash.

1.2.2 Tashuvchilar: Dispersiya va yopishish komponenti

Tashuvchilar masterbatch matritsasi hisoblanadi, buxgalteriya hisobi 10%-80% masterbatch tarkibi, asosan pigmentlarni / bo'yoqlarni tarqatish va plastik xom ashyolarga yopishish rolini o'ynaydi. Tashuvchi pigmentlar/bo'yoqlar va maqsadli plastik xom ashyo bilan yaxshi mos kelishi kerak (rang berish uchun plastik xom ashyo), aks holda bu pigmentlarning tarqalishiga va mahsulotlarning rang berish effektiga ta'sir qiladi. Umumiy tashuvchi materiallarga polietilen kiradi (PE), polipropilen (PP), polivinilxlorid (PVX), poliamid (PA), polietilen tereftalat (PET), va hokazo., maqsadli plastik xom ashyo turiga qarab tanlanadi: masalan, PE tashuvchisi PE plastik rang berish uchun ishlatiladi, PP tashuvchisi PP plastik rang berish uchun ishlatiladi, va PA tashuvchisi muhandislik plastik PA rang berish uchun ishlatiladi.

Tashuvchi ham yaxshi ishlov berish suyuqligiga ega bo'lishi kerak, ekstruziya bilan ishlov berish va masterbatchni maqsadli plastik xom ashyo bilan aralashtirish jarayonida pigmentlarning bir xil tarqalishiga yordam beradi.. Bunga qo'chimcha, tashuvchining erish nuqtasi va ishlov berish harorati maqsadli plastik xom ashyoga mos kelishi yoki undan biroz pastroq bo'lishi kerak., qayta ishlash jarayonida tashuvchining yoki maqsadli plastmassaning parchalanishiga yo'l qo'ymaslik uchun.

1.2.3 Qo'shimchalar: Yordamchi funktsional komponent

Qo'shimchalar - bu ishlov berish samaradorligini oshirish uchun qo'shiladigan yordamchi komponentlar, disperslik va masterbatchning foydalanish ko'rsatkichlari, buxgalteriya hisobi 1%-10% masterbatch tarkibi. Qo'shimchalarning turi va dozasi masterbatch turiga va qayta ishlash talablariga muvofiq belgilanadi. Umumiy qo'shimchalar o'z ichiga oladi:

• Dispersantlar: Masterbatchdagi eng muhim qo'shimcha, pigmentlarning sirt tarangligini kamaytirishi mumkin, pigment aglomeratsiyasini oldini oladi, va pigmentlarni tashuvchida bir xilda taqsimlanadi. Umumiy dispersantlarga polietilen mumi kiradi, polipropilen mumi, stearin kislotasi, kaltsiy stearati, va hokazo. Dispersantlarning qo'shilishi masterbatchning tarqalishini sezilarli darajada yaxshilashi mumkin, mahsulotlarning bir xil ranglanishini ta'minlash, va ekstruziya uskunasining eskirishini kamaytirish.
• Muvofiqlashtiruvchilar: Pigmentlar va tashuvchilar o'rtasidagi muvofiqlikni yaxshilash uchun ishlatiladi, va masterbatch va maqsadli plastik xom ashyo o'rtasida. Masalan, tashuvchi va maqsadli plastmassa zaif muvofiqlikka ega bo'lganda (PE tashuvchisi va PA plastmassa kabi), moslashtiruvchilar (maleik angidrid payvandlangan polietilen kabi) ular orasidagi bog'lanish kuchini oshirish uchun qo'shilishi mumkin, qayta ishlash jarayonida masterbatch va maqsadli plastmassani ajratishdan saqlaning, va mahsulotlarning mexanik xususiyatlarini yaxshilash.
• Issiqlik stabilizatorlari: Pigmentlarning parchalanishini oldini olish uchun ishlatiladi, yuqori haroratli ekstruziyani qayta ishlash jarayonida tashuvchilar va maqsadli plastmassalar. Umumiy issiqlik stabilizatorlari qo'rg'oshin tuzlarini o'z ichiga oladi, kaltsiy-sink stabilizatorlari, organik qalay stabilizatorlari, va hokazo., ishlov berish harorati va atrof-muhitni muhofaza qilish talablariga muvofiq tanlanadi.
• Yorug'lik stabilizatorlari va antioksidantlar: Masterbatch va rangli plastik mahsulotlarning ob-havoga chidamliligi va qarish qarshiligini yaxshilash uchun ishlatiladi, quyosh nuri va kislorod ta'sirida mahsulotlarning rangi o'zgarishini va ish faoliyatini yomonlashishini oldini olish, va mahsulotlarning xizmat muddatini uzaytiradi.
• Moylash materiallari: Materiallar va ekstruziya uskunalari orasidagi ishqalanishni kamaytirish uchun ishlatiladi (vint, bochka, o'lik bosh), qayta ishlash suyuqligini yaxshilash, energiya sarfini kamaytirish, va materialning uskunaga yopishib qolishidan saqlaning, bu ekstruziyani qayta ishlashning silliq rivojlanishiga yordam beradi.

1.2.4 Masterbatchning ishlash printsipi

Masterbatchning ishlash printsipi tashuvchida yuqori konsentratsiyali pigmentlarning bir xil tarqalishiga asoslangan.. Plastmassa mahsulotlarini qayta ishlash jarayonida, oz miqdorda masterbatch (odatda 1%-5%) rangsiz plastik xom ashyo bilan aralashtiriladi. Ekstruziya yoki qarshi kalıplama paytida yuqori harorat va kesish kuchi ta'sirida, masterbatchning tashuvchisi eriydi va maqsadli plastik xom ashyo bilan aralashadi, va bir xil tarqalgan pigmentlar chiqariladi va maqsadli plastik matritsada bir tekis taqsimlanadi, Shunday qilib, plastik mahsulotlarni bo'yash maqsadiga erishish. Ushbu jarayonning kaliti shundaki, masterbatchdagi pigmentlar aglomeratsiyasiz bir tekis taqsimlanishi kerak., aks holda rangli dog'lar paydo bo'ladi, rangli mahsulotlardagi rang farqi va boshqa nuqsonlar.

1.3 Common Classification of Masterbatch

Masterbatch can be divided into different types according to different classification standards, such as coloring type, carrier type, application field, functional type, va hokazo. The correct classification helps to better understand the performance characteristics and processing requirements of masterbatch, and select appropriate extrusion equipment and processing techniques.

1.3.1 Classification by Coloring Type

According to the type of coloring component, masterbatch can be divided into color masterbatch, white masterbatch and black masterbatch.

• Rangli Masterbatch: The most common type of masterbatch, which uses organic or inorganic pigments of various colors (such as red, yellow, blue, green, orange) as coloring components, and is used for coloring plastic products of various colors. The tinting strength, rangning yorqinligi va rangli masterbatchning dispersligi uning sifatini o'lchash uchun asosiy ko'rsatkichlardir.
• Oq Masterbatch: Titan dioksididan foydalanish (TiO2) asosiy rang beruvchi komponent sifatida, u plastik mahsulotlarni oqartirish uchun yoki ochiq rangli masterbatch uchun asosiy rang sifatida ishlatiladi. Oqlik, oq masterbatchning qoplovchi quvvati va dispersligi asosiy ko'rsatkichlardir. Titan dioksidi yuqori qattiqlikka ega, ekstruziya uskunasining aşınma qarshiligiga yuqori talablarga ega.
• Qora Masterbatch: Asosiy rang berish komponenti sifatida qora ugleroddan foydalanish, plastik mahsulotlarni qora rangga bo'yash uchun ishlatiladi. Uglerod qorasi yaxshi UV qarshilik va ob-havoga chidamliligiga ega, va shuningdek, plastik mahsulotlarning mexanik xususiyatlarini yaxshilashi mumkin. Uglerod qorasining tarqalishi qora masterbatch sifatining kalitidir. Poor dispersibility will cause black spots and streaks in products.

1.3.2 Classification by Carrier Type

According to the type of carrier, masterbatch can be divided into PE masterbatch, PP masterbatch, PVC masterbatch, PA masterbatch, PET masterbatch, va hokazo.

• PE Masterbatch: Using PE as the carrier, it is suitable for coloring PE plastic products (such as PE films, PE pipes, PE injection molding parts). It has good compatibility with PE raw materials, good processing fluidity and uniform coloring.
• PP Masterbatch: Using PP as the carrier, it is suitable for coloring PP plastic products (such as PP fibers, PP injection molding parts, PP sheets). It has good heat resistance and is suitable for high-temperature processing of PP.
• PVC Masterbatch: Using PVC as the carrier, it is suitable for coloring PVC plastic products (such as PVC pipes, PVC profiles, PVC films). It needs to be matched with PVC heat stabilizers to avoid PVC decomposition during processing.
• Engineering Plastic Masterbatch: Using engineering plastics (PA, Kompyuter, PBT, va hokazo.) as carriers, it is suitable for coloring engineering plastic products (such as automotive parts, electrical components). It has good heat resistance and compatibility with engineering plastics, and has high requirements on extrusion processing equipment.

1.3.3 Classification by Application Field

According to the application field of masterbatch, it can be divided into fiber masterbatch, film masterbatch, blow molding masterbatch, extrusion masterbatch, injection molding masterbatch, va hokazo., which correspond to the five major application fields of masterbatch.

• Fiber Masterbatch: Used for coloring chemical fibers (such as polyester fiber, nylon fiber), which is used in carpets, textiles, cushions and other products. It requires high dispersibility and color fastness, and no color fading during spinning and weaving.
• Film Masterbatch: Used for coloring plastic films (such as shopping bags, casting films, multi-layer films), which requires high transparency and uniform coloring, and no color spots or streaks on the film surface.
• Blow Molding Masterbatch: Used for coloring blow molding products (such as medical and cosmetic containers, lubricating oil and paint containers), which requires good processing fluidity and uniform coloring, and no deformation or color difference of the container.
• Extrusion Masterbatch: Used for coloring extrusion products (such as sheets, quvurlar, simlar va kabellar), which requires good dimensional stability and uniform coloring, and no color difference on the product surface.
• Injection Molding Masterbatch: Used for coloring injection molding products (such as automotive parts, electronic products, qurilish materiallari, maishiy texnika, mebel, o'yinchoqlar), bu yuqori disperslik va barqaror ishlashni talab qiladi, va mahsulot partiyalari o'rtasida rang farqi yo'q.

1.3.4 Funktsional turi bo'yicha tasniflash

Masterbatchning qo'shimcha funktsiyalariga ko'ra, uni oddiy masterbatchga bo'lish mumkin (faqat rang berish funktsiyasi) va funktsional masterbatch (rang berish + qo'shimcha funktsiyalar). Funktsional masterbatch - sanoatning rivojlanish tendentsiyasi, va keng tarqalgan turlari olovga chidamli masterbatchni o'z ichiga oladi, antistatik masterbatch, antibacterial masterbatch, UV-resistant masterbatch, qattiqlashtiruvchi masterbatch, va hokazo. Funktsional masterbatch oddiy masterbatch asosida mos keladigan funktsional qo'shimchalarni qo'shishni talab qiladi., ekstruziya uskunalarini aralashtirish va tarqatish ta'siriga nisbatan yuqori talablarga ega.

2. Masterbatchning asosiy qayta ishlash texnologiyasi: Ikki vintli ekstruziya texnologiyasi

Masterbatchni qayta ishlash asosan aralashtirishni o'z ichiga oladi, ekstruziya, sovutish, granulyatsiya va boshqa jarayonlar, Ular orasida ikki vintli ekstruziya texnologiyasi masterbatch aralashtirish va granulyatsiya qilishning asosiy texnologiyasidir.. Bir vintli ekstruziya texnologiyasi bilan solishtirganda, Ikki vintli ekstruziya texnologiyasi kuchli aralashtirish va tarqatish qobiliyatining afzalliklariga ega, haroratni aniq nazorat qilish, qisqa yashash vaqti, yuqori ishlab chiqarish samaradorligi va xom ashyoga kuchli moslashuvchanlik, masterbatchni qayta ishlashning asosiy muammolarini samarali hal qila oladi (pigment aglomeratsiyasi kabi, notekis aralashtirish, past ishlab chiqarish samaradorligi) va masterbatch mahsulotlari sifatini ta'minlash.

Masterbatch aralashtirish ikki vintli ekstruderlarning asosiy ilovalaridan biridir. Masterbatchning sifati to'g'ridan-to'g'ri ikkita vintli ekstruderning ishlashi va ishlov berish jarayonining oqilonaligi bilan belgilanadi.. Ikki vintli ekstruderlar uchun masterbatchni qayta ishlashning asosiy talablari: kuchli aralashtirish va tarqatish ta'siri (pigmentlarning bir xil tarqalishini ta'minlash), haroratni aniq nazorat qilish (pigment parchalanishini va tashuvchining degradatsiyasini oldini olish uchun), tegishli kesish kuchi (pigment zarralarini shikastlamasdan pigment aglomeratlarini buzish), yuqori ishlab chiqarish samaradorligi (ommaviy ishlab chiqarish ehtiyojlarini qondirish uchun) va yaxshi aşınma qarshilik (titan dioksidi va uglerod qora kabi yuqori qattiqlikdagi pigmentlarning aşınmasına moslashish).

2.1 Masterbatchni qayta ishlashdagi qiyinchiliklar va ekstruziya uskunalariga qo'yiladigan talablar

Ikki vintli ekstruziya texnologiyasi masterbatchni qayta ishlash uchun mos bo'lsa-da, masterbatch tarkibining o'ziga xosligi tufayli (yuqori pigment tarkibi, pigmentlarning oson aglomeratsiyasi) va qayta ishlash talablari (bir xil dispersiya, stable performance), haqiqiy qayta ishlashda hali ko'p qiyinchiliklar mavjud. Asosiy ishlov berish qiyinchiliklari va ekstruziya uskunalari uchun mos talablar quyidagilardir:

2.1.1 Pigment aglomeratsiyasi va zaif dispersiya

Pigmentlar (ayniqsa titanium dioksid va uglerod qora kabi noorganik pigmentlar) kuchli qutblanish va katta o'ziga xos sirt maydoniga ega, saqlash va aralashtirish jarayonida katta zarrachalarga oson aglomeratsiya qilinadi. Ekstruziyani qayta ishlash jarayonida aglomeratlarni to'liq sindirish va tarqatish mumkin bo'lmasa, masterbatch zaif dispersiyaga ega bo'ladi, va rangli plastmassa mahsulotlari rangli dog'larga ega bo'ladi, rangli chiziqlar va notekis rang berish, bu mahsulot sifatiga jiddiy ta'sir qiladi. Bu masterbatchni qayta ishlashda eng keng tarqalgan va asosiy qiyinchilik.

Bu ekstruziya uskunasining kuchli aralashtirish va tarqatish qobiliyatiga va tegishli kesish kuchiga ega bo'lishini talab qiladi. Ikki vintli ekstruder bir-biriga bog'langan birgalikda aylanadigan tuzilmani qabul qilishi kerak, va vint aylanish jarayonida kuchli kesish kuchi va yoğurma kuchini yaratish uchun etarli miqdorda aralashtirish elementlari va kesish elementlari bilan jihozlangan bo'lishi kerak., pigment aglomeratlarini to'liq sindirishi va pigmentlarni tashuvchida bir tekis taqsimlanishi mumkin.. Bunga qo'chimcha, vida tezligi va ekstruziya bosimi har xil turdagi pigmentlar va masterbatch konsentratsiyasiga moslashish uchun sozlanishi kerak.

2.1.2 Haddan tashqari qizib ketishdan kelib chiqadigan pigmentning parchalanishi va tashuvchining degradatsiyasi

Ko'pgina pigmentlar (ayniqsa organik pigmentlar) past issiqlik qarshiligiga ega, va tashuvchi (such as PE, PP) ma'lum bir harorat qarshiligi chegarasiga ham ega. Ekstruziya harorati juda yuqori bo'lsa yoki ekstruderda materialning yashash muddati juda uzoq bo'lsa, pigment parchalanadi (natijada rangning xiralashishiga olib keladi, rangsizlanish), va tashuvchisi yomonlashadi (masterbatchning mexanik xususiyatlarining pasayishiga olib keladi). Bu masterbatchni qayta ishlashda yana bir asosiy qiyinchilik.

Bu ekstruziya uskunasining haroratni aniq nazorat qilish qobiliyatiga va qisqa yashash vaqtiga ega bo'lishini talab qiladi. Ekstruderning barrelini bir nechta haroratni nazorat qilish bo'limlariga bo'lish kerak, va har bir bo'limning harorati optimal diapazonda aniq nazorat qilinishi kerak (oddiy masterbatch uchun odatda 150-220 ℃, 200-280℃ muhandislik plastik masterbatch uchun), ± 1 ℃ haroratni nazorat qilish aniqligi bilan. Ekstruderda materialning yashash vaqtini qisqartirish uchun vida tuzilishi optimallashtirilishi kerak (odatda 1-3 daqiqa), material va yuqori harorat o'rtasidagi uzoq muddatli aloqadan qochish.

2.1.3 Yuqori qattiqlikdagi pigmentlar sabab bo'lgan vint va barrelning aşınması

Titan dioksidi va uglerod qora kabi noorganik pigmentlar yuqori qattiqlikka ega (Mohs qattiqligi 5-7), ekstruziyani qayta ishlash jarayonida ekstruderning vintini va barrelini jiddiy aşınmaya olib keladi. Agar vint va barrel yomon aşınma qarshilikka ega bo'lsa, ular tezda kiyiladi, buning natijasida ekstruderning kesish kuchi va aralashtirish quvvati kamayadi, masterbatchning tarqalishiga ta'sir qiladi va uskunaning ishlash muddatini qisqartiradi.

Bu ekstruderning vintini va barrelini yuqori sifatli aşınmaya bardoshli materiallardan tayyorlanishini va ilg'or ishlab chiqarish texnologiyasi bilan qayta ishlanishini talab qiladi.. Masalan, vint va barrel import qilingan aşınmaya bardoshli qotishma po'latdan tayyorlanishi mumkin, va bimetalik kompozit ishlov berish yoki lazer qoplamasi bilan ishlov berish, vida va barrelning aşınma qarshiligi va korroziyaga chidamliligini sezilarli darajada oshirishi mumkin, va yuqori qattiqlik pigmentlari bilan masterbatchni qayta ishlashga moslash.

2.1.4 Partiyalar orasidagi mahsulot sifatining beqarorligi

Masterbatchni qayta ishlash turli parametrlarni qattiq nazorat qilishni talab qiladi (formula nisbati kabi, aralashtirish vaqti, ekstruziya harorati, vida tezligi, oziqlantirish tezligi). Parametrlar o'zgarib tursa, masterbatch sifati (konsentratsiya kabi, tarqalish qobiliyati, rang berish kuchi) beqaror bo'ladi, rangli mahsulotlar partiyalari o'rtasidagi rang farqiga olib keladi, ishlab chiqaruvchining obro'siga ta'sir qiladi.

Bu ekstruziya uskunasining aqlli boshqaruv qobiliyati va barqaror ishlashini talab qiladi. Ekstruder PLC aqlli boshqaruv tizimi bilan jihozlangan bo'lishi kerak, oziqlantirish tezligini aniq nazorat qilishni amalga oshirishi mumkin, vida tezligi, ekstruziya harorati va boshqa parametrlar, and store multiple sets of formula parameters. When producing different batches of masterbatch, faqat mos keladigan parametrlarni chaqirish kerak, takroriy nosozliklarni tuzatishdan qochish, ensuring the stability of product quality between batches.

2.1.5 High Requirements on Processing Fluidity

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

This requires the extrusion equipment to have strong conveying capacity and adjustable shear force. The twin-screw extruder should adopt a reasonable screw pitch, lead and compression ratio design, and the screw should be equipped with sufficient conveying elements to ensure the smooth conveying of materials. Bunga qo'chimcha, materialning qayta ishlash suyuqligini yaxshilash uchun ekstruziya harorati mos ravishda sozlanishi mumkin, va materiallar orasidagi ishqalanishni kamaytirish uchun moylash materiallari qo'shilishi mumkin.

2.2 Masterbatch egizak vintli ekstruziyaning ishlash printsipi va jarayon oqimi

Masterbatchning ikkita vintli ekstruziya jarayoni murakkab jismoniy aralashtirish jarayonidir, Bu asosan xom ashyoni oldindan tozalashni o'z ichiga oladi, oldindan aralashtirish, oziqlantirish, erish, aralashtirish va kesish, ekstruziya, sovutish, granulyatsiya, skrining va qadoqlash. Asosiy maqsad pigmentlarni bir xilda tarqatishdir, yuqori sifatli masterbatch granulalarini hosil qilish uchun tashuvchilar va qo'shimchalar. Muayyan ish printsipi va jarayon oqimi quyidagicha:

2.2.1 Xom ashyoni oldindan tayyorlash

Xom ashyoni oldindan tayyorlash masterbatch ekstruziyasini qayta ishlashning asosidir, aralashtirish effekti va mahsulot sifatiga bevosita ta'sir qiladi. The raw materials of masterbatch mainly include pigments/dyes, carriers, qo'shimchalar (dispersants, moslashtiruvchilar, heat stabilizers, va hokazo.). The pretreatment steps are as follows:

• Drying Treatment: Some pigments (such as organic pigments) and carriers (such as PA, PET) have high water absorption. If the moisture content is too high, it will cause bubbles, agglomeration and other defects in the masterbatch during extrusion processing, and even cause hydrolytic degradation of the carrier. Therefore, the raw materials must be dried before processing. The drying temperature and time are determined according to the type of raw material: masalan, organic pigments are dried at 60-80℃ for 2-4 soat, PE/PP carriers are dried at 80-100℃ for 3-5 soat, and PA carriers are dried at 100-120℃ for 6-8 soat. The moisture content of the dried raw materials should be controlled below 0.1%.
• Crushing and Sieving: For pigments with large particle size (such as titanium dioxide agglomerates) and carriers with uneven particle size, crushing and sieving treatment should be carried out to ensure the uniformity of raw materials. The particle size of the crushed raw materials should be controlled at 20-40 to'r, which is conducive to the uniform mixing of raw materials and the breaking of pigment agglomerates during extrusion.
• Nopoklikni olib tashlash: The raw materials may contain impurities (such as metal particles, stones, chang) during production and transportation. Impurities not only affect the quality of the masterbatch, but also wear the screw and barrel of the extruder, and even cause equipment blockage. Therefore, the raw materials must be filtered and removed before use, using a filter screen with appropriate mesh size to remove impurities.

2.2.2 Oldindan aralashtirish

Oldindan aralashtirish masterbatchning aralashtirish va tarqatish ta'sirini yaxshilashning asosiy bosqichidir. Formula nisbati bo'yicha, quritilgan, ezilgan va nopoklikdan tozalangan pigmentlar, tashuvchilar va qo'shimchalar oldindan aralashtirish uchun yuqori tezlikda ishlaydigan mikserga solinadi. Oldindan aralashtirishning maqsadi pigmentlar va qo'shimchalarning tashuvchi zarrachalar yuzasiga bir xilda yopishishini ta'minlashdir., dastlabki aralashmani hosil qiling, va ekstruziya paytida bir xil dispersiya uchun poydevor qo'ying.

Oldindan aralashtirishning asosiy parametrlari aralashtirish tezligidir, aralashtirish vaqti va aralashtirish harorati. Aralash tezligi odatda 800-1200 rpm, aralashtirish vaqti 5-10 daqiqa, va aralashtirish harorati 40-60 ℃ da nazorat qilinadi. Tegishli aralashtirish harorati qo'shimchalarning yopishishini yaxshilashi mumkin (dispersantlar kabi) tashuvchiga va pigmentlarga, bir xil aralashtirishni targ'ib qilish. Yuqori pigmentli masterbatch uchun (kabi 50% yuqorida), oldindan aralashtirish vaqti mos ravishda uzaytirilishi mumkin, va pigmentlarning tarqalishini yaxshilash uchun birinchi navbatda oz miqdorda dispersant qo'shilishi mumkin. Oldindan aralashtirilgandan keyin, aralashmaning rangi bir xil bo'lishi kerak, aniq pigment aglomeratlari va qo'shimcha zarralarsiz.

2.2.3 Oziqlantirish va tashish

Oldindan aralashtirilgan aralash vintli oziqlantiruvchi yoki tasmali oziqlantiruvchi orqali egizak vintli ekstruderning oziqlantiruvchi idishiga yuboriladi.. Ekstruderning oziqlantirish moslamasi odatda chastotani o'zgartirish tezligini tartibga solish funktsiyasi bilan jihozlangan, Materiallar ekstruziya bo'shlig'iga barqaror va bir xilda kirishini ta'minlash uchun oziqlantirish tezligini vint tezligi va ekstruziya tezligiga qarab sozlashi mumkin., material to'planishidan yoki etarli darajada oziqlantirishdan qochish.

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

2.2.4 Melting, 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, vintlardek va barrel ta'sirida materiallar asta-sekin siqiladi, va ekstruziya bo'shlig'idagi bosim asta-sekin o'sib boradi (odatda 5-12MPa).

Xuddi o'sha payt, materiallar vintlar va barrel orasidagi nisbiy harakat natijasida hosil bo'lgan kuchli kesish kuchi va ishqalanish kuchiga duchor bo'ladi., shuningdek, vida parvozlari o'rtasida. Kesish kuchi va ishqalanish kuchi pigmentlarning aglomeratlarini to'liq sindirishi mumkin, pigmentlarni eritilgan tashuvchida bir xilda tarqatish, va pigment o'rtasidagi termoyadroviy va moslikni rag'batlantiradi, tashuvchi va qo'shimchalar. Ishqalanish kuchi ham ma'lum miqdorda issiqlik hosil qilishi mumkin, barrelning tashqi isishi bilan birlashtirilgan (elektr isitish yoki bug 'isitish) tashuvchini asta-sekin eritib, plastiklashtirish uchun.

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

The screw of the twin-screw extruder adopts a modular design, turli vida elementlarini erkin birlashtira oladigan (such as conveying elements, mixing elements, shearing elements) masterbatch turiga ko'ra. Masalan, yuqori pigmentli tarkibga va oson aglomeratsiyaga ega bo'lgan masterbatchni qayta ishlashda, aralashtirish va tarqatish effektini kuchaytirish uchun ko'proq aralashtirish elementlari va kesish elementlarini sozlash mumkin; masterbatchni yaxshi suyuqlik bilan qayta ishlashda, ishlab chiqarish samaradorligini oshirish uchun ko'proq tashish elementlarini sozlash mumkin.

2.2.5 Ekstruziya va shakllantirish

To'liq erigan, aralash va dispers material vintlar bilan ekstruderning qolip boshiga suriladi. Masterbatch ekstruderining kallasi odatda bir nechta dumaloq o'lik teshiklari bilan jihozlangan (qolip teshiklarining soni va o'lchami masterbatchning zarracha hajmiga qarab belgilanadi). Uzluksiz chiziq shaklidagi yarim tayyor mahsulotlarni hosil qilish uchun material yuqori tezlikda qolip boshidan chiqariladi. (Ipning diametri odatda 2-5 mm, mijozning ehtiyojlariga qarab sozlanishi mumkin).

Qolib boshining harorati homogenlashtiruvchi qismdan bir oz pastroq, haddan tashqari harorat tufayli materialning parchalanishiga yo'l qo'ymaslik va chiziqning shakllanish ta'sirini ta'minlashi mumkin. Ekstruziya tezligi masterbatch turiga va zarracha hajmi talabiga qarab boshqariladi, odatda 1-3 m / min oralig'ida. Ekstruziya bosimi barqaror bo'lishi kerak (±0,5MPa ichida tebranish), Ipning bir xil diametrini va masterbatch sifatining mustahkamligini ta'minlashi mumkin.

2.2.6 Sovutish va qattiqlashuv

Ekstrudirovka qilingan chiziq shaklidagi yarim tayyor mahsulotlar tez sovutish va qotib qolish uchun sovutish moslamasiga yuboriladi.. The cooling method for masterbatch is usually water tank cooling, and the cooling water temperature is controlled at 20-30℃. The length of the cooling water tank is 3-5 meters, and the cooling time is 2-4 daqiqa. Rapid cooling can make the strip solidify quickly, maintain the shape and size of the strip, and avoid deformation and adhesion.

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

2.2.7 Cutting and Granulation

After cooling and solidification, tasma donador masterbatch mahsulotlarini hosil qilish uchun kesish uchun granulyatorga yuboriladi. Granulyator aylanadigan pichoq va mahkamlangan pichoq bilan jihozlangan, va kesish tezligi sozlanishi (umuman 500-1000 rpm). Masterbatchning zarracha o'lchami kesish tezligini va chiziqni tashish tezligini sozlash orqali boshqariladi. Masterbatchning umumiy zarracha hajmi 2-5 mm (uzunligi va diametri asosan bir xil), keyinchalik foydalanish paytida plastik xom ashyo bilan aralashtirish uchun qulay.

Granulyator sifatsiz zarralarni olib tashlash uchun skrining qurilmasi bilan jihozlangan bo'lishi kerak (juda katta kabi, juda kichik, aglomeratsiyalangan yoki singan zarralar). Malakali zarralar keyingi jarayonga kiradi, va malakasiz zarralar eziladi va qayta ishlanadi (quritish va oldindan aralashtirishdan keyin, ular qayta ekstrudirovka qilinadi va granullanadi).

2.2.8 Skrining, Inspection and Packaging

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

After screening, the masterbatch needs to undergo quality inspection. The inspection items mainly include: rang (bir xillik, consistency with the standard sample), tarqalish qobiliyati (observed by microscope or test piece coloring), concentration (tinting strength test), namlik miqdori, particle size distribution, va hokazo. Only the masterbatch that meets the quality standards can be packaged.

The packaging of masterbatch adopts sealed and moisture-proof packaging (such as plastic woven bags with inner plastic film, aluminum foil bags), and the packaging weight is usually 25kg/bag or 50kg/bag. The packaging bag is marked with the product name, model, rang, concentration, carrier type, production date, shelf life, manufacturer and other information. The packaged masterbatch should be stored in a dry, cool and ventilated warehouse, avoiding direct sunlight and moisture, and the shelf life is generally 6-12 oylar.

2.3 Key Factors Affecting Masterbatch Twin-Screw Extrusion Effect

The effect of twin-screw extrusion directly affects the quality of masterbatch (tarqalish qobiliyati, rang berish kuchi, stability). There are many factors affecting the extrusion effect, mainly including raw material characteristics, formula ratio, premixing effect, extrusion parameters and equipment performance. Mastering these key factors and making scientific adjustments can ensure the stability of the extrusion effect and the consistency of product quality.

2.3.1 Raw Material Characteristics

The type, zarracha hajmi, namlik miqdori va xom ashyoning tozaligi ekstruziya ta'siriga katta ta'sir ko'rsatadi. Pigmentlar uchun, zarracha hajmi bir xil va nozik bo'lishi kerak (20-40 to'r), va aglomeratsiya darajasi past bo'lishi kerak; organik pigmentlar zaif issiqlikka chidamliligiga ega, shuning uchun ekstruziya harorati qat'iy nazorat qilinishi kerak; noorganik pigmentlar yuqori qattiqlikka ega, shuning uchun ekstruder yaxshi aşınma qarshilikka ega bo'lishi kerak. Tashuvchilar uchun, erish nuqtasi va ishlov berish harorati maqsadli plastik xom ashyo bilan mos kelishi kerak, va pigmentlar bilan muvofiqligi yaxshi bo'lishi kerak. Qo'shimchalar uchun, turi va dozasi oqilona bo'lishi kerak, va tashuvchilar va pigmentlar bilan muvofiqligi yaxshi bo'lishi kerak.

Bunga qo'chimcha, xom ashyoning namligi quyida qat'iy nazorat qilinishi kerak 0.1%; agar namlik juda yuqori bo'lsa, it will cause bubbles and agglomeration in the masterbatch. The purity of raw materials is also very important; impurities in raw materials will not only affect the product quality, but also wear the screw and barrel of the extruder.

2.3.2 Formula Ratio

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

The dosage of dispersants is generally 1%-5% of the pigment dosage; too little dispersant will lead to poor dispersibility of pigments, va juda ko'p dispersant masterbatch va rangli mahsulotlarning mexanik xususiyatlariga ta'sir qiladi. Boshqa qo'shimchalarning dozasi (moslashtiruvchilar, heat stabilizers, moylash materiallari) umumiy hisoblanadi 0.5%-3%, masterbatch turiga va qayta ishlash talablariga muvofiq sozlanishi kerak. Formulalar nisbati qat'iy nazorat qilinishi kerak, va xatolik ±1% ichida bo'lishi kerak, partiyalar orasidagi mahsulot sifatining izchilligini ta'minlash.

2.3.3 Oldindan aralashtirish effekti

Premixing ekstruziyani qayta ishlashning asosidir. Oldindan aralashtirishning bir xilligi ekstruziya paytida pigmentlarni aralashtirish va tarqatish ta'siriga bevosita ta'sir qiladi. Agar oldindan aralashtirish notekis bo'lsa, pigmentlarni tashuvchining yuzasiga bir xilda yopishtirish mumkin emas, pigmentlarning mahalliy aglomeratsiyasiga olib keladi, ekstruziya paytida materiallarni notekis aralashtirish, va mahsulot dispersiyasini kamaytiradi.

Oldindan aralashtirish effektini ta'minlash uchun, it is necessary to control the mixing speed (800-1200 rpm), aralashtirish vaqti (5-10 daqiqa) and mixing temperature (40-60℃). Yuqori pigmentli masterbatch uchun, oldindan aralashtirish vaqti mos ravishda uzaytirilishi mumkin, and the dispersant can be added first and mixed with the pigment, then mixed with the carrier and other additives. Bunga qo'chimcha, the premixed mixture should be inspected; if there are obvious pigment agglomerates, it should be crushed and remixed.

2.3.4 Extrusion Parameters

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

• Screw Speed: The screw speed of twin-screw extruders for masterbatch processing generally ranges from 200 uchun 800 rpm. 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 pigments, and the higher the production efficiency. Biroq, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete melting of the carrier, insufficient mixing of materials, and uneven dispersibility; if the screw speed is too low, the shear force and friction force are insufficient, the pigment agglomerates cannot be fully broken, and the production efficiency is low.
• The screw speed should be adjusted according to the type of masterbatch: for masterbatch with high pigment content and easy agglomeration (such as black masterbatch, white masterbatch), a higher screw speed (500-800 rpm) is needed to ensure the uniform dispersion of pigments; for masterbatch with organic pigments (poor heat resistance), a moderate screw speed (300-500 rpm) is needed to avoid overheating and pigment decomposition.
• Extrusion Temperature: Ekstruziya harorati tashuvchining erishi va pigmentning barqarorligini ta'minlashning kalitidir.. Barrel va qolip boshining har bir qismining harorati masterbatch turiga qarab aniq nazorat qilinishi kerak. (carrier type, pigment type). Oziqlantirish qismining harorati pastroq (xom ashyoni quritish haroratidan bir oz yuqoriroq), Bu asosan materiallarning pishishiga yo'l qo'ymaslik va silliq oziqlantirishni ta'minlashdir; erish qismining harorati o'rtacha, bu asosan tashuvchining erishi va plastifikatsiyasini rag'batlantirishdir; aralashtirish qismining harorati yuqoriroq, Bu asosan kesish va aralashtirish effektini kuchaytirishdir, va pigmentlarning bir xil tarqalishiga yordam beradi; homogenlashtiruvchi qismning harorati aralashtirish qismidan bir oz pastroq, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, which is to ensure the shaping effect of the strip.
• The temperature control precision should reach ±1℃. Masalan, when processing PP masterbatch with organic pigments, the temperature of each section is: feeding section 110-130℃, melting section 170-190℃, mixing section 180-200℃, homogenizing section 170-190℃, die head section 160-180℃. If the temperature is too high, the pigment will decompose and the carrier will degrade; if the temperature is too low, the carrier will not be fully melted, and the pigment cannot be uniformly dispersed.
• Extrusion Pressure: The extrusion pressure of masterbatch twin-screw extrusion generally ranges from 5 to 12MPa. The pressure in the extrusion cavity is mainly determined by the compression ratio of the screw, the die hole size and the screw speed. The higher the extrusion pressure, the better the mixing and dispersing effect of materials, and the denser the strip. Biroq, if the pressure is too high, 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 strip is loose, and the dispersibility is poor.
• The extrusion pressure should be adjusted according to the type of masterbatch and the die head size: for masterbatch with high pigment content and poor fluidity, a higher extrusion pressure is needed; for masterbatch with good fluidity, a moderate extrusion pressure is sufficient. Ekstruziya bosimi barqaror bo'lishi kerak, and the fluctuation should be within ±0.5MPa, to ensure the uniform diameter of the strip and the consistency of the masterbatch quality.

2.3.5 Equipment Performance

The performance of the twin-screw extruder directly determines the extrusion effect. The key performance indicators of the extruder include mixing and dispersing capacity, haroratni nazorat qilish aniqligi, aşınma qarshilik, conveying capacity and intelligent control capacity. Zhuoyue ekstruderlarining to'liq seriyasi (HTS BASIC/PLUS/SUPER, ZTE, HTE) masterbatch qayta ishlash uchun maxsus mo'ljallangan, with excellent performance in these aspects, which can effectively meet the processing needs of different types of masterbatch.

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

Zhuoyue has long been engaged in the research, development and production of high-performance twin-screw extruders, and has accumulated rich experience in the field of masterbatch processing. According to the processing characteristics of masterbatch (yuqori pigment tarkibi, pigmentlarning oson aglomeratsiyasi, strict temperature control requirements, high wear resistance requirements) and the diverse needs of manufacturers (different production scales, different masterbatch types, different application fields), Zhuoyue has launched a full series of extruders suitable for masterbatch processing, including HTS BASIC series, HTS PLUS seriyali, HTS SUPER series, ZTE series and HTE series. Each series has its own performance characteristics and targeted adaptation scenarios, which can provide personalized and efficient processing solutions for masterbatch manufacturers of different scales.

3.1 Core Advantages of Zhuoyue’s Extruders for Masterbatch Processing

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

3.1.1 Excellent Mixing and Dispersing Effect

The core requirement of masterbatch processing is the uniform dispersion of pigments. Zhuoyuening barcha egizak vintli ekstruderlari bir-biriga bog'langan birgalikda aylanadigan tuzilmani qabul qiladi, oqilona vida qadami bilan, lead and compression ratio design. The intermeshing and rotating of the twin screws can generate strong shear force and kneading force, which can fully break the agglomerates of pigments (even small agglomerates of 100μm above), and make the pigments uniformly dispersed in the carrier. The mixing uniformity of the extruders can reach more than 95%, which is much higher than that of ordinary twin-screw extruders (85%-90%).

Bunga qo'chimcha, the screws of all series of extruders adopt a modular design, which can freely combine different types of screw elements (conveying elements, mixing elements, shearing elements) masterbatch turiga ko'ra (such as color masterbatch, white masterbatch, black masterbatch) and pigment characteristics. Masalan, when processing black masterbatch with carbon black (easy agglomeration), aralashtirish va tarqatish effektini kuchaytirish uchun ko'proq aralashtirish elementlari va kesish elementlarini sozlash mumkin; when processing color masterbatch with organic pigments (poor heat resistance), more conveying elements and fewer shearing elements can be configured to shorten the residence time and avoid pigment decomposition.

3.1.2 Haroratni aniq nazorat qilish, Avoiding Pigment Decomposition

Masterbatch processing has strict requirements on temperature control, and the temperature fluctuation must be controlled within ±1℃ to avoid pigment decomposition and carrier degradation. All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, which is composed of high-precision temperature sensors, heating elements and cooling elements. The barrel is divided into 4-6 independent temperature control sections, va har bir bo'limning harorati real vaqtda aniq sozlanishi va nazorat qilinishi mumkin.

Haroratni nazorat qilish tizimi real vaqt rejimida monitoring va signalizatsiya funktsiyasi bilan jihozlangan: har qanday uchastkaning harorati belgilangan diapazondan oshsa, tizim o'z vaqtida signal beradi, va haroratni belgilangan diapazonga qaytarish uchun isitish quvvatini avtomatik ravishda sozlang yoki sovutish tizimini ishga tushiring. Bunga qo'chimcha, ekstruderning barreli ikki qavatli ko'ylagi dizaynini qabul qiladi, tez isitish va sovutishni amalga oshirishi mumkin, va haroratni nazorat qilishning javob tezligini yaxshilang. Qolib boshi, shuningdek, mustaqil haroratni nazorat qilish moslamasi bilan jihozlangan, bu qolip boshining bir xil haroratini va chiziqning barqaror shakllanishini ta'minlaydi.

3.1.3 Yuqori aşınma qarshilik, Uzoq xizmat muddati

Titan dioksidi va uglerod qora kabi noorganik pigmentlar yuqori qattiqlikka ega, which will cause serious wear to the screw and barrel of the extruder during processing. Zhuoyue’s extruders adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components.

The screws and barrels of HTS PLUS series, HTS SUPER series and HTE series are made of imported wear-resistant alloy steel (such as 38CrMoAlA), va bimetalik kompozit ishlov berish yoki lazer qoplamasi bilan ishlov berish. The surface hardness of the screws and barrels can reach ≥65 HRC (HTS PLUS seriyali, HTE seriyali) and ≥70 HRC (HTS SUPER series), which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by high-hardness pigments. The service life of the screws and barrels is 2-3 oddiy ekstruderlarga qaraganda ko'proq, reducing the frequency of component replacement and the maintenance cost of the equipment.

HTS BASIC va ZTE seriyalarining vintlari va bochkalari nitridlash bilan ishlov berilgan yuqori sifatli aşınmaya bardoshli qotishma po'latdan yasalgan., va sirt qattiqligi ≥60 HRC ga yetishi mumkin, oddiy masterbatchning qayta ishlash ehtiyojlarini qondira oladi (pigment miqdori ≤50%) va o'rtacha xarajat ko'rsatkichiga ega.

3.1.4 Yuqori ishlab chiqarish samaradorligi, Energiyani tejash va atrof-muhitni muhofaza qilish

Zhuoyue ekstruderlari yuqori momentli vites qutisini va optimallashtirilgan vintli strukturani qabul qiladi, kuchli tashish qobiliyatiga va yuqori ishlab chiqarish samaradorligiga ega. Oddiy ikkita vintli ekstruderlar bilan solishtirganda, Zhuoyue ekstruderlarining ishlab chiqarish samaradorligini oshirish mumkin 20%-50%. Masalan, HTS SUPER seriyali ekstruderlarning ishlab chiqarish quvvati soatiga 1000-3000 kg ga yetishi mumkin, katta hajmdagi ommaviy ishlab chiqarish uchun javob beradi; ZTE seriyali ekstruderlarning ishlab chiqarish quvvati 100-500kg/soat, which is suitable for small and medium-sized batch production.

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

3.1.5 Intelligent Control, Easy Operation and Maintenance

All Zhuoyue’s 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 (up to 100 sets), and when producing different types of masterbatch, only the corresponding formula and parameters need to be called, without repeated debugging, which saves time and improves production efficiency.

The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (such as temperature, bosim, vida tezligi, oziqlantirish tezligi) in real time, and record the production data (such as output, processing time) for later query and analysis. For the HTS SUPER series extruders, we also provide a cloud control function, which can realize remote parameter adjustment, production data monitoring and predictive maintenance of equipment, ishlab chiqarishni aqlli boshqarishni amalga oshirish.

Bunga qo'chimcha, the extruders adopt a reasonable structural design, which makes the maintenance more convenient. Vintlar, barrels and die heads can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Zhuoyue kompaniyasining sotuvdan keyingi xizmat ko'rsatish jamoasi professional o'rnatishni ta'minlaydi, mijozlar uchun ishga tushirish va o'qitish xizmatlari, mijozlar uskunadan muammosiz foydalanishlarini ta'minlash.

3.1.6 Keng qo'llash diapazoni, Kuchli moslashuvchanlik

Zhuoyue-ning to'liq seriyali ekstruderlari keng qo'llash doirasiga ega, har xil turdagi masterbatchlarni qayta ishlash ehtiyojlariga moslasha oladi, shu jumladan rangli masterbatch, white masterbatch, black masterbatch, oddiy masterbatch, funktsional masterbatch (olovga chidamli masterbatch, antistatik masterbatch), va turli tashuvchilar bilan masterbatch (PE, PP, PVX, PA, PET, va hokazo.). Ekstruderlar, shuningdek, turli xil pigment tarkibiga ega masterbatchni qayta ishlashga moslasha oladi (10%-80%), va turli dastur maydonlarining qayta ishlash ehtiyojlarini qondirishi mumkin (tolalar, filmlar, puflash, ekstruziya, inyeksion kalıplama).

Oddiy masterbatch ishlab chiqaradigan kichik va o'rta ishlab chiqaruvchi bo'ladimi, yoki yuqori darajadagi funktsional masterbatch ishlab chiqaruvchi yirik ishlab chiqaruvchi, Zhuoyue can provide suitable extruder solutions. Bunga qo'chimcha, the extruders can be matched with different auxiliary equipment (such as high-speed mixers, quritgichlar, sovutgichlar, granulyatorlar, screening machines, packaging machines) to'liq avtomatik ishlab chiqarish liniyasini shakllantirish, realizing continuous production from raw material pretreatment to product packaging.

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

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

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

HTS BASIC seriyali ekstruderlari kichik va o'rta o'lchamdagi masterbatch ishlab chiqaruvchilari yoki asosan oddiy masterbatch ishlab chiqaradigan ishlab chiqaruvchilar uchun mo'ljallangan, tejamkor mahsulot seriyasidir.. Ushbu ekstruderlar seriyasi Evropaning etakchi ishlab chiqaruvchilarining o'rta momentli vites qutilarini ishlatadi, barqaror ishlashning afzalliklariga ega, past shovqin, yuqori samaradorlik va uzoq xizmat muddati. Ekstruderlarning o'ziga xos momenti 10-12 Nm / sm³ ni tashkil qiladi, oddiy masterbatchning qayta ishlash ehtiyojlarini qondira oladi (pigment miqdori ≤50%), PE / PP rangli masterbatch kabi, past konsentratsiyali oq masterbatch va qora masterbatch.

Strukturaviy dizayn nuqtai nazaridan, HTS BASIC seriyali ekstruderlari ikkita vintli parallel aylanuvchi strukturani qabul qiladi, 30 mm dan 65 mm gacha bo'lgan vida diametri bilan, va siqish nisbati 4～8, masterbatch turiga qarab sozlanishi mumkin. 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, avtomatik haroratni nazorat qilish, 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 small and medium-sized masterbatch manufacturers that mainly produce ordinary masterbatch for films, injection molding and extrusion products. One of the biggest advantages of this series is that it can provide flexible options through different configuration combinations. Customers can choose different screw elements, die heads, feeding devices and post-processing equipment according to their own product types and production needs, so as to form a production line suitable for their own needs. The HTS BASIC series extruders have a reasonable price, which can help small and medium-sized manufacturers reduce the initial investment cost while ensuring the basic processing quality of masterbatch. It is an ideal choice for enterprises that are just entering the masterbatch industry or have limited production scale and budget. Bunga qo'chimcha, this series of extruders has simple operation and low maintenance cost, and its after-sales service support is consistent with other high-end series, which can fully meet the daily production needs of small and medium-sized manufacturers.

3.2.2 HTS PLUS seriyali ekstruderlar: Muhandislik plastmassalari va to'ldiruvchi Masterbatch uchun yuqori momentli yechim

HTS PLUS seriyali ekstruderlar o'rta va yuqori darajadagi mahsulotlar sifatida joylashtirilgan, yuqori talablarga ega masterbatch qayta ishlash stsenariylari uchun maxsus ishlab chiqilgan, muhandislik plastik masterbatch va plomba masterbatch kabi. HTS BASIC seriyasidan farq qiladi, ushbu seriya Zhuoyue tomonidan mustaqil ravishda ishlab chiqilgan va ishlab chiqarilgan yuqori momentli vites qutilarini qabul qiladi, 13-16Nm/sm³ o'ziga xos moment bilan, kuchliroq kesish kuchi va yoğurma kuchini ta'minlaydi, yuqori viskoziteli ishlov berish qiyinchiliklarini samarali hal qilish, yuqori qattiqlikdagi masterbatch materiallari.

Asosiy komponentlar nuqtai nazaridan, HTS PLUS seriyasining vintlari va bochkalari import qilingan aşınmaya bardoshli qotishma po'latdan yasalgan va bimetalik kompozit ishlov berishdan o'tadi.. Sirt qattiqligi ≥65 HRC ga etadi, mukammal aşınma qarshilik va korroziyaga chidamliligiga ega, va to'ldiruvchi masterbatchdan kelib chiqadigan aşınmaya osongina dosh bera oladi (masalan, kaltsiy karbonat, talk pudrasi bilan to'ldirilgan masterbatch) va muhandislik plastik masterbatch (such as PA, Kompyuter masterbatch). Vida modulli dizaynni qabul qiladi, va kengaytirilgan aralashtirish elementlari va kesish elementlari bilan jihozlangan, tashuvchida plomba va pigmentlarni to'liq tarqatishi mumkin, masterbatchning bir xilligi va barqarorligini ta'minlash. The barrel is divided into 5-6 temperature control sections, ± 1 ℃ haroratni nazorat qilish aniqligi bilan, muhandislik plastmassalarini qayta ishlash haroratini aniq nazorat qila oladi (200-280℃) va materialning parchalanishidan saqlaning.

HTS PLUS seriyali ekstruderlarning ishlab chiqarish quvvati soatiga 300 kg dan 1200 kg gacha., muhandislik plastik masterbatch ishlab chiqaradigan o'rta va katta hajmdagi masterbatch ishlab chiqaruvchilari uchun javob beradi, to'ldiruvchi masterbatch, yuqori konsentratsiyali rangli masterbatch (pigment tarkibi 50%-70%) va boshqa mahsulotlar. Masalan, PA muhandislik plastik masterbatch qayta ishlashda, HTS PLUS seriyali PA tashuvchisi to'liq eritilishini ta'minlash uchun yuqori moment va aniq harorat nazoratiga tayanishi mumkin., va pigmentlar va funktsional qo'shimchalar bir xilda tarqalgan, rangli dog'lar muammolaridan qochish, chiziqlar va masterbatchning yomon mexanik xususiyatlari. To'ldiruvchi masterbatchni qayta ishlashda, uning kuchli kesish kuchi plomba zarralarini to'liq tarqatishi mumkin (ularni aglomeratsiya qilish oson) tashuvchida, plomba va tashuvchi o'rtasidagi muvofiqlikni yaxshilash, va quyi oqimdagi plastik xom ashyo bilan aralashtirilganda masterbatchni qayta ishlash ko'rsatkichlarini ta'minlash.

Bunga qo'chimcha, HTS PLUS seriyali ekstruderlar takomillashtirilgan PLC aqlli boshqaruv tizimi bilan jihozlangan, aniqroq parametrlarni boshqarish va ma'lumotlar monitoringini amalga oshirishi mumkin. Tizim avtomatik ravishda vida tezligini sozlashi mumkin, materialning yopishqoqligi va ishlov berish effektiga ko'ra oziqlantirish tezligi va ekstruziya bosimi, ensuring the stability of product quality between batches. Ekstruder, shuningdek, majburiy oziqlantirish moslamasi va vakuumli egzoz moslamasi bilan jihozlangan: majburiy oziqlantirish moslamasi yuqori viskoziteli materiallarni silliq oziqlantirishni ta'minlashi mumkin; vakuumli egzoz qurilmasi namlikni samarali ravishda olib tashlashi mumkin, uchuvchi moddalar va materiallardagi havo, masterbatchda pufakchalar va teshiklardan qochish, va masterbatchning zichligi va sifatini yaxshilash. Ushbu ekstruderlar seriyasi ishlash va narxni muvozanatlashtiradi, and is suitable for manufacturers that need to improve product quality and expand production scale.

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

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

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

In terms of mixing and dispersing effect, the HTS SUPER series is equipped with a new type of multi-stage mixing screw combination, including high-shear mixing elements, kneading blocks and dispersing elements, which can generate multi-directional shear force and kneading force, fully breaking the agglomerates of pigments and fillers (even agglomerates below 50μm), and making the pigments, fillers and carriers uniformly mixed. The mixing uniformity of the masterbatch can reach more than 98%, yuqori konsentratsiyali qayta ishlash uchun javob beradi, yuqori dispersli masterbatch (pigment tarkibi 70%-80%). Bunga qo'chimcha, bu ekstruderlar seriyasi yuqori aniqlikdagi o'zgaruvchan chastotali tezlikni tartibga solish tizimini qabul qiladi, va vida tezligi oralig'ida sozlanishi mumkin 300-1000 rpm, masterbatch turiga va qayta ishlash talablariga muvofiq moslashuvchan tarzda sozlanishi mumkin, eng yaxshi ishlov berish effektini ta'minlash.

HTS SUPER seriyali ekstruderlarning ishlab chiqarish quvvati soatiga 1000 kg dan 3000 kg gacha., katta hajmdagi uchun mos keladi, yuqori darajadagi bozorlarga e'tibor qaratadigan yuqori standartli masterbatch ishlab chiqaruvchilari. Masalan, yangi energiya avtomobil qismlari uchun masterbatchni qayta ishlashda (avtomobil ichki va tashqi qismlari kabi, batareya qobig'i masterbatch), HTS SUPER seriyali masterbatchning mukammal ob-havoga chidamliligini ta'minlashi mumkin, yuqori haroratga chidamlilik va disperslik, avtomobil ishlab chiqaruvchilarining qat'iy sifat talablariga javob berish; tibbiy darajadagi masterbatchni qayta ishlashda (tibbiy kateterlar uchun masterbatch kabi, tibbiy idishlar), toza ishlab chiqarishni amalga oshirishi mumkin, moddiy ifloslanishdan saqlaning, va masterbatchning tibbiy darajadagi atrof-muhitni muhofaza qilish standartlariga javob berishini ta'minlash. Ushbu ekstruderlar seriyasi, shuningdek, aqlli bulutni boshqarish tizimi bilan jihozlangan, which can realize remote parameter adjustment, ishlab chiqarish ma'lumotlarini monitoring qilish, nosozliklarni erta ogohlantirish va prognozli texnik xizmat ko'rsatish. Ishlab chiqaruvchilar mobil telefonlar yoki kompyuterlar orqali real vaqt rejimida uskunaning ishlab chiqarish holatini kuzatishi mumkin, aqlli ishlab chiqarish boshqaruvini amalga oshirish, ishlab chiqarish samaradorligi va boshqaruv darajasini sezilarli darajada yaxshilaydi.

3.2.4 ZTE seriyali ekstruderlar: Universal Masterbatch ishlov berish uchun tejamkor tanlov

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

Strukturaviy dizayn nuqtai nazaridan, the ZTE series adopts a twin-screw parallel co-rotating structure, with a screw diameter ranging from 25mm to 65mm, and a specific torque of 8-11Nm/cm³, which can provide sufficient shear force and conveying capacity for ordinary masterbatch processing. The screws and barrels are made of high-quality wear-resistant alloy steel with nitriding treatment, va sirt qattiqligi ≥60 HRC ga etadi, oddiy pigmentlarning aşınma talablariga javob berishi mumkin (such as organic pigments, past qattiqlikdagi noorganik pigmentlar) va uzoq xizmat muddatiga ega. The barrel is divided into 4 temperature control sections, ± 2 ℃ haroratni nazorat qilish aniqligi bilan, oddiy masterbatchning ishlov berish haroratini aniq nazorat qila oladi (150-220℃), pigment parchalanishi va tashuvchining degradatsiyasidan qochish.

ZTE seriyali ekstruderlarning ishlab chiqarish quvvati soatiga 50 kg dan 400 kg gacha., kichik va o'rta o'lchamli masterbatch ishlab chiqaruvchilari uchun mos keladi, ko'p navli masterbatchning kichik partiyalarini ishlab chiqarishga muhtoj bo'lgan kichik ustaxonalar va korxonalar. Ushbu ekstruderlar seriyasi oddiy tuzilishning afzalliklariga ega, oson ishlash, kam energiya iste'moli va past texnik xarajatlar. Operatsion interfeysi oddiy sensorli ekran dizaynini qabul qiladi, o'rganish va o'zlashtirish oson, va tajribasi kam bo'lgan operatorlar uchun javob beradi. Bunga qo'chimcha, ZTE seriyasi ham mijozlar ehtiyojlariga ko'ra moslashuvchan tarzda sozlanishi mumkin, majburiy oziqlantirish moslamasini qo'shish kabi, vakuumli egzoz qurilmasi yoki maxsus qolip boshi, turli mijozlarning shaxsiylashtirilgan qayta ishlash ehtiyojlarini qondirish uchun. Garchi ZTE seriyasi tejamkor bo'lsa-da, uning asosiy ko'rsatkichlari (aralashtirish bir xilligi kabi, haroratni nazorat qilish aniqligi) bozordagi oddiy ekstruderlarga qaraganda ancha yuqori, ishlab chiqarilgan masterbatchning bir xil rangga ega bo'lishini ta'minlashi mumkin, barqaror ishlash va quyi oqim mijozlarining asosiy foydalanish talablariga javob beradi. Bu cheklangan byudjetga ega va asosan oddiy masterbatch ishlab chiqaradigan korxonalar uchun ideal tanlovdir.

3.2.5 HTE seriyali ekstruderlar: Yuqori samarali va tejamkor integratsiyalashgan yechim

HTE seriyali ekstruderlar yuqori mahsuldorlik va iqtisodiy samaradorlikning afzalliklarini birlashtiradi, xarajatlarni nazorat qilishda ishlab chiqarish samaradorligi va mahsulot sifatini yaxshilash kerak bo'lgan o'rta o'lchamdagi masterbatch ishlab chiqaruvchilarga qaratilgan. Ushbu ekstruderlar seriyasi ishlashni muvozanatlash uchun mo'ljallangan, samaradorlik va xarajat, va masterbatchni qayta ishlashning turli stsenariylari uchun javob beradi, shu jumladan yuqori konsentratsiyali rangli masterbatch (pigment tarkibi 50%-60%), oddiy funktsional masterbatch (olovga chidamli masterbatch, antistatik masterbatch) va filmlar uchun masterbatch, puflash va inyeksion kalıplama mahsulotlari.

Asosiy ishlash nuqtai nazaridan, HTE seriyali Zhuoyue tomonidan mustaqil ravishda ishlab chiqilgan yuqori torkli vites qutisini qabul qiladi, 12-14Nm/sm³ o'ziga xos moment bilan, bu HTS BASIC va ZTE seriyalariga qaraganda yuqori, va kuchli kesish kuchi va yoğurma kuchini ta'minlashi mumkin, ensuring the uniform dispersion of pigments and additives. The screws adopt a modular design, and are equipped with a combination of conveying elements, mixing elements and shearing elements, which can be flexibly adjusted according to the type of masterbatch, improving the adaptability of the extruder. The screws and barrels are made of imported wear-resistant alloy steel with bimetallic composite treatment, and the surface hardness reaches ≥65 HRC, which has excellent wear resistance and can cope with the processing of high-hardness pigments (such as titanium dioxide, carbon black) and low-content filler masterbatch.

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

HTE seriyasi ishlab chiqarish ko'lamini kengaytirish va mahsulot sifatini oshirish bosqichida bo'lgan o'rta o'lchamdagi masterbatch ishlab chiqaruvchilari uchun javob beradi.. Bu nafaqat yuqori sifatli masterbatchni qayta ishlash ehtiyojlarini qondira olmaydi, balki ishlab chiqarish tannarxini ham samarali nazorat qiladi, korxonalarga bozor raqobatbardoshligini oshirishga yordam berish. HTS PLUS seriyali bilan solishtirganda, HTE seriyali yanada maqbul narxga ega; ZTE seriyasi bilan solishtirganda, u yaxshi ishlash va yuqori ishlab chiqarish samaradorligiga ega, bu o'rta va yuqori darajadagi mahsulotlar o'rtasida iqtisodiy jihatdan samarali tanlovdir.

4. Masterbatch va mos keladigan Zhuoyue ekstruder echimlarining keng qo'llanilishi

Plastmassa sanoatida ajralmas asosiy material sifatida, masterbatch tolalarda keng qo'llaniladi, filmlar, puflash, ekstrusion kalıplama, qarshi kalıplama va boshqa sohalar. Different application fields have different requirements on the performance of masterbatch (such as dispersibility, temperature resistance, color fastness) va ishlab chiqarish samaradorligi, which also determines the selection of twin-screw extruders. Zhuoyue’s full series of extruders can provide targeted solutions for different application fields, ensuring that the produced masterbatch meets the specific requirements of downstream products. The following is a detailed introduction to the application fields of masterbatch and the matching Zhuoyue extruder series.

4.1 Fiber Field: High-Dispersibility and Color Fastness Requirements

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

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

4.2 Film Field: High Transparency and Uniform Coloring Requirements

Masterbatch in the film field is mainly used for coloring plastic films, such as shopping bags, casting films, multi-layer films, packaging films, agricultural films, va hokazo. The key requirements of this field for masterbatch are: first, high transparency. For transparent or translucent films (such as food packaging films, agricultural mulch films), the masterbatch must have good transparency, avoiding affecting the appearance and visibility of the packaged products; second, uniform coloring. The film surface must be uniform in color, without color spots, color streaks and color difference, ensuring the aesthetic property of the film; third, good processing fluidity. The film extrusion speed is fast, and the masterbatch must have good fluidity, which is conducive to the uniform mixing of the masterbatch and the film base material, and avoiding affecting the film forming efficiency.

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

4.3 Blow Molding Field: Good Fluidity and Dimensional Stability Requirements

Masterbatch in the blow molding field is mainly used for coloring blow molding products, such as medical and cosmetic containers, lubricating oil and paint containers, beverage bottles, plastic barrels, va hokazo. The requirements of this field for masterbatch are: first, good processing fluidity. Blow molding products need to be formed by high-temperature blow molding, and the masterbatch must have good fluidity, which is conducive to the uniform distribution of the masterbatch in the parison, avoiding uneven wall thickness and color difference of the product; second, good dimensional stability. The blow molding products have strict requirements on dimensional accuracy, and the masterbatch must have stable performance, avoiding the deformation of the product due to uneven shrinkage; third, environmental protection. Especially for medical and cosmetic containers, the masterbatch must meet environmental protection standards, non-toxic and harmless, without volatile substances.

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

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

Masterbatch in the extrusion molding field is mainly used for coloring extrusion products, such as sheets, quvurlar, simlar va kabellar, profillar, va hokazo. The key requirements of this field for masterbatch are: first, high dimensional stability. Extrusion products (such as pipes, profillar) have strict requirements on dimensional accuracy, and the masterbatch must have stable performance, avoiding the deformation and color difference of the product due to uneven shrinkage; second, yaxshi aşınma qarshilik. Ishqalanish va ekstruziyaga chidamli bo'lishi kerak bo'lgan quvurlar va simlar va kabellar kabi mahsulotlar uchun, masterbatch yaxshi aşınma qarshilikka ega bo'lishi kerak, mahsulotning xizmat qilish muddatini ta'minlash; third, yaxshi ob-havoga qarshilik. Tashqi ekstruziya mahsulotlari uchun (profillarni qurish kabi, tashqi quvurlar), masterbatch yaxshi ob-havoga chidamli bo'lishi kerak, quyosh nuri va yomg'ir ostida ranglarning o'zgarishi va ishlashning pasayishiga yo'l qo'ymaslik.

Ekstrusion kalıplama maydoni uchun, the suitable Zhuoyue extruder series are HTS PLUS series, HTE seriyali va HTS SUPER seriyali. Oddiy ekstruziya masterbatch uchun (ichki choyshablar kabi, oddiy quvurlar), HTE seriyali va HTS BASIC seriyali tavsiya etiladi. Ularning yaxshi aralashtirish va tarqatish ta'siri mahsulotning bir xil rang berishini ta'minlaydi, va barqaror ishlash mahsulotning o'lchov aniqligini ta'minlashi mumkin. O'rta darajadagi ekstrusion masterbatch uchun (simlar va kabellar kabi, profillarni qurish), the HTS PLUS series is recommended. Uning yuqori momentli vites qutisi va aşınmaya bardoshli vint/barrel yuqori qattiqlikni qayta ishlashga bardosh bera oladi., yuqori viskoziteli masterbatch, mahsulotning aşınma va ob-havoga chidamliligini ta'minlash. Yuqori darajadagi ekstruziya masterbatch uchun (yuqori haroratga chidamli quvurlar kabi, ochiq havoda yuqori sifatli profillar), the HTS SUPER series is recommended. Uning ultra yuqori moment va aniq haroratni nazorat qilish masterbatchning barqaror ishlashini ta'minlashi mumkin, va yaxshilangan aşınma qarshilik mahsulotning xizmat muddatini yanada uzaytirishi mumkin.

4.5 Inyeksion kalıplama maydoni: Yuqori disperslik va partiyaning barqarorligi talablari

Inyeksion kalıplama sohasida Masterbatch eng ko'p qo'llaniladi, asosan inyeksion kalıplama mahsulotlarini bo'yash uchun ishlatiladi, such as automotive parts, electronic products, qurilish materiallari, maishiy texnika, mebel, o'yinchoqlar, va hokazo. Masterbatch uchun ushbu sohaning talablari xilma-xildir, lekin asosiy talablar: first, high dispersibility. Inyeksion kalıplama mahsulotlari murakkab shakllar va kichik o'lchamlarga ega, va masterbatch yuqori dispersiyaga ega bo'lishi kerak, rangli dog'lardan qochish, rangli chiziqlar va mahsulotning notekis ranglanishi; second, yaxshi partiya barqarorligi. Inyeksion kalıplama mahsulotlari odatda katta partiyalarda ishlab chiqariladi, and the masterbatch must have stable performance, mahsulot partiyalari o'rtasida rang farqi yo'qligini ta'minlash; third, maqsadli funktsional talablar. Masalan, avtomobil qismlari yuqori haroratga chidamliligi va olovga chidamliligi bilan masterbatchni talab qiladi, elektron mahsulotlar antistatik ishlashga ega masterbatchni talab qiladi, va o'yinchoqlar toksik bo'lmagan va atrof-muhitni muhofaza qilish ko'rsatkichlariga ega masterbatchni talab qiladi.

Inyeksion kalıplama maydoni uchun, Zhuoyue-ning to'liq ekstruderlar seriyasi turli xil mahsulot darajalariga mos keladigan echimlarni taqdim etishi mumkin. Oddiy inyeksion kalıplama masterbatch uchun (o'yinchoqlar kabi, oddiy maishiy texnika), the ZTE series and HTS BASIC series are recommended. Their cost-effective advantages can reduce production costs, and the basic mixing and dispersing effect can meet the requirements of ordinary products. For medium-grade injection molding masterbatch (such as electronic products, ordinary automotive parts), the HTE series and HTS PLUS series are recommended. Their high mixing and dispersing effect and batch stability can ensure the quality of the product, and the targeted functional masterbatch processing capacity can meet the special requirements of the product. For high-end injection molding masterbatch (such as high-grade automotive parts, precision electronic products), the HTS SUPER series is recommended. Its ultra-high dispersibility, batch stability and high-temperature resistance can meet the strict quality requirements of high-end products, va aqlli boshqaruv tizimi keng ko'lamli ishlab chiqarishning samaradorligi va barqarorligini ta'minlashi mumkin.

5. Masterbatch ikkita vintli ekstruziyani qayta ishlashda umumiy muammolar va echimlar

Masterbatchning haqiqiy ishlab chiqarish jarayonida, xom ashyoning ta'siri tufayli, formula, ishlov berish parametrlari va uskunaning ishlashi, ko'pincha turli xil muammolar yuzaga keladi, masterbatch sifati va ishlab chiqarish samaradorligiga ta'sir qiladi. Ko'p yillik sanoat tajribasiga asoslangan, Zhuoyue masterbatch egizak vintli ekstruziyani qayta ishlashda umumiy muammolarni umumlashtiradi, sabablarini batafsil tahlil qiladi, va tegishli yechimlarni taqdim etadi, ishlab chiqaruvchilarga ishlab chiqarish muammolarini tezda hal qilishga va ishlab chiqarish samaradorligini va mahsulot sifatini yaxshilashga yordam beradi.

5.1 Umumiy muammo 1: Masterbatch ning yomon tarqalish qobiliyati, Mahsulotlardagi rangli dog'lar va chiziqlar

Bu masterbatchni qayta ishlashda eng keng tarqalgan muammo, which is mainly manifested in uneven coloring of the masterbatch, aniq pigment aglomeratlari, and color spots and streaks in the colored plastic products. The main causes and solutions are as follows:

5.1.1 Main Causes:

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

5.1.2 Yechimlar:

• (1) Xom ashyoni optimallashtirish: Select pigments with small particle size and low agglomeration degree, and dry them thoroughly (moisture content ≤0.1%); select carriers compatible with pigments; replace appropriate dispersants and increase the dosage appropriately (within 1%-5% of the pigment dosage).
• (2) Improve premixing effect: Increase the mixing speed to 800-1200 rpm, extend the mixing time to 5-10 daqiqa, and control the mixing temperature at 40-60℃; for high-concentration masterbatch, add dispersant first and mix with pigment, then mix with carrier and other additives.
• (3) Ekstruziya parametrlarini sozlang: Increase the screw speed appropriately (500-800 rpm for high-concentration masterbatch), improve the shear force; tashuvchining to'liq eritilishini ta'minlash uchun ekstruziya haroratini mos ravishda oshiring (tashuvchi turiga qarab sozlang).
• (4) Uskunani saqlash: Eskirgan vintni aralashtirish elementlarini almashtiring, barrel va vint; tiqilib qolmaslik uchun qolip boshini muntazam tozalang; vint va barrel to'g'ri mos kelishini ta'minlash uchun jihozni muntazam tekshirib turing.

5.2 Umumiy muammo 2: Masterbatchning pigmentning parchalanishi va rangi o'zgarishi

Bu muammo, asosan, masterbatchning rangi o'zgarishida namoyon bo'ladi (sarg'ish kabi, qorayish), rang standart namunaga mos kelmaydi, va hatto o'ziga xos hid hosil bo'ladi. Ko'pincha ekstruziyani qayta ishlash jarayonida materialning haddan tashqari qizishi tufayli yuzaga keladi, organik pigment masterbatch va muhandislik plastik masterbatch keng tarqalgan. The main causes and solutions are as follows:

5.2.1 Main Causes:

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

5.2.2 Yechimlar:

• (1) Adjust extrusion temperature: Reduce the temperature of the mixing section, homogenizing section and die head appropriately, and control it within the heat resistance range of the pigment and carrier (150-220℃ for ordinary masterbatch, 200-280℃ muhandislik plastik masterbatch uchun); haroratni aniq nazorat qilish uchun harorat sensorini muntazam tekshirib turing.
• (2) Yashash vaqtini qisqartiring: Increase the screw speed appropriately, vintning siqilish nisbatini kamaytiring, va materialning ekstruziya bo'shlig'ida qolish muddatini ta'minlash 1-3 daqiqa.
• (3) Sovutish tizimini saqlang: Sovutish suvining aylanish tizimini muntazam tekshirib turing, sovutish trubkasini tozalang, va barrel issiqlikni an'anaviy tarzda tarqatishiga ishonch hosil qiling; noto'g'ri sovutish elementini o'z vaqtida almashtiring.
• (4) Xom ashyoni optimallashtirish: Yaxshi issiqlikka chidamli pigmentlarni tanlang (yuqori haroratli ishlov berish uchun noorganik pigmentlar kabi); barqaror ishlashi va yomonlashishi oson bo'lmagan tashuvchilarni tanlang; tegishli issiqlik stabilizatorlarini qo'shing (0.5%-3%) pigment parchalanishini va tashuvchining degradatsiyasini oldini olish.

5.3 Umumiy muammo 3: Vint va barrelning yuqori aşınması, Qisqa xizmat muddati

Ushbu muammo oq masterbatchni qayta ishlashda keng tarqalgan, qora masterbatch va plomba masterbatch, bu asosan vida va barrelning tez aşınmasında namoyon bo'ladi, ekstruderning kesish kuchi va aralashtirish quvvati kamayadi, va texnik xizmat ko'rsatish xarajatlarining oshishi. The main causes and solutions are as follows:

5.3.1 Main Causes:

• (1) Raw material problems: Pigment yoki plomba moddasi yuqori qattiqlikka ega (such as titanium dioxide, carbon black, kaltsiy karbonat), va zarracha hajmi juda katta, bu vint va barrelning qattiq aşınmasına olib keladi.
• (2) Extrusion parameter problems: Vida tezligi juda yuqori, kesish kuchi juda katta, va material va vint/barrel orasidagi ishqalanish kuchayadi; ekstruziya bosimi juda yuqori, bu vint va barrelning aşınmasını oshiradi.
• (3) Equipment problems: Vint va barrel yomon aşınma qarshilikka ega bo'lgan materiallardan tayyorlangan, yoki ishlov berish texnologiyasi noto'g'ri; vint va barrel to'g'ri mos kelmaydi, natijada notekis stress va eskirish kuchayadi.

5.3.2 Yechimlar:

• (1) Xom ashyoni optimallashtirish: Kichik zarracha o'lchamli pigmentlar yoki plomba moddalarini tanlang (20-40 to'r) and low hardness; crush and sieve the raw materials to remove large particles; add appropriate lubricants (0.5%-2%) to reduce the friction between the material and the screw/barrel.
• (2) Ekstruziya parametrlarini sozlang: Reduce the screw speed and extrusion pressure appropriately, and control the shear force within a reasonable range; avoid long-term high-speed and high-pressure operation of the equipment.
• (3) Select high-wear-resistant equipment: Select extruders with high-wear-resistant screws and barrels, such as Zhuoyue’s HTS PLUS, HTS SUPER and HTE series, whose screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite or laser cladding treatment, which can greatly improve the service life; regularly check the wear of the screw and barrel, and replace them in time when the wear is serious.

5.4 Umumiy muammo 4: Partiyalar orasidagi mahsulot sifatining beqarorligi, Color Difference

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

5.4.1 Main Causes:

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

5.4.2 Yechimlar:

• (1) Strictly control the formula ratio: Xom ashyoni tortish uchun yuqori aniqlikdagi tortish uskunasidan foydalaning, va xatolik ±1% ichida nazorat qilinadi; formulalarni boshqarish tizimini yaratish, va har bir xom ashyoning dozasini batafsil yozib oling.
• (2) Xom ashyoni xarid qilish va tekshirishni standartlashtirish: Barqaror sifatga ega xom ashyo yetkazib beruvchilarni tanlang, va xom ashyoning ishlashini tekshirish (rang berish kuchi kabi, zarracha hajmi, namlik miqdori) ishlatishdan oldin; turli partiyalarning xom ashyolari uchun, izchil ishlashni ta'minlash uchun birinchi navbatda sinov ishlab chiqarishni o'tkazing.
• (3) Qayta ishlash parametrlarini standartlashtirish: Aqlli boshqaruv tizimidan foydalaning (Zhuoyue ning PLC boshqaruv tizimi kabi) turli masterbatchlarning qayta ishlash parametrlarini saqlash uchun, va turli partiyalarni ishlab chiqarishda mos keladigan parametrlarni chaqiring, takroriy nosozliklarni tuzatishdan qochish; barqaror ishlashini ta'minlash uchun uskunaning parametrlarini muntazam tekshirib turing.
• (4) Sifatni tekshirish tizimini yaratish: Masterbatchning har bir partiyasida qat'iy sifat tekshiruvini o'tkazing, shu jumladan rang, tarqalish qobiliyati, konsentratsiya va boshqa ko'rsatkichlar, va faqat standartlarga javob beradigan mahsulotlarni yetkazib berish.

5.5 Umumiy muammo 5: Masterbatch ning yomon ishlov berish suyuqligi, Qiyin ekstruziya, Uskunaning bloklanishi

Bu muammo, asosan, materialni tashish va ekstruziya qilish qiyinligida namoyon bo'ladi, past ishlab chiqarish samaradorligi, beqaror ekstruziya bosimi, va hatto qolip boshi va ekstruziya bo'shlig'ining bloklanishi, bu normal ishlab chiqarishga ta'sir qiladi. The main causes and solutions are as follows:

5.5.1 Main Causes:

• (1) Raw material problem: Tashuvchi zaif suyuqlikka ega, yoki pigment miqdori juda yuqori (more than 80%), natijada aralashmaning suyuqligi yomon bo'ladi; xom ashyo yuqori namlikka ega, bu materialning aglomeratsiyasiga olib keladi va oziqlantirish portini bloklaydi.
• (2) Oldindan aralashtirish muammosi: Oldindan aralashtirish notekis, va dispersant to'liq aralashmaydi, natijada materialning yomon suyuqligi.
• (3) Ekstruziya parametrlari muammosi: Ekstruziya harorati juda past, the carrier is not fully melted, va suyuqligi yomon; vida tezligi juda past, tashish qobiliyati etarli emas; qolip boshi teshigi juda kichik, va ekstruziya qarshiligi juda katta.
• (4) Equipment problem: Vintli uzatuvchi elementlar eskirgan, tashish qobiliyati kamayadi; oziqlantirish moslamasi ishlamay qoladi, notekis oziqlantirishga olib keladi.

5.5.2 Yechimlar:

• (1) Xom ashyoni optimallashtirish: Yaxshi oqimga ega tashuvchilarni tanlang; pigment tarkibini mos ravishda kamaytiring (ichida nazorat qilish 80%); quyida joylashgan namlikni nazorat qilish uchun xom ashyoni yaxshilab quriting 0.1%.
• (2) Improve premixing effect: Oldindan aralashtirish vaqtini uzaytiring, aralashtirish tezligini oshiring, dispersantning pigment va tashuvchi bilan to'liq aralashtirilganligiga ishonch hosil qiling, va aralashmaning suyuqligini yaxshilaydi.
• (3) Ekstruziya parametrlarini sozlang: Tashuvchining to'liq eritilishini ta'minlash uchun ekstruziya haroratini mos ravishda oshiring; tashish qobiliyatini yaxshilash uchun vida tezligini oshiring; ekstruziya qarshiligini kamaytirish uchun qolip boshini kattaroq teshiklari bilan almashtiring.
• (4) Uskunani saqlash: Eskirgan vintli uzatish elementlarini almashtiring; oziqlantirish moslamasini muntazam ravishda tekshiring, va noto'g'ri qismlarni o'z vaqtida ta'mirlash yoki almashtirish; material to'planishi va bloklanishining oldini olish uchun oziqlantirish porti va ekstruziya bo'shlig'ini muntazam tozalang.

6. Masterbatch ishlov berishda Zhuoyue ekstruderlarini amaliy qo'llash holatlari

Masterbatch ishlov berishda Zhuoyue-ning to'liq seriyali ekstruderlarining ishlash afzalliklari va qo'llash effektlarini qo'shimcha tekshirish uchun., Ushbu bo'limda bir nechta amaliy amaliy holatlar ko'rib chiqiladi, har xil masterbatch turlarini qamrab oladi, ishlab chiqarish ko'lami va qo'llash sohalari. Ushbu holatlar Zhuoyue ekstruderlari turli ishlab chiqaruvchilar uchun maqsadli va samarali ishlov berish echimlarini taqdim etishi mumkinligini to'liq ko'rsatadi., helping manufacturers improve production efficiency, product quality and market competitiveness.

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

Customer Background: A large-scale masterbatch manufacturer in Jiangsu, Xitoy, mainly produces high-end functional masterbatch, focusing on the new energy vehicle field. The customer needs to produce high-concentration black masterbatch (carbon black content 70%) for automotive battery shell parts. The masterbatch requires ultra-high dispersibility (no black spots and streaks in the product), high temperature resistance (can withstand 200℃ high temperature without discoloration), and good batch stability. The customer’s original equipment has problems such as insufficient mixing and dispersing effect, unstable temperature control, and low production efficiency, ishlab chiqarish talablariga javob bera olmaydi.

Yechim: Zhuoyue HTS SUPER seriyali ikkita vintli ekstruderlarni tavsiya qiladi (vint diametri 75 mm) mijoz uchun. Ushbu seriya ultra yuqori momentli vites qutilarini va lazer bilan qoplangan aşınmaya bardoshli vintlar / bochkalarni qabul qiladi., kuchli kesish kuchi va aşınma qarshiligini ta'minlaydi, uglerod qora aglomeratsiyasi muammosini samarali hal qilish; 6 qismli haroratni aniq nazorat qilish tizimi (haroratni nazorat qilish aniqligi ± 1 ℃) ekstruziya haroratini aniq nazorat qila oladi, uglerod qora parchalanishining oldini olish; ko'p bosqichli aralashtirish vintlari birikmasi uglerod qorasining pe tashuvchisida bir xilda tarqalishini ta'minlaydi; aqlli bulutni boshqarish tizimi masofadan parametrlarni sozlash va ma'lumotlarni kuzatishni amalga oshirishi mumkin, partiyaning barqarorligini ta'minlash.

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

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

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

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

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

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

Customer Background: A small and medium-sized masterbatch manufacturer in Zhejiang, Xitoy, mainly produces film masterbatch, focusing on the packaging film field. The customer needs to produce PE film masterbatch (pigment tarkibi 40%) for food packaging films. The masterbatch requires good transparency, uniform coloring, and low production cost. The customer’s original equipment has problems such as high energy consumption, unstable product quality, and low production efficiency, which cannot meet the market competition needs.

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

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

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

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

Yechim: Zhuoyue recommends the ZTE series twin-screw extruders (screw diameter 35mm) mijoz uchun. This series has excellent cost performance, simple structure and easy operation, which is suitable for operators with little experience; the modular screw design can be flexibly adjusted according to different types of masterbatch, with strong adaptability; the wear-resistant screw/barrel and stable temperature control system can meet the basic processing requirements of ordinary masterbatch; kam energiya iste'moli va past texnik xarajatlar mijozga dastlabki investitsiyalar va kundalik foydalanish xarajatlarini kamaytirishga yordam beradi.

Ilova effekti: ZTE seriyali ekstruderlardan foydalangandan so'ng, mijoz moslashuvchan tarzda bir nechta turdagi oddiy masterbatch ishlab chiqarishi mumkin, va mahsulot sifati mahalliy plastik mahsulot ishlab chiqaruvchilarning asosiy talablariga javob beradi; uskunaning ishlashi oddiy, va operator uni tezda o'zlashtira oladi; texnik xizmat ko'rsatish narxi past, va yillik texnik xizmat ko'rsatish narxi kamroq 5000 yuan; ishlab chiqarish samaradorligi kichik partiyalar ishlab chiqarish ehtiyojlarini qondirishi mumkin (50-200kg/soat). ZTE seriyali ekstruderlar mijozga mahalliy bozorni barqarorlashtirishga yordam berdi va kelajakda kengayish uchun poydevor qo'ydi..

7. Masterbatch va ikkita vintli ekstruziya texnologiyasining kelajakdagi rivojlanish tendentsiyasi

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

7.1 Development Trend of Masterbatch Industry

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

With the strengthening of global environmental protection awareness and the strictness of environmental protection policies (such as the European Union’s REACH directive, China’s “double carbon” goal), atrof-muhitni muhofaza qilish masterbatch bozorning asosiy oqimiga aylanadi. Kelajakda atrof-muhitni muhofaza qilish bo'yicha masterbatch toksik bo'lmagan narsalarga qaratiladi, harmless, past uchuvchan, parchalanadigan va qayta ishlanishi mumkin, and toxic and harmful pigments (such as heavy metal pigments) va qo'shimchalar butunlay yo'q qilinadi. Masalan, suvga asoslangan masterbatch, bio-asoslangan masterbatch va qayta ishlanadigan masterbatch keng bozor istiqbollariga ega bo'ladi. Xuddi o'sha payt, masterbatch chiqindilarini qayta ishlash ham muhim rivojlanish yo'nalishiga aylanadi, resurs chiqindilari va atrof-muhit ifloslanishini kamaytirishi mumkin.

7.1.2 Funktsional integratsiya va yuqori samaradorlik.

Pastki oqim mahsulot talablarini diversifikatsiya qilish bilan, masterbatch funktsional integratsiya tomon rivojlanadi, ya'ni, bir nechta funktsiyalarni birlashtirish (rang berish kabi, olovga chidamli, antistatik, antibakterial, UVga chidamli) bitta masterbatchga, bu masterbatchning qo'shilish miqdorini kamaytirishi mumkin, qayta ishlash jarayonini soddalashtirish, and reduce production costs. Masalan, new energy vehicle masterbatch will integrate high temperature resistance, olovga chidamli, antistatic and other functions; medical masterbatch will integrate non-toxic, antibakterial, high transparency and other functions. Bunga qo'chimcha, high-performance masterbatch (such as high-concentration, high-dispersibility, high-temperature resistant, corrosion-resistant masterbatch) will be more widely used in high-end fields such as aerospace, precision electronics and new energy.

7.1.3 Customization and Personalization.

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

7.2 Development Trend of Twin-Screw Extrusion Technology

7.2.1 Intelligence and Automation Upgrading.

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

7.2.2 High Efficiency, Energiyani tejash va atrof-muhitni muhofaza qilish.

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

7.2.3 High Performance and Wear Resistance.

With the development of high-concentration, high-hardness masterbatch (such as filler masterbatch, engineering plastic masterbatch), the requirements for the performance and wear resistance of twin-screw extruders will be higher. The future extruders will adopt more high-performance wear-resistant materials (such as new alloy steel, ceramic materials) and advanced manufacturing technologies (such as laser cladding, bimetallic composite), vida va barrelning aşınma qarshiligi va korroziyaga chidamliligini sezilarli darajada oshirishi mumkin, extend the service life of the equipment. Xuddi o'sha payt, the extruders will be equipped with higher torque gearboxes and more advanced mixing elements, kuchliroq kesish kuchi va yoğurma kuchini ta'minlaydi, meeting the processing needs of high-performance masterbatch.

7.2.4 Modularization and Flexibility.

Modularization and flexibility will become an important development trend of twin-screw extruders. The future extruders will adopt a more perfect modular design, and the screw, bochka, die head and other components can be freely combined and replaced according to the type of masterbatch and processing requirements, which can improve the adaptability of the equipment and reduce the investment cost of the customer. Masalan, when producing different types of masterbatch, only the corresponding screw elements and die head need to be replaced, without replacing the entire extruder. Bunga qo'chimcha, kichik va o'rta modulli ekstruderlar ko'proq mashhur bo'ladi, kichik va o'rta ishlab chiqaruvchilarning kichik partiyali va ko'p navli ishlab chiqarish ehtiyojlarini qondira oladi.

7.3 Kelajakdagi rivojlanish tendentsiyasida Zhuoyuening tartibi

Masterbatch sanoatining kelajakdagi rivojlanish tendentsiyasi va ikkita vintli ekstruziya texnologiyasi, Zhuoyue texnologik innovatsiyalar va mahsulotni yangilashga e'tibor qaratadi, va quyidagi jihatlarda maket qiling: first, R ni kuchaytirish&Aqlli ekstruziya texnologiyasining D, integratsiyalashgan AI, ekstruder dizayniga katta ma'lumotlar va Internet narsalar texnologiyalari, yanada aqlli va avtomatik ekstruderlarni ishga tushiring, va mijozlarga aqlli ishlab chiqarishni amalga oshirishga yordam bering; second, R ni oshiring&D yuqori samarali aşınmaya bardoshli materiallar va energiya tejovchi texnologiyalarga sarmoya, yanada samarali rivojlantiradi, energiya tejaydigan va aşınmaya bardoshli ekstruderlar, ishlab chiqarish tannarxini va mijozlarning atrof-muhitga ta'sirini kamaytirish; third, R ni kuchaytirish&D moslashtirilgan yechimlar, turli mijozlarning shaxsiy ehtiyojlariga ko'ra, maqsadli ekstruder konfiguratsiyasi va ishlov berish echimlarini taqdim eting, va mijozlar ehtiyojini qondirishni yaxshilash; fourth, R ni kengaytiring&Atrof-muhitni muhofaza qilish masterbatch ishlov berish texnologiyasining D, suvga asoslangan masterbatch uchun mos ekstruderlarni ishga tushirish, bio-asoslangan masterbatch va qayta ishlanadigan masterbatchni qayta ishlash, va masterbatch sanoatiga yashil rivojlanishga erishishga yordam bering.

8. Xulosa

Masterbatch, plastik rang berish va funktsional modifikatsiyaning asosiy materiali sifatida, global plastmassa sanoatida ajralmas rol o'ynaydi. Ikki vintli ekstruziya texnologiyasi, masterbatchning asosiy qayta ishlash texnologiyasi sifatida, sifatini bevosita belgilaydi, masterbatch mahsulotlarining ishlab chiqarish samaradorligi va bozor raqobatbardoshligi. Atrof-muhitni muhofaza qilish yo'lida masterbatch sanoatining uzluksiz rivojlanishi bilan, functionalization, yuqori konsentratsiya va aql, ikki vintli ekstruderlarga qo'yiladigan talablar tobora ortib bormoqda.

Zhuoyue, ikki vintli ekstruderlarning professional ishlab chiqaruvchisi sifatida, ekstruderlarning to'liq seriyasini ishga tushirdi (HTS BASIC/PLUS/SUPER, ZTE, HTE) masterbatch qayta ishlash uchun maxsus mo'ljallangan, each series has its own unique performance characteristics and targeted adaptation scenarios, turli miqyosdagi va sohalardagi masterbatch ishlab chiqaruvchilari uchun shaxsiylashtirilgan va samarali qayta ishlash echimlarini taqdim etishi mumkin. Ushbu ekstruderlar mukammal aralashtirish va tarqatish effektining afzalliklariga ega, haroratni aniq nazorat qilish, yuqori aşınma qarshilik, yuqori ishlab chiqarish samaradorligi, energiya tejash va atrof-muhitni muhofaza qilish, aqlli boshqaruv va keng dastur oralig'i, ko'plab amaliy holatlarda to'liq tasdiqlangan.

Ushbu maqola masterbatch haqidagi asosiy bilimlarni har tomonlama ishlab chiqadi, ikkita vintli ekstruziya texnologiyasining printsipi va jarayoni, Zhuoyue-ning to'liq seriyali ekstruderlarning ishlash afzalliklari, masterbatch dastur maydonlari, qayta ishlashda umumiy muammolar va yechimlar, amaliy qo'llash holatlari, va kelajakdagi rivojlanish tendentsiyasi. Umid qilamizki, ushbu maqola masterbatch ishlab chiqaruvchilari uchun keng qamrovli va professional ma'lumot beradi, qayta ishlash bo'yicha texnik xodimlar, sanoat amaliyotchilari va tegishli tadqiqotchilar.

Kelajakda, Zhuoyue texnologik innovatsiyalar va mijozlarga yo'naltirilgan kontseptsiyaga rioya qilishni davom ettiradi, sanoatning rivojlanish tendentsiyasini kuzatib boring, mahsulotlar va texnologiyalarni doimiy ravishda yangilash, yanada ilg'or ta'minlash, samarali va ekologik toza ikkita vintli ekstruziya yechimlari, va masterbatch sanoatining yuqori sifatli rivojlanishiga yordam berish uchun butun dunyo bo'ylab masterbatch ishlab chiqaruvchilari bilan birgalikda ishlash.