I-Filler Masterbatch Advanced Granulation Production Lines kunye ne-Extrusion Technology Application

Ngophuhliso olukhawulezayo lweshishini leplastiki yehlabathi, imfuno yeemveliso zeplastiki iyanda imihla ngemihla, kunye neemfuno zokusebenza kwemveliso, ulawulo lweendleko kunye nokhuseleko lokusingqongileyo nazo ziya ziba ngqongqo ngakumbi. Filler masterbatch, njengento eyongezelelweyo esebenzayo kwiprosesa yeplastiki, isetyenziswe ngokubanzi kwiinkalo ezahlukeneyo zemveliso yeplastiki ngenxa yeenzuzo zayo zokunciphisa iindleko zemveliso, ukuphucula ukusebenza kwemveliso kunye nokuphucula ukusebenza kakuhle. Sizibophelele ekuboneleleni ngemigca yemveliso yegranulation ephezulu kunye ne-extruders ephezulu yokusebenza kwiindidi ezahlukeneyo ze-filler masterbatch., ukuthembela kumava atyebileyo kuphando lweteknoloji ye-extrusion kunye nophuhliso kunye nokuveliswa, ukubonelela ngokujoliswe kuko, izisombululo ezisebenzayo nezithembekileyo zokusetyenzwa kwabavelisi be-filler masterbatch, ukunceda amashishini ukuphucula ukusebenza kakuhle kwemveliso, qinisekisa umgangatho wemveliso, kwaye ufumane inzuzo yokukhuphisana kukhuphiswano oluqatha lwemarike.

Eli nqaku liza kugxila kwintsimi ye-filler masterbatch, Ukucacisa nzulu kwiikhonsepthi ezisisiseko, ukuhlelwa, inkqubo yokuvelisa ye-filler masterbatch, indima ephambili yetekhnoloji ye-extrusion kwimveliso yayo yegranulation, iingenelo zothotho lwethu lwe-extruder kunye nohlengahlengiso olujolise kubo kwi-filler masterbatch processing, ngokunjalo nemimandla yesicelo ethile, iindlela zokusetyenziswa kunye neengxaki eziqhelekileyo kunye nezisombululo kwimveliso. Iza kuncedisa iiparameters ezineenkcukacha zobugcisa, iinkcukacha zenkqubo kunye namanqaku entlungu yoshishino ukutyebisa umxholo, ukuhlangabezana nemfuno yokubalwa kwamagama ye 3000-4000 amazwi, kunye nokubonelela ngereferensi ebanzi kunye neyobuchwephesha kumashishini afanelekileyo kunye neengcali kwishishini le-filler masterbatch.

1. Isishwankathelo seFiller Masterbatch Industry kunye neMveliso yeMveliso

1.1 Imeko yangoku kunye neNdlela yoPhuhliso yeFiller Masterbatch Industry

Kule minyaka yangoku, eqhutywa luphuhliso olukhawulezayo lwamashishini asezantsi afana nokupakishwa, ukwakhiwa, iimoto, i-elektroniki kunye nezinto eziyimfuneko zemihla ngemihla, Imakethi ye-filler masterbatch yehlabathi ibonise ukukhula okuzinzileyo. I-Filler masterbatch luhlobo lwemathiriyeli edibeneyo eyenziwa ngokuxutywa, Ukunyibilika, i-extruding kunye ne-granulating fillers ye-inorganic (njenge-calcium carbonate, i-talc, barium sulfate, njl.) kunye nabathwali bepolymer (njenge polyethylene, polypropylene, polyvinyl chloride, njl.) kunye nezongezo ezifanelekileyo (njengabasasazo, abahambelanayo, izinto zokuthambisa, njl.) ngokomlinganiselo othile. Umsebenzi wayo ophambili kukunciphisa iindleko zokuvelisa iimveliso zeplastiki ngelixa uphucula okanye ugcina umsebenzi osisiseko weemveliso zeplastiki.

Ngokweenkcukacha-manani ezifanelekileyo zedatha, ubungakanani bemarike ye-filler masterbatch yehlabathi igqithile 20 iibhiliyoni zeedola zaseMelika, kwaye kulindeleke ukuba kugcinwe izinga lokukhula kwe 6%-9% kwiminyaka embalwa ezayo. Phakathi kwabo, calcium carbonate (CaCO3) i-filler masterbatch lolona hlobo lwemveliso lusetyenziswa kakhulu, ukubalwa ngaphezulu kwe 60% kwimarike ye-filler masterbatch iyonke, ilandelwa yi-talc filler masterbatch, barium sulfate (I-BaSO4) i-filler masterbatch kunye nezinye ii-masterbatches ezikhethekileyo zokuzalisa. Ummandla weAsia-Pacific yeyona mveliso inkulu yehlabathi yokuzalisa i-masterbatch kunye nentengiso yokusetyenziswa, ukubalwa ngaphezulu kwe 50% yesabelo semarike yehlabathi, nto leyo ibangelwa ikakhulu kuphuhliso olukhawulezayo lweshishini lokulungisa iplastiki eTshayina, I-Indiya kunye namanye amazwe, imfuno enkulu yokunciphisa iindleko kunye nokuphucula ukusebenza kweemveliso zeplastiki, and the continuous improvement of industrial supporting capacity.

The development trend of the filler masterbatch industry is mainly reflected in four aspects: Ekuqaleni, high performance and functionalization. With the upgrading of downstream plastic product requirements, filler masterbatch is no longer limited to cost reduction, but gradually develops towards functionalization, such as improving the rigidity, toughness, ukumelana nobushushu, weather resistance and barrier properties of plastic products, and developing special functional filler masterbatches such as flame retardant, antistatic and antibacterial; Isibini, high filling amount and good dispersibility. Under the premise of ensuring product performance, increasing the filling amount of inorganic fillers can further reduce production costs, ebeka iimfuno eziphezulu kwi-dispersibility ye-filler masterbatch-i-dispersibility egqwesileyo inokuqinisekisa ukuba i-filler isasazwa ngokulinganayo kwi-matrix yeplastiki., ukuphepha ukubonakala kwamabala amhlophe, amabala amnyama okanye i-agglomeration kwimveliso yokugqibela; Isithathu, ukhuseleko lokusingqongileyo kunye nongcoliseko oluphantsi. Ngokuqiniswa kwemigaqo-nkqubo yehlabathi yokukhuselwa kwendalo kunye nokuphuculwa kolwazi lokhuseleko lwendalo esingqongileyo, abavelisi be-filler masterbatch ngokuthe ngcembe bamkela izongezo ezihambelana nokusingqongileyo kunye neenkqubo zemveliso, ukunciphisa ukukhutshwa kwezinto ezinobungozi, kunye nokuphuhlisa i-masterbatch ye-filler eyonakeleyo ukuziqhelanisa nendlela yophuhliso lweeplastiki eziluhlaza; Isine, ubukrelekrele kunye nokusebenza kakuhle kwezixhobo zokuvelisa. Ukuze kuhlangatyezwane nomlinganiselo omkhulu, iimfuno eziqhubekayo kunye nomgangatho ophezulu we-filler masterbatch, abavelisi bahlala bezisa imigca yemveliso yegranulation ephezulu kunye neenkqubo zokulawula ezikrelekrele, ukuphucula ukusebenza kakuhle kwemveliso, ukunciphisa iindleko zabasebenzi kunye nokuqinisekisa uzinzo lomgangatho wemveliso.

Ngokuchasene nale mvelaphi, iteknoloji yegranulation extrusion, njengetekhnoloji ephambili yemveliso ye-filler masterbatch, ibe ngundoqo ekumiseleni umgangatho we-filler masterbatch kunye nokhuphiswano lwamashishini. Ukusebenza kwee-extruders kuchaphazela ngokuthe ngqo i-dispersibility, imilo yamasuntswana, isalathisi sokunyibilika kunye nezinye izikhombisi eziphambili ze-filler masterbatch. I-extruders yethu yobuchwephesha kunye nemigca yemveliso yegranulation ye-filler masterbatch iphuhliswa ukuphendula kwiimpawu zoshishino kunye nemfuno yemarike., enokusombulula ngempumelelo amanqaku entlungu kwi-filler masterbatch processing (njengokuhlakazeka okubi, ubungakanani bamasuntswana angalinganiyo, inani eliphantsi lokuzalisa, ukusetyenziswa kwamandla aphezulu, njl.) kunye nokunceda amashishini afezekise umgangatho ophezulu kunye nemveliso esebenzayo.

1.2 Ukuhlelwa kweFiller Masterbatch kunye neempawu zayo eziphambili

I-filler masterbatch inokwahlulwa ibe ziindidi ezahlukeneyo ngokohlobo lokuzalisa, i-resin yokuthwala, indawo yesicelo kunye nesixa sokugcwalisa. Uhlobo ngalunye lwe-filler masterbatch luneempawu zalo ezizodwa kunye neemeko ezisebenzayo. Oku kulandelayo sisingeniso esineenkcukacha kuhlelo oluqhelekileyo kunye neempawu eziphambili ze-filler masterbatch:

1.2.1 UHlelo ngoNxibelelo lweSizalisi:

Le yeyona ndlela iqhelekileyo yokuhlela ye-filler masterbatch. Ngokohlobo lwe-inorganic filler, inokwahlulwa ikakhulu ibe yicalcium carbonate (CaCO3) filler masterbatch, i-talc filler masterbatch, barium sulfate (I-BaSO4) filler masterbatch, kunye nezinye ii-masterbatches zokugcwalisa ezikhethekileyo (njenge kaolin filler masterbatch, carbon black filler masterbatch, glass fiber filler masterbatch, njl.).

• Calcium carbonate (CaCO3) Isigcwalisi Masterbatch: Yeyona isetyenziswa kakhulu i-filler masterbatch enexabiso eliphantsi. Isigcwalisi ikakhulu i-calcium carbonate ekhanyayo okanye i-heavy calcium carbonate. I-calcium carbonate ekhanyayo inobungakanani bamasuntswana amahle, i-dispersibility enhle kunye nomhlophe ophezulu, efanelekileyo kwiimveliso zeplastiki ezineemfuno eziphezulu kwimbonakalo kunye nobuhle (njengeefilimu zeplastiki, isitofu ukubumba iimveliso); i-calcium carbonate enzima inobunzima obuphezulu, Ukumelana nokunxiba kakuhle kunye nexabiso eliphantsi, efanelekileyo kwiimveliso zeplastiki ezineemfuno eziphezulu kwi-rigidity kunye nolawulo lweendleko (ezifana neengxowa ezilukiweyo, amabhanti okupakisha, imibhobho, njl.). I-calcium carbonate filler masterbatch ayinakho ukunciphisa iindleko zemveliso kuphela, kodwa nokuphucula ukuqina, ukumelana nobushushu kunye nokuzinza kwe-dimensional yeemveliso zeplastiki, kwaye inefuthe elithile lokuthambisa, enokuthi iphucule ukusetyenzwa kwe-fluidity yeeplastiki.
• I-Talc Filler Masterbatch: I-filler yi-talc powder ene-layer structure. I-talc powder ineempawu ezintle zoomatshini, ukumelana nobushushu kunye nokuzinza kweekhemikhali. I-talc filler masterbatch isetyenziswa ikakhulu kwipolypropylene (PP) iimveliso zeplastiki, enokuphucula kakhulu ubungqongqo, iqondo lobushushu lokuguqula ubushushu kunye namandla empembelelo yeemveliso zePP, kwaye isetyenziswa kakhulu kwiindawo zemoto, amaqokobhe esixhobo sasekhaya, imibhobho yeplastiki kunye nezinye iindawo ezifuna ukusebenza okuphezulu.
• Barium sulfate (I-BaSO4) Isigcwalisi Masterbatch: Isigcwalisi yi-barium sulfate powder, enobumhlophe obuphezulu, kakuhle elubala, inertness imichiza kunye nokumelana radiation. I-Barium sulfate filler masterbatch ifanelekile kwiimveliso zeplastiki ezineemfuno eziphezulu ekukhanyeni, ubumhlophe kunye nokuzinza kweekhemikhali (njengeefilimu zeplastiki, iibhotile zeplastiki, iimveliso zeplastiki zonyango, njl.), kwaye isenokusetyenziswa kwiimveliso zeplastiki ezinobungqina bemitha (ezifana nezixhobo zokhuselo lwezonyango, izincedisi kwiplanti yamandla enyukliya, njl.).

1.2.2 Ukuhlelwa ngeCarrier Resin:

Ngokohlobo lwe-resin ye-carrier esetyenzisiweyo, i-filler masterbatch inokohlulwa ibe yi-polyethylene (PE) filler masterbatch, polypropylene (PP) filler masterbatch, polyvinyl chloride (I-PVC) filler masterbatch, i-polyethylene terephthalate (I-PET) filler masterbatch, njl. Ukukhethwa kwe-resin ye-carrier kuchongwa ngokukodwa luhlobo lweemveliso zeplastiki ezisezantsi. Umzekelo, I-PE filler masterbatch ifanelekile kwiimveliso zeplastiki ze-PE (njengeefilimu zeplastiki, iingxowa, imibhobho); I-PP filler masterbatch ifanelekile kwiimveliso zeplastiki zePP (ezifana neengxowa ezilukiweyo, ukubumba iindawo zokutofa, iindawo zemoto); I-PVC filler masterbatch ifanelekile kwiimveliso zePVC zeplastiki (njengemibhobho yePVC, iiprofayili, amaphepha).

1.2.3 Ukuhlelwa ngokweNdawo yeSicelo:

Ngokwentsimi yesicelo seemveliso zeplastiki ezisezantsi, i-filler masterbatch inokohlulwa ibe yifilim-grade filler masterbatch, I-injection-grade filler masterbatch, i-extrusion-grade filler masterbatch, vuthela ukubumba-grade filler masterbatch, njl. Ifilm-grade filler masterbatch ifuna i-dispersibility elungileyo, ubuhle obuphezulu kwaye akukho kungcola, ukuqinisekisa ukuba ifilimu evuthelweyo ayinamabala amhlophe, amabala amnyama okanye imingxunya, kwaye igcina ukungafihli kakuhle kunye nokomelela; I-injection-grade filler masterbatch ifuna ubumanzi obulungileyo kunye nobungakanani bamasuntswana afanayo, ukuziqhelanisa nenkqubo yokubumba inaliti ekhawulezayo kunye nokuqinisekisa ukubonakala kunye nokuchaneka komda weemveliso zokutofa; I-extrusion-grade filler masterbatch ifuna uzinzo oluhle lwe-thermal kunye neempawu zoomatshini, ukulungelelanisa ubushushu obuphezulu kunye nenkqubo yoxinzelelo oluphezulu lwemibhobho, iiprofayili kunye nezinye iimveliso.

1.2.4 Ukuhlelwa ngokugcwalisa isixa:

Ngokwexabiso lokuzaliswa kwe-inorganic fillers, i-filler masterbatch inokwahlulwa ibe yi-masterbatch yokugcwalisa okuphantsi (imali yokuzalisa 30%-50%), ukugcwalisa okuphakathi masterbatch (imali yokuzalisa 50%-70%) kunye nokuzaliswa okuphezulu kwe-masterbatch (imali yokuzalisa 70% nangaphezulu). Isixa sokuzaliswa sinqunywe ngokweemfuno zokusebenza kweemveliso ezisezantsi kunye nomthamo wokucubungula izixhobo. Ukuzaliswa okuphezulu kwe-masterbatch kunesiphumo esicacileyo sokunciphisa iindleko, kodwa ineemfuno eziphezulu kwi-dispersibility of fillers kunye nokusebenza kwee-extruders-i-high-performance extruders kuphela inokuqinisekisa ukudibanisa okufanayo kunye nokunyibilika kwezinto eziphezulu zokuzalisa., ukuphepha ukudityaniswa kunye nokungahambi kakuhle kokusetyenzwa.

Kuyafaneleka ukuba uqaphele ukuba izalathi zokusebenza eziphambili ze-filler masterbatch ikakhulu zibandakanya i-dispersibility, ukufana kobungakanani besuntswana, isalathisi sokunyibilika, ubumhlophe (kwiimveliso ezinombala okhanyayo) kunye nokuhambelana ne-carrier resin. Phakathi kwabo, I-dispersibility sesona sibonakaliso sibaluleke kakhulu-ukusasazeka okungalunganga kuya kukhokelela ekusabalazweni okungalinganiyo kwezigcwalisi kwiimveliso zeplastiki., okubangela iziphene ezifana namabala amhlophe, amabala amnyama, i-agglomeration kunye neemveliso ezinqabileyo, ezichaphazela kakhulu ukubonakala kunye nokusebenza kweemveliso zeplastiki. Ngoko ke, Ukukhethwa kwezixhobo eziphambili ze-extrusion kunye netekhnoloji yokucubungula isayensi kubalulekile ukuqinisekisa ukusasazeka kunye nomgangatho opheleleyo we-filler masterbatch.

2. Ubuchwephesha obungundoqo boMveliso weFiller Masterbatch: Extrusion Granulation Technology

Itekhnoloji ye-Extrusion granulation yitekhnoloji engundoqo yemveliso ye-filler masterbatch, edibanisa ukuxuba, Ukunyibilika, ukucheba, ukusasazeka kunye negranulation. Inenzuzo yokusebenza kakuhle kwemveliso, umgangatho omhle wemveliso, ukulungelelaniswa okunamandla kwizinto ezikrwada kunye noluhlu olubanzi lwesicelo. Kwimveliso ye-filler masterbatch, Itekhnoloji ye-extrusion granulation isetyenziswa ikakhulu ukuqonda ukusasazwa okufanayo kwezigcwalisi ezingaphiliyo kwi-polymer carrier., nyibilika kwaye wenze iplastiki umxube, kwaye emva koko ukhuphe kunye negranulate ukwenza i-masterbatch yegranular filler enobungakanani obufanayo, fluidity elungileyo kunye nokusebenza ezinzile. Umgangatho we-extrusion granulation umisela ngokuthe ngqo izikhombisi zentsebenzo eziphambili ze-filler masterbatch, njengokuhlakazeka, ubungakanani besuntswana kunye nesalathisi sokunyibilika.

2.1 Iimpawu zeFiller Masterbatch Raw Materials kunye neeMfuno zeExtrusion Equipment

Izinto eziluhlaza ze-filler masterbatch ikakhulu zibandakanya iinxalenye ezintathu: izigcwalisi ezingaphiliyo (njengeCaCO3, i-talc, I-BaSO4), abathwali bepolymer (njenge PE, PP, I-PVC) kunye nezongezo (njengabasasazo, abahambelanayo, izinto zokuthambisa, antioxidants, njl.). Iimpawu zezi zixhobo ekrwada zahluke kakhulu, ebeka phambili iimfuno ezikhethekileyo zezixhobo ze-extrusion:

Ekuqaleni, izigcwalisi ezingaphiliyo zinobunzima obuphezulu, ukungahambisani kakuhle nabathwali bepolymer, kwaye kulula ukuhlanganisa. Uninzi lwezihluzi ze-inorganic (njengeCaCO3, i-talc) zi hydrophilic, ngelixa abathwali bepolymer be-hydrophobic, nto leyo ekhokelela ekungahambelani kakuhle phakathi kwezizalisi kunye nabathwali. Ukuba ukuxuba kunye nokucheba akwanelanga, izigcwalisi ziya kudibana, which cannot be uniformly dispersed in the carrier, resulting in poor quality of filler masterbatch. Ukwengeza, the high hardness of inorganic fillers will cause serious wear to the screw and barrel of the extruder during the extrusion process, which requires the screw and barrel of the extruder to have extremely high wear resistance.

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

Isithathu, the processing temperature range is narrow. Iintlobo ezahlukeneyo ze-resin zomthwali zineendawo ezahlukeneyo zokunyibilika kunye nokuzinza kwe-thermal. Umzekelo, indawo yokunyibilika ye-PE yi-100-130℃, indawo yokunyibilika yePP yi-160-170℃, kunye nePVC kulula ukubola kumaqondo obushushu aphezulu (ngaphezulu kwe-160 ℃). Ngoko ke, izixhobo zokukhupha kufuneka zibe nomthamo ochanekileyo wokulawula ubushushu ukuqinisekisa ukuba umxube unyibilike ngokupheleleyo ngaphandle kokubola kwe-thermal., kunye nokuphepha ukubola kwezongezo kunye nokuwohloka kokusebenza kwemveliso.

Ngokusekelwe kwiimpawu ezingentla, I-extruders ye-screw eyodwa ayifanelekanga kwimveliso enkulu kunye nekhwalithi ephezulu ye-filler masterbatch. Ngenxa yokuba i-extruder-screw extruder inoluhlu olumxinwa lokucheba, amandla okumpompa kakubi kwaye akukho siphumo sokuzicoca. Xa kusetyenzwa i-high-viscosity kunye ne-high-filler mixes, kulula ukubangela ukuqokelelana kwezinto, ukuvaleka kunye nokuxuba okungafaniyo kwi-barrel extruder, resulting in poor dispersibility of filler masterbatch, ubungakanani bamasuntswana angalinganiyo kunye nomgangatho wemveliso ongazinzanga. Ukwengeza, i-extruder ye-screw enye inokusetyenziswa kwamandla aphezulu xa kusetyenzwa izixhobo zokuzalisa eziphezulu, kwaye i-screw kunye nebhere zigugile kakhulu, okwandisa iindleko zemveliso kunye neendleko zokugcina izixhobo zamashishini.

I-twin-screw extruders, kwelinye icala, banezibonelelo ezicacileyo kwimveliso ye-filler masterbatch kwaye baye baba sesona sixhobo siphambili sokuzalisa i-masterbatch extrusion granulation.. I-twin-screw extruders inoluhlu olubanzi lokucheba, isiphumo esisebenzayo sokumpompa kunye nesiphumo sokuzicoca, enokusombulula ngempumelelo iingxaki zokungahambelani kakuhle, i-agglomeration elula kunye nolwelo olulambathayo lwefiller masterbatch imathiriyeli ekrwada. Ukudibanisa kunye nokujikeleza kwezikrufu zamawele kunokuvelisa amandla aqinileyo okucheba kunye namandla okuxova, ezinokuthi zaphule ngokupheleleyo iiagglomerates ze-inorganic fillers, yenza iifayili zihlakazwe ngokufanayo kwi-polymer carrier, kunye nokuqinisekisa ukusasazeka kunye nokuzinza kwemveliso. Ukwengeza, i-twin-screw extruder inokuchaneka kokulawula ubushushu obulungileyo, ukuziqhelanisa okunamandla kwizinto ezikrwada, kwaye inokuziqhelanisa nokusetyenzwa kweentlobo ezahlukeneyo, Izixa ezahlukeneyo zokuzalisa ze-filler masterbatch, kwaye inokusebenza kakuhle kwemveliso kunye nokusetyenziswa kwamandla aphantsi.

2.2 Umgaqo-siseko wokuSebenza weFiller Masterbatch Extrusion Granulation

Inkqubo ye-extrusion granulation ye-filler masterbatch yinkqubo enzima yomzimba kunye neekhemikhali, ebandakanya intsebenziswano yezinto ezininzi ezifana nobushushu, uxinzelelo, ukucheba amandla kunye nexesha. Umgaqo othile wokusebenza kunye nokuhamba kwenkqubo zezi zilandelayo:

Ekuqaleni, ukunyangwa kwezinto ekrwada. Iimathiriyeli ekrwada ye-filler masterbatch (izigcwalisi ezingaphiliyo, i-resin yokuthwala, izongezo) kufuneka zilungiswe kwangaphambili ukuqinisekisa umgangatho wemveliso yokugqibela. Amanyathelo athile abandakanya: 1) Ukomisa unyango: Izigcwalisi ezingaphiliyo (njengeCaCO3, i-talc) zidla ngokuba yi-hydrophilic kwaye ziqulethe umlinganiselo othile wokufuma. Ukuba isiqulatho sokufuma siphezulu kakhulu, iya kuchaphazela umphumo wokuxuba kunye ne-dispersibility yezinto eziphathekayo, kwaye abangele amaqamza kwi-masterbatch ekhutshiweyo. Ngoko ke, iifayili kufuneka zomiswe kwindawo yokomisa (njengesomisi somoya oshushu, umatshini wokucoca) ukunciphisa umthamo wokufuma ube ngaphantsi 0.5%. 2) Ukutyumza kunye nokuhluzwa: I-resin yokuthwala (njenge PE, PP) icunyuziwe ibe ngamasuntswana amancinane okanye umgubo kunye nobungakanani bamasuntswana 20-40 umnatha, ehambelana nokuxubana okufanayo kunye nezihlungi kunye nezongezo. Iifayili ze-inorganic nazo zihluzwa ukususa ukungcola kunye namaqhekeza amakhulu, ukuqinisekisa ukucoleka kunye nokufana kwezizalisi. 3) Premixing: Ngokomlinganiselo wefomula, iifayili ezomileyo, i-carrier resin particles kunye ne-additives (abasasaza, abahambelanayo, izinto zokuthambisa, njl.) zifakwe kwi-high-speed mixer yokuxutywa kwangaphambili. Isantya sokuxuba ngokuqhelekileyo 800-1200 rpm, kwaye ixesha lokuxuba li 5-10 imizuzu. Injongo ye-premixing kukwenza ukuba izongezo zihambelane ngokulinganayo kumphezulu we-fillers kunye ne-carrier resin., ukuphucula ukuhambelana phakathi kwezihlungi kunye nomthwali, kwaye ubeke isiseko sokuxuba okulandelayo kwe-extrusion. I-dispersant iyona nto yokongeza kwi-premixing, enokwenza ifilimu ekhuselayo kumphezulu wokugcwalisa, ukunciphisa amandla angaphezulu okugcwalisa, ukuthintela isigcwalisi ukusuka agglomerating, kunye nokuphucula i-dispersibility ye-filler kwi-resin ye-carrier carrier.

Isibini, ukutyisa nokuhambisa. Umxube oxutyiweyo uthunyelwa kwi-hopper yokutya ye-twin-screw extruder ngokusebenzisa i-screw feeder okanye ibhanti lokutya.. Isantya sokutya kufuneka sifane kwaye sizinzile, ehambelana nesantya se-screw kunye nesantya se-extrusion ye-extruder, ukuqinisekisa ukuba izixhobo zingena kwi-extrusion cavity ngokuzinzileyo kwaye zigweme ukuqokelela kwezinto okanye ukutya okunganeleyo. Isixhobo sokutyisa se-extruder sihlala sixhotyiswe ngomsebenzi wokulawula isantya sokuguqula isantya, ekwazi ukulungelelanisa isantya sokutyisa ngokweyona meko yemveliso.

Isithathu, Ukunyibilika, ukuxuba kunye nokucheba. Izixhobo ezingena kwi-extrusion cavity ye-twin-screw extruder zityhalelwa phambili ngokuqhubekayo zizikrufu ezijikelezayo.. I-extrusion cavity yenziwe nge-screw kunye ne-barrel, kwaye umthamo we-extrusion cavity uyancipha ngokuthe ngcembe kwicala le-axis. Xa izikrufu zijikeleza, izinto eziphathekayo zinyanzeliswa ngokuthe ngcembe phantsi kwesenzo se-screws kunye ne-barrel, kwaye uxinzelelo kwi-extrusion cavity lukhula ngokuthe ngcembe (ngokubanzi 3-15MPa). Ngaxeshanye, izixhobo ziphantsi kwegunya eliqinileyo lokucheba kunye namandla okukhuhlana okuveliswa yintshukumo ehambelanayo phakathi kwezikrufu kunye nomphanda., kunye naphakathi kwe-flights screw.

Amandla okucheba kunye namandla okukhuhlana anokwaphula ngokupheleleyo i-agglomerates ye-inorganic fillers, yenza iifayili zihlakazwe ngokufanayo kwi-resin carrier carrier, kunye nokukhuthaza ukudibanisa kunye nokuhambelana phakathi kweefayili kunye nomthwali. Amandla okukhuhlana nawo anokwenza umlinganiselo othile wobushushu, edibaniswe nokufudumeza kwangaphandle kombhobho (ukufudumeza kombane okanye ukufudumeza umphunga) ukwenza i-resin ephetheyo inyibilike ngokuthe ngcembe kwaye iplastiki. Umgqomo we-extruder udla ngokuhlulwa 3-6 amacandelo okulawula ubushushu (icandelo lokutyisa, icandelo lokunyibilika, icandelo lokuxuba, icandelo le-homogenizing, njl.), kwaye ubushushu becandelo ngalinye bulawulwa ngokuchanekileyo ngokohlobo lwe-resin ye-carrier kunye nesigcwalisi. Umzekelo, xa kusetyenzwa i-PE carrier filler masterbatch, ubushushu becandelo lokutya yi-80-100℃, icandelo lokunyibilika yi-120-140℃, icandelo lokuxuba yi-140-150 ℃, kunye necandelo le-homogenizing yi-130-140 ℃; xa kusetyenzwa iPP carrier filler masterbatch, ubushushu becandelo ngalinye yi-20-30℃ ngaphezulu kwe-PE carrier.

Isine, i-extrusion kunye nokubunjwa. Inyibilike ngokupheleleyo, izinto ezixubeneyo nezihlakaziweyo zityhalelwa kwintloko yokufa ye-extruder ngezikrufu. Intloko yokufa ixhotyiswe ngemingxunya emininzi yokufa (inani kunye nobukhulu imingxunya die zimiselwe ngokobungakanani amasuntswana masterbatch), kwaye izinto zikhutshiwe kwimingxuma yokufa ngesantya esiphezulu ukwenza imicu eqhubekayo yobunzima obufanayo. Ubushushu bentloko yokufa bungaphantsi kancinci kunecandelo le-homogenizing, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the strips.

Fifth, cooling and cutting. The extruded strips are sent to a cooling device (such as a water tank, an air-cooled conveyor) for rapid cooling. The cooling temperature is generally 20-30℃, and the cooling time is 2-5 imizuzu. Ukupholisa ngokukhawuleza kunokwenza imicu yokuqina ngokukhawuleza, gcina imilo kunye nobukhulu bemicu, kwaye uphephe deformation. Emva kokupholisa, imicu ithunyelwa kwigranulator yokusika. I-granulator ixhotyiswe ngemela ejikelezayo, enokusika imicu ibe yi-masterbatch yegranular filler enobungakanani obufanayo (ubungakanani bamasuntswana ngokuqhelekileyo yi-2-5mm, enokulungiswa ngokweemfuno zabathengi). Isantya somese ojikelezayo sihambelana nesantya sokuhambisa imicu ukuze kuqinisekiswe ukuba ubukhulu beqhekeza le-masterbatch bufana..

Isithandathu, ukuhlolwa kunye nokupakishwa. I-masterbatch ye-granular filler cut cut ithunyelwa kwiscreen esingcangcazelayo ukuze sihlolwe, enokususa amasuntswana angafanelekanga (njengenkulu kakhulu, amasuntswana amancinci kakhulu okanye agglomerated) kwaye uqinisekise ukufana kwemveliso. I-masterbatch eqeqeshiweyo emva koko ithunyelwa kumatshini wokupakisha ozenzekelayo wokupakisha. Iimpawu zokupakisha zinokuhlengahlengiswa ngokweemfuno zabathengi (njenge 25kg/bag, 50kg/ibhegi), kwaye ukupakishwa kufuneka kutywinwe kunye nobungqina bokufuma ukukhusela i-masterbatch ekufunxeni ukufuma kunye nokuchaphazela umgangatho.. Emva kokupakisha, iimveliso zigcinwe kwindawo eyomileyo, Isitora esipholileyo nesingena umoya.

2.3 Imiba ephambili echaphazela iFiller Masterbatch Extrusion Granulation Effect

Umphumo we-extrusion granulation uchaphazela ngokuthe ngqo umgangatho we-filler masterbatch. Kukho izinto ezininzi ezichaphazela umphumo we-granulation, ikakhulu kuquka iimpawu zemathiriyeli ekrwada, umlinganiselo wefomula, isiphumo sokuxutywa, iparameters extrusion kunye ne-die head structure. Mastering these key factors and making scientific adjustments can ensure the stability of the granulation effect and the consistency of product quality.

2.3.1 Iimpawu zeMathiriyeli ekrwada:

Uhlobo, ubungakanani besuntswana, moisture content and purity of raw materials have a great impact on the granulation effect. Umzekelo, the particle size of inorganic fillers directly affects the dispersibility and fineness of the masterbatch. The finer the particle size of the filler (ngokubanzi 800-2000 umnatha), the better the dispersibility, but the higher the cost and the easier it is to agglomerate; the coarser the particle size, the lower the cost, but the dispersibility is poor, which will affect the appearance and performance of the masterbatch. The moisture content of raw materials (especially fillers) should be controlled below 0.5%; if the moisture content is too high, it will cause bubbles in the masterbatch, affect the density and mechanical properties of the product. The purity of raw materials is also very important; impurities in raw materials (such as stones, metals, dust) will not only affect the quality of the masterbatch, but also wear the screw and barrel of the extruder, and even cause equipment blockage.

2.3.2 Formula Ratio:

The formula ratio of filler masterbatch (the ratio of filler, carrier resin and additives) sisitshixo sokumisela ukusebenza kunye neendleko zemveliso. Isixa sokuzaliswa kwesigcwalisi kufuneka simiselwe ngokweemfuno zokusebenza kwemveliso esezantsi kunye nomthamo wokucutshungulwa kwezixhobo.. Isixa sokuzalisa esiphezulu kakhulu siya kukhokelela ekuhlakazekeni okubi, ukuqina okuphantsi kunye nokungahambi kakuhle kokusebenza kwe-masterbatch; ixabiso lokuzalisa eliphantsi kakhulu liya kunciphisa umphumo wokunciphisa iindleko. Uhlobo kunye nedosi yezongezo nazo kufuneka zihambelane ngokufanelekileyo. Umzekelo, idosi ye-disperant jikelele 1%-3% yedosi yokuzalisa; i-dispersansi encinci kakhulu iya kukhokelela ekuhlakazekeni okungalunganga kwesihluzi, kunye ne-dispersant kakhulu iya kuchaphazela ukuhambelana phakathi kwe-masterbatch kunye neemveliso zeplastiki ezisezantsi, kunye nokunciphisa iimpawu zemishini yeemveliso. I-compatibilizer isetyenziselwa ukuphucula ukuhambelana phakathi kokugcwalisa kunye ne-resin carrier; idosi ngokubanzi 0.5%-2%, enokuphucula kakhulu i-dispersibility kunye nepropathi yomatshini ye-masterbatch. I-lubricant isetyenziselwa ukunciphisa ingxabano phakathi kwezinto kunye ne-screw, umphanda kunye nokufa intloko, ukuphucula ukusetyenzwa kwamanzi, kwaye uthintele izixhobo zokunamathela kwisixhobo; idosi ngokubanzi 0.3%-1%.

2.3.3 Premixing Effect:

I-Premixing sisiseko se-extrusion granulation. Ukufana kwe-premixing kuchaphazela ngokuthe ngqo i-dispersibility ye-filler kwi-resin ye-carrier carrier. Ukuba i-premixing ayilingani, izongezo azikwazi ukunyathela ngokufanayo kumphezulu wokuzalisa kunye nomthwali, okukhokelela kwi-agglomeration yendawo yesigcwalisi, ukuxubana ngokungalingani kwezinto ngexesha lokukhupha, kunye nomgangatho ophantsi we-masterbatch. Ukuqinisekisa umphumo we-premixing, kuyimfuneko ukulawula isantya sokuxuba, ixesha lokuxuba kunye nobushushu bokuxuba. Isantya sokuxuba ngokuqhelekileyo 800-1200 rpm, ixesha lokuxuba li 5-10 imizuzu, kwaye ubushushu bokuxuba bulawulwa kwi-40-60 ℃ (ubushushu obufanelekileyo bunokuphucula ukunamathela kwezongezo kunye nokukhuthaza ukuxubana okufanayo).

2.3.4 Extrusion Parameters:

Iiparamitha zokukhupha zizinto ezibalulekileyo ezichaphazela umphumo we-granulation, ikakhulu ibandakanya isantya screw, ubushushu be-extrusion kunye noxinzelelo lwe-extrusion.

• Isantya seScrew: Isantya se-screw ngokubanzi sisuka kwi 150 ukuya 600 rpm. Isantya esiphezulu se-screw, Okukhona kukhulu amandla okucheba kunye namandla okukhuhlana afunyanwa zizixhobo, ngcono ukuxuba kunye nokusabalalisa umphumo we-filler, kunye nokusebenza kakuhle kwemveliso. Nangona kunjalo, ukuba isantya se-screw siphezulu kakhulu, ixesha lokuhlala lezinto kwi-extrusion cavity lifutshane kakhulu, okubangela ukunyibilika okungaphelelanga kwe-resin ye-carrier, ukuxuba okungonelanga kwezinto, kunye nomlinganiselo wamasuntswana ongalinganiyo we-masterbatch; ukuba isantya sokujija sisezantsi kakhulu, amandla okucheba kunye namandla okukhuhla awanelanga, isigcwalisi asinakuchithwa ngokupheleleyo, kunye nokusebenza kakuhle kwemveliso kuphantsi. Isantya se-screw kufuneka sihlengahlengiswe ngokwexabiso lokuzaliswa kunye nohlobo lwe-filler masterbatch-kwi-masterbatch ephezulu yokuzalisa., isantya esiphezulu se-screw siyafuneka ukuqinisekisa ukucheba okwaneleyo kunye nokuxuba.
• Extrusion Temperature: Ubushushu be-extrusion buhlukaniswe ngamacandelo amaninzi (icandelo lokutyisa, icandelo lokunyibilika, icandelo lokuxuba, icandelo le-homogenizing, icandelo lentloko yokufa), kunye nobushushu becandelo ngalinye kufuneka balawulwe ngokuchanekileyo ngokohlobo lwe-resin ye-carrier kunye ne-filler. Ubushushu becandelo lokutya buphantsi (phezulu kancinci kunendawo yokunyibilika ye-resin ephetheyo), which is mainly to prevent the materials from caking and ensure smooth feeding; ubushushu becandelo lokunyibilika buphakathi, which is mainly to promote the melting and plasticization of the carrier resin; the temperature of the mixing section is higher, eyona nto iphucula ukucheba kunye nesiphumo sokuxuba, kunye nokukhuthaza ukusasazwa okufanayo kwefayili; ubushushu becandelo le-homogenizing lingaphantsi kancinci kunecandelo lokuxuba, eyona nto iqinisekisa ubushushu obufanayo kunye ne-viscosity yezinto, kwaye uphephe ukubola kwe-thermal; ubushushu becandelo lentloko yokufa lingaphantsi kancinci kunecandelo le-homogenizing, oko kukuqinisekisa isiphumo sokubumba imicu.
• Uxinzelelo lwe-Extrusion: Uxinzelelo lwe-extrusion ngokubanzi luyi-3-15MPa. Uxinzelelo kwi-cavity ye-extrusion inqunywe ngokukodwa ngumlinganiselo wokunyanzeliswa kwe-screw, ubungakanani bomngxuma wokufa kunye nesantya sokujija. Ukuphakama koxinzelelo lwe-extrusion, ngcono ukuxuba kunye nokusabalalisa umphumo wezinto eziphathekayo, kunye ne-denser i-masterbatch particles. Nangona kunjalo, ukuba uxinzelelo luphezulu kakhulu, iya kwandisa ukusetyenziswa kwamandla kunye nokuguga kwezixhobo, and even cause the die head to block; ukuba uxinzelelo luphantsi kakhulu, the materials cannot be fully compressed and mixed, the masterbatch particles are loose, and the performance is unstable.

2.3.5 Die Isakhiwo seNtloko:

Ulwakhiwo lwentloko yeefa ikakhulu lubandakanya inani, imilo kunye nobukhulu beemingxuma zokufa. The shape of the die hole determines the cross-sectional shape of the extruded strips (njengesetyhula, isikwere), and the size of the die hole determines the initial diameter of the strips and the final particle size of the masterbatch. The smaller the die hole size, the greater the extrusion pressure, the better the mixing and dispersing effect, but the production capacity will be reduced; the larger the die hole size, the lower the extrusion pressure, isezantsi ukusebenza kakuhle kwemveliso, kodwa ubungakanani besuntswana le masterbatch likhulu. Inani lemingxuma yokufa lichaphazela umthamo wemveliso; ngakumbi inani die imingxuma, amandla emveliso aphezulu, kodwa kuyimfuneko ukuqinisekisa ukuba ukuhanjiswa koxinzelelo kufana, ukuze uthintele ubukhulu obungalinganiyo bemicu kunye nobungakanani besuntswana elingalinganiyo le-masterbatch.

3. Extruders zethu: Izinto eziluncedo kunye neCandelo leMveliso yeFiller Masterbatch Production

Kudala sizibandakanya kuphando, uphuhliso kunye nokuveliswa kwe-extruders ephezulu yokusebenza kunye nemigca yokuvelisa i-granulation, kwaye baqokelele amava atyebileyo kwintsimi ye-filler masterbatch processing. Ngokweempawu ze-filler masterbatch izinto ezikrwada (ubunzima obuphezulu, ukungahambelani kakuhle, viscosity ephezulu) kunye neemfuno zokuqhuba (ukusasazeka kakuhle, ubungakanani bamasuntswana afanayo, imali yokuzalisa ephezulu), siphuhlise uthotho lwe-twin-screw extruders ezifanelekileyo ngokukodwa kwi-filler masterbatch production. I-extruders yethu ineenzuzo zokumelana nokunxiba okuphezulu, amandla okucheba anamandla, ulawulo lobushushu oluchanekileyo, ukusebenza okuzinzileyo kunye neendleko eziphantsi zokusebenza, enokuhlangabezana neemfuno zokusetyenzwa kweentlobo ngeentlobo, Izixa ezahlukeneyo zokuzalisa ze-filler masterbatch (CaCO3, i-talc, I-BaSO4, njl.), kunye nokunceda amashishini aphucule ukusebenza kakuhle kwemveliso, qinisekisa umgangatho wemveliso kunye nokunciphisa iindleko zemveliso.

3.1 Izinto eziNgcono ziPhambili kwii-Extruders zethu zeFiller Masterbatch Production

3.1.1 Ukumelana nokuNxitywa okuphezulu, Ubomi Obude Benkonzo:

Ijolise kwingxaki yokuba izigcwalisi ezingaphiliyo (njengeCaCO3, i-talc) ube nobunzima obuphezulu kwaye kulula ukunxiba isikrufu kunye nomphanda, Samkela umgangatho ophezulu wezinto zokunxiba kunye netekhnoloji ephezulu yokuvelisa ukuqinisekisa ukunxitywa kwezinto eziphambili ze-extruder.. I-screw kunye ne-barrel zenziwe ngentsimbi ye-alloy ekwazi ukumelana nokunxiba (njenge 38CrMoAlA), kwaye emva konyango lwe-nitriding okanye unyango lwe-bimetallic composite, ukuqina komphezulu kunokufikelela kwi-≥65 HRC, enoxhathiso olomeleleyo lokunxiba kunye nokumelana nomhlwa, kwaye inokuxhathisa ngokufanelekileyo ukunxiba okubangelwa ukungqubana phakathi kwe-high-hardness filler kunye namacandelo. Oku kwandisa kakhulu ubomi benkonzo ye-screw kunye nomgqomo, kunciphisa ukuphindaphinda kokutshintshwa kwecandelo, kunye nokunciphisa iindleko zokugcina izixhobo. Ukwengeza, sikwabonelela ngeenkonzo zokubona ukunxitywa kobuchwephesha kwisikrufu kunye nomgqomo. Iqela lethu lobuchwephesha liya kuhlala libona idigri yokunxiba yesikrufu kunye nomgqomo kubathengi, khupha ingxelo eneenkcukacha zokunxiba, kunye nokubeka phambili iingcebiso ezithagethiweyo zokutshintshwa nokugcinwa kwazo, ensuring that customers only replace components when necessary, avoiding unnecessary waste.

3.1.2 Strong Shearing and Mixing Capacity, Excellent Dispersibility:

The key to filler masterbatch production is to ensure the uniform dispersion of fillers. Our twin-screw extruders adopt an intermeshing co-rotating twin-screw structure, with a reasonable screw pitch, lead and compression ratio design. Ukudibanisa kunye nokujikeleza kwezikrufu zamawele kunokuvelisa amandla aqinileyo okucheba kunye namandla okuxova, ezinokuthi zaphule ngokupheleleyo iiagglomerates ze-inorganic fillers, yenza iifayili zihlakazwe ngokufanayo kwi-resin carrier carrier, and ensure the dispersibility of the masterbatch. The screw is designed with a modular structure, and different screw elements (such as conveying elements, ukuxuba izinto, shearing elements) can be freely combined according to the type and filling amount of filler masterbatch, so as to adjust the shear force and mixing effect, and achieve the best processing effect. Umzekelo, when processing high-filling CaCO3 masterbatch, singaqwalasela izinto ezininzi zokucheba ukunyusa isiphumo sokucheba kunye nokuqinisekisa ukusasazwa okufanayo kwesigcwalisi; xa kusetyenzwa i-talc masterbatch efuna ukufana okuphezulu kokuxuba, sinokuqwalasela izinto ezininzi zokuxuba ukuphucula umphumo wokuxuba.

3.1.3 Ulawulo lobushushu obuchanekileyo, Ukusebenza okuzinzileyo:

Ii-extruders zethu zamkela iinkqubo zokulawula ubushushu obukrelekrele, enokuqonda ulawulo oluchanekileyo lobushushu becandelo ngalinye lomphanda kunye nentloko yokufa. Ukuchaneka kokulawula ubushushu kunokufikelela kwi-±1℃, enokuqinisekisa ukuba i-resin ye-carrier iyancibilika ngokupheleleyo ngaphandle kokubola kwe-thermal, kwaye izongezo aziboli, ukuqinisekisa ukuzinza kokusebenza kwemveliso. Inkqubo yokulawula ubushushu ixhotyiswe ngokubeka iliso ngexesha langempela kunye nomsebenzi we-alamu. If the temperature of any section exceeds the set range, the system will issue an alarm prompt in time, and even automatically adjust the heating power or shut down the equipment if necessary, to avoid equipment failure and product quality problems. Ukwengeza, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time. If the pressure is too high or too low, the system will adjust the screw speed or feeding speed automatically, ensuring the stability of the extrusion process.

3.1.4 Uluhlu olubanzi lwesicelo, Strong Flexibility:

Our extruder series can adapt to the processing needs of various types of filler masterbatch, including CaCO3 filler masterbatch, i-talc filler masterbatch, BaSO4 filler masterbatch, kunye nezinye ii-masterbatches zokugcwalisa ezikhethekileyo. The filling amount can be adjusted from 30% ukuya 80%, which can meet the different cost and performance requirements of customers. Uyilo lwemodyuli ye-extruder (isikrufu, umphanda, fa intloko, njl.) yenza ukutshintshwa kwamacandelo kube lula kwaye ngokukhawuleza. Xa abathengi kufuneka balungise uhlobo lwemveliso okanye isixa sokuzalisa, kufuneka kuphela ukubuyisela amacandelo ahambelanayo, ngaphandle kokutshintsha isixhobo sonke, okunciphisa iindleko zokuguqulwa kwezixhobo kunye nokuphucula ukuguquguquka kunye nokuguquguquka kwezixhobo. Ukwengeza, ii-extruders zethu zinokudityaniswa nezixhobo ezahlukeneyo ezincedisayo (njengemixube enesantya esiphezulu, ezomisi, izinto ezipholileyo, iigranulators, oomatshini bokuhlola, oomatshini bokupakisha) ukwenza umgca wemveliso wegranulation opheleleyo ozenzekelayo, ukuqonda imveliso eqhubekayo ukusuka kunyango lwangaphambili ukuya kupakisho lwemveliso.

3.1.5 UFaneka oluPhezulu lweMveliso, Ukusetyenziswa kwamandla aphantsi:

I-twin-screw extruders yethu inemveliso ephezulu yokusebenza kakuhle, which is much higher than that of single-screw extruders. Umthamo wemveliso ye-extruders yethu isukela kwi-100kg/h ukuya kwi-3000kg/h, enokuhlangabezana neemfuno zemveliso yezikali ezahlukeneyo zamashishini (encinci, phakathi kunye enkulu). Inkqubo yokuqhuba i-torque ephezulu kunye noyilo olulungisiweyo lwe-screw ye-extruder inokuphucula ngokufanelekileyo umthamo wokuhambisa kunye nokusebenza kakuhle kweplastiki yezixhobo., ukunciphisa ixesha lokuhlala lezinto kwi-cavity extrusion kunye nokuphucula ukusebenza kakuhle kwemveliso. Ngaxeshanye, i-extruder ithatha uyilo lokugcina amandla, njengemoto esebenza ngamandla, isixhobo sokubuyisela ubushushu, njl., enokunciphisa iyunithi yokusetyenziswa kwamandla 15%-25% xa kuthelekiswa nee-extruders eziqhelekileyo, ukunceda amashishini ukunciphisa iindleko zemveliso.

3.1.6 Ukusebenza ngokulula kunye noLondolozo:

I-extruders yethu ithatha inkqubo ye-PLC yokulawula ehlakaniphile kunye ne-interface yokusebenza kwesikrini, elula kwaye enomdla, kulula ukusebenza. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of filler masterbatch, badinga kuphela ukubiza ifomula ehambelanayo kunye neeparamitha, ngaphandle kolungiso oluphindaphindiweyo, which saves time and improves production efficiency. The modular design of the equipment makes the maintenance more convenient. The screw, umphanda, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Our after-sales service team will provide professional installation, commissioning and training services for customers, ensuring that customers can use the equipment smoothly.

3.2 Our Extruder Product Series and Their Adaptation to Filler Masterbatch

In order to meet the diverse production needs of filler masterbatch enterprises of different scales and product types, we have launched a full range of twin-screw extruder products, including HTS BASIC series, HTS PLUS series, HTS SUPER series, ZTE series and HTE series. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, product type, budget and other factors.

3.2.1 HTS BASIC Series Extruders: Cost-Effective Choice for Medium and Small-Scale Enterprises.

The HTS BASIC series extruders are a cost-effective product series independently developed by us, which are specially designed for filler masterbatch processing enterprises with medium and small production scales or initial entry into the industry. This series of extruders uses medium-torque gearboxes from leading European manufacturers, which have the advantages of stable performance, low noise, high efficiency and long service life. The medium-torque design can meet the processing needs of most common filler masterbatch (such as low-to-medium filling CaCO3 masterbatch, PE/PP carrier masterbatch), and at the same time, it has a reasonable price, which can help enterprises reduce the initial investment cost.

In terms of structural design, the HTS BASIC series extruders adopt a twin-screw parallel structure, with a screw diameter ranging from 30mm to 65mm, and a compression ratio of 4～8, enokuthi ihlengahlengiswe ngokohlobo kunye nokuzaliswa kwemali ye-filler masterbatch. Umphanda wenziwe ngentsimbi ye-alloy engagungqiyo kunye nonyango lwe-nitriding, kwaye isikrufu senziwe ngentsimbi engagugiyo kunye ne-corrosion-resistant alloy steel, enokumelana nokunxiba kakuhle. I-extruder ixhotyiswe ngenkqubo yokulawula ye-PLC kunye ne-interface yokusebenza kwesikrini sokuchukumisa, ezinokuthi zifumane ukutya okuzenzekelayo, ulawulo lobushushu oluzenzekelayo, ukulawula uxinzelelo oluzenzekelayo kunye nokusika okuzenzekelayo, kwaye ilula kwaye kulula ukuyisebenzisa.

Umthamo wemveliso ye-HTS BASIC i-extruders series ranges ukusuka kwi-100kg/h ukuya kwi-500kg/h., elilungele amashishini aphakathi kunye namancinci okuzalisa i-masterbatch avelisa ubukhulu becala i-masterbatch yokugcwalisa eqhelekileyo (njengeCaCO3 masterbatch yeefilimu zeplastiki, iingxowa ezilukiweyo). Enye yeenzuzo ezinkulu zolu luhlu kukuba inokubonelela ngeenketho eziguquguqukayo ngokusebenzisa imidibaniso eyahlukeneyo yoqwalaselo. Abathengi banokukhetha izinto ezahlukeneyo ze-screw, kufa iintloko, izixhobo zokutya, izixhobo zokomisa kunye nezixhobo zasemva kokulungiswa ngokweentlobo zazo zemveliso, umthamo wemveliso kunye nohlahlo lwabiwo-mali, ukuze benze umgca wemveliso olungele iimfuno zabo.

3.2.2 HTS PLUS Series Extruders: UKhetho oluPhezulu lokuSebenza kubuNjineli bePlastiki kunye neFiller Masterbatch.

Ii-HTS PLUS uthotho lwee-extruders zisebenzisa ii-gearbox ze-torque eziphezulu ngokuzimeleyo eziphuhliswe kwaye zenziwe sithi, ezinetorque eyomeleleyo kunye nomthamo wokuthwala umthwalo kunothotho lwe-HTS BASIC. Olu chungechunge lwe-extruders lusetyenziselwa ukusetyenzwa kwe-masterbatch ye-filler ephezulu, ezifana nokuzaliswa okuphezulu kweCaCO3 masterbatch (umyinge wokuzalisa ≥60%), talc masterbatch, BaSO4 masterbatch, and filler masterbatch for engineering plastics (such as PP, PA, I-PC).

The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～600 rpm. The screw and barrel adopt bimetallic composite treatment, enokumelana nokunxiba okuphezulu kunye nokumelana nomhlwa, kwaye iyakwazi ukuziqhelanisa nokusetyenzwa kweefayili ezinobunzima obuphezulu (njenge-calcium carbonate enzima, i-talc) kunye nezixhobo zokuzalisa eziphezulu. I-extruder ixhotyiswe ngenkqubo yolawulo olukrelekrele oluphambili, enokuqonda ulawulo oluchanekileyo lweeparamitha ze-extrusion kunye nokubeka iliso ngexesha lokwenyani ledatha yemveliso. Umthamo wemveliso usukela kwi-500kg/h ukuya kwi-2000kg/h, elilungele amashishini aphakathi kunye namakhulu e-filler masterbatch alandela ukusebenza okuphezulu kunye nesixa esikhulu sokuzalisa.

Ukwengeza, i-HTS PLUS ii-extruders ze-series zinomxube onamandla kunye nokucheba umthamo, ezinokuthi zisasaze ngokupheleleyo iifayili zokuzalisa eziphezulu kwi-resin carrier, ukuqinisekisa ukusabalalisa kunye nokuzinza kwe-masterbatch. It is especially suitable for the production of filler masterbatch used in automotive parts, amaqokobhe esixhobo sasekhaya, high-grade plastic films and other high-performance plastic products.

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

The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us. Aiming at the high torque and high speed characteristics of this series, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. This series of extruders is mainly used for the processing of high-end, special and high-performance filler masterbatch, such as high-filling BaSO4 masterbatch (for medical plastics, high-grade films), glass fiber reinforced filler masterbatch, flame-retardant filler masterbatch, and filler masterbatch for special engineering plastics.

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

The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for large-scale high-end filler masterbatch enterprises that pursue high efficiency, high performance and intelligence. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end filler masterbatch.

3.2.4 ZTE Series Extruders: Cost-Effective Choice for General Filler Masterbatch.

The ZTE series extruders have excellent cost performance, and their designed parameters are suitable for most filler masterbatch materials (such as low-to-medium filling CaCO3 masterbatch, PE/PP carrier masterbatch). This series of extruders adopts a simplified and optimized structure, which reduces the production cost while ensuring the basic performance, and is suitable for small and medium-sized enterprises with limited budget and general product requirements.

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

3.2.5 HTE Series Extruders: High-Efficiency and Energy-Saving Choice for Large-Scale Production.

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

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

3.3 Selection Suggestions for Filler Masterbatch Extruders

When selecting extruders for filler masterbatch production, enterprises need to comprehensively consider their own production needs, product types, imali yokuzalisa, budget and other factors to ensure that the selected equipment can meet the actual production needs and bring maximum economic benefits. The following are some specific selection suggestions:

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

Different types and filling amounts of filler masterbatch have different requirements for extruders. Umzekelo, if the enterprise mainly produces low-to-medium filling CaCO3 masterbatch (filling amount ≤60%) and common PE/PP carrier masterbatch, the HTS BASIC series or ZTE series extruders are suitable; if the enterprise produces high-filling masterbatch (umyinge wokuzalisa ≥60%), talc masterbatch or BaSO4 masterbatch, the HTS PLUS series extruders are recommended; if the enterprise produces high-end, special filler masterbatch (such as glass fiber reinforced masterbatch, flame-retardant masterbatch), the HTS SUPER series extruders are the best choice; if the enterprise pursues large-scale, energy-saving and high-efficiency production, the HTE series extruders are suitable.

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

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

3.3.3 Qwalasela i-Wear Resistance yeZixhobo:

Ukuxhatshazwa kokugqoka kwe-screw kunye ne-barrel yinto ephambili echaphazela ubomi benkonzo kunye neendleko zokusebenza ze-extruder. Kumashishini aqhuba izigcwalisi ezinobunzima obuphezulu (njenge-calcium carbonate enzima, i-talc) okanye i-masterbatch ephezulu yokuzalisa, kuyimfuneko ukukhetha i-extruders kunye nokumelana nokunxiba okuphezulu (ezifana Screw kunye umphanda ngonyango bimetallic composite okanye laser cladding unyango), ezifana HTS PLUS series kunye HTS SUPER series, ukunciphisa ukuphindaphinda kweendleko zokutshintshwa kwecandelo kunye nokugcinwa kwazo.

3.3.4 Qwalasela iNdleko-Ngempumelelo yeSixhobo:

Amashishini akufuneki anikele ingqalelo kuphela kwiindleko zokuqala zotyalo-mali lwezixhobo, kodwa kwakhona uqwalasele iindleko zokusebenza kwexesha elide (such as energy consumption, maintenance cost, spare parts cost). Umzekelo, although the initial investment of the HTS SUPER series extruders is high, their wear resistance, stability and production efficiency are better, and the long-term operating cost is lower; the ZTE series extruders have a low initial investment, but their production capacity and wear resistance are limited, which is suitable for enterprises with limited budget and small-scale production.

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

The after-sales service of the equipment is crucial for the normal operation of the production line. Enterprises should select manufacturers with perfect after-sales service systems, which can provide professional installation, ukugunyazisa, uqeqesho, maintenance and spare parts supply services. We have a professional after-sales service team, which can respond to customer needs in a timely manner (provide solutions within 24 iiyure) and send technicians to the site for maintenance if necessary, ensuring the normal operation of the production line.

3.3.6 Consider the Flexibility and Expandability of the Equipment:

With the changes of market demand, enterprises may need to adjust their product types and filling amounts. Ngoko ke, when selecting extruders, enterprises should consider the flexibility and expandability of the equipment. Our extruders adopt a modular design, which can be freely combined and upgraded according to the needs of enterprises, improving the flexibility and expandability of the equipment, and reducing the cost of equipment transformation.

4. Application Fields and Usage Methods of Filler Masterbatch

Filler masterbatch, njengento eyongezelelweyo esebenzayo kwiprosesa yeplastiki, has a wide range of application fields, covering various fields such as plastic packaging, ukwakhiwa, iimoto, izinto zombane, daily necessities and agriculture. Its core role is to reduce the production cost of plastic products while improving or maintaining the basic performance of plastic products. The following will introduce the specific application fields and usage methods of filler masterbatch in detail:

4.1 Application Fields of Filler Masterbatch

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

4.1.1 Plastic Packaging Industry:

This is the largest application field of filler masterbatch, ukubalwa ngaphezulu kwe 50% of the total application amount. Filler masterbatch is widely used in the production of plastic films, plastic bags, iingxowa ezilukiweyo, amabhanti okupakisha, packaging containers and other packaging products.

• Iifilimu zePlastiki: Kubandakanya iifilimu zeplastiki ezincinci, iifilimu ezishinyeneyo, ezolula iifilimu, iifilimu zegreenhouse, njl. I-filler masterbatch esetyenziselwa iifilimu zeplastiki ikakhulu ukukhanya kwe-calcium carbonate filler masterbatch okanye i-barium sulfate filler masterbatch., efuna ukusasazeka okulungileyo, ubuhle obuphezulu kwaye akukho kungcola, ukuqinisekisa ukuba ifilimu evuthelweyo ayinamabala amhlophe, amabala amnyama okanye imingxunya, kwaye igcina ukungafihli kakuhle, ukuqina kunye namandla okuqina. Ukongeza isixa esifanelekileyo se-filler masterbatch ayinakunciphisa kuphela iindleko zokuvelisa ifilimu, kodwa nokuphucula ukuqina, ukumelana nobushushu kunye nokuzinza kwe-dimensional yefilimu, kwaye unciphise izinga lokuncipha kwefilimu. Umzekelo, kwimveliso yeengxowa zokuthenga zeplastiki, ukongeza 1%-3% yeCaCO3 filler masterbatch inokunciphisa ixabiso nge 5%-10% ngaphandle kokuchaphazela ubunzima kunye nomthamo wokuthwala umthwalo weengxowa.
• Iingxowa zePlastiki: Kubandakanywa neengxowa zokuthenga, iingxowa zevest, iingxowa zenkunkuma, iingxowa zokupakisha ukutya, njl. The filler masterbatch used for plastic bags is mainly heavy calcium carbonate filler masterbatch, which has low cost and good wear resistance. Adding 2%-5% of filler masterbatch can reduce the cost and improve the rigidity and wear resistance of the bags. For garbage bags, adding an appropriate amount of filler masterbatch can also improve the toughness and tear resistance of the bags, making them not easy to break.
• Woven Bags and Packaging Belts: Woven bags are widely used in the packaging of grain, fertilizer, isamente, chemical products and other goods; packaging belts are used for the bundling of goods. The filler masterbatch used for woven bags and packaging belts is mainly heavy calcium carbonate filler masterbatch or talc filler masterbatch, which requires high rigidity and wear resistance. Adding 5%-10% ye-filler masterbatch inokuphucula ukuqina, ukomelela nokunxitywa kweengxowa ezilukiweyo kunye namabhanti okupakisha, ukunciphisa iindleko, kunye nokwandisa ubomi benkonzo yeemveliso.
• Izikhongozeli zokuPakisha: Kubandakanywa neebhotile zeplastiki, imigqomo yeplastiki, iibhokisi zeplastiki, njl. I-filler masterbatch esetyenziselwa ukupakisha izikhongozeli ikakhulu yi-barium sulfate filler masterbatch okanye ukukhanya kwe-calcium carbonate filler masterbatch., efuna ukungafihli kakuhle kunye nokuzinza kweekhemikhali. Ukongeza isixa esifanelekileyo se-filler masterbatch kunokunciphisa iindleko kwaye kuphuculwe ukuqina kunye namandla empembelelo yezikhongozeli..

4.1.2 Ishishini loLwakhiwo lwePlastiki:

I-filler masterbatch isetyenziswa ngokubanzi kwimveliso yeepayipi zeplastiki, iiprofayili zeplastiki, amaphepha eplastiki, iithayile zeplastiki kunye nezinye iimveliso zokwakha.

• Imibhobho yePlastiki: Kubandakanya imibhobho yePVC, Imibhobho ye-PE, imibhobho yePP, njl., which are used for water supply, drainage, gas transmission, cable protection and other fields. The filler masterbatch used for plastic pipes is mainly calcium carbonate filler masterbatch or talc filler masterbatch, which requires high rigidity, heat resistance and pressure resistance. Adding 5%-15% ye-filler masterbatch inokuphucula ukuqina, heat distortion temperature and pressure resistance of the pipes, ukunciphisa iindleko, and prevent the pipes from deforming under high temperature and pressure.
• Plastic Profiles: Including PVC profiles for doors and windows, plastic decorative profiles, njl. The filler masterbatch used for plastic profiles is mainly calcium carbonate filler masterbatch, which requires good weather resistance and impact strength. Adding 5%-10% ye-filler masterbatch inokuphucula ukuqina, weather resistance and impact strength of the profiles, ukunciphisa iindleko, and ensure the service life of the profiles in outdoor environments.
• Plastic Sheets: Including PVC sheets, PE sheets, Amaphepha ePP, njl., ezisetyenziselwa ukuhombisa ngaphakathi, ukupakishwa, ukuthintela amanzi kunye neminye imimandla. I-filler masterbatch esetyenziselwa amaphepha eplastiki ikakhulu yi-calcium carbonate filler masterbatch okanye i-barium sulfate filler masterbatch., nto leyo ifuna ukuthamba okuhle kunye nokuqina. Adding 3%-8% ye-filler masterbatch inokunciphisa iindleko kunye nokuphucula ukuqina kunye nokuqina kwamaphepha.

4.1.3 Ishishini lokuBumba lePlastiki yesitofu:

I-Filler masterbatch isetyenziswa ngokubanzi kwimveliso yeemveliso ezahlukeneyo zokubumba inaliti, njengeeplastiki eziyimfuneko zemihla ngemihla, iithoyi zeplastiki, iindawo zeplastiki, amaqokobhe eplastiki njalo njalo.

• IiMfuno zePlastiki zemihla ngemihla: Kubandakanywa izitya zeplastiki, iipleyiti zeplastiki, iikomityi zeplastiki, iingobozi zeplastiki, iibhakethi zeplastiki kunye nezinye izinto eziyimfuneko. I-filler masterbatch esetyenziselwa ezi mveliso ikakhulu yi-calcium carbonate filler masterbatch, enexabiso eliphantsi kunye nokhuseleko oluhle. Adding 2%-5% of filler masterbatch can reduce the cost and improve the rigidity and impact strength of the products, making them not easy to break.
• Plastic Toys: Including various plastic toys for children. The filler masterbatch used for plastic toys is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires high safety, non-toxicity, good dispersibility and no odor, in line with international toy safety standards (such as EN 71, ASTM F963). The particle size of the filler should be fine (ngaphezulu 1250 umnatha) to avoid scratching children’s skin and ensure the smoothness of the toy surface. Adding 1%-3% of light calcium carbonate filler masterbatch can reduce the production cost of toys without affecting the toughness and colorability of the toys; barium sulfate filler masterbatch is suitable for transparent or semi-transparent plastic toys, which can improve the transparency and surface gloss of the toys, making them more beautiful.
• Plastic Parts and Shells: Including plastic parts for home appliances, automotive interior parts, electronic product shells, njl. The filler masterbatch used for these products is mainly talc filler masterbatch or glass fiber reinforced filler masterbatch, which requires high rigidity, heat resistance and impact strength. Umzekelo, in the production of automotive interior parts (such as instrument panels, door panels), ukongeza 5%-8% of talc filler masterbatch can improve the rigidity and heat distortion temperature of the parts, reduce the shrinkage rate, and make the parts not easy to deform under high temperature environment in the car; in the production of electronic product shells (such as mobile phone shells, router shells), ukongeza 3%-5% yeglasi yefiber eyomeleziweyo yokuzalisa i-masterbatch inokuphucula amandla empembelelo kunye nokuchaneka komda kwamaqokobhe., ukwandisa ukuqina kweemveliso.

4.1.4 Ishishini lePlastiki yeemoto:

Ngomkhwa wokukhaphukhaphu kunye nokonga amandla kushishino lweemoto, izinto zeplastiki zisetyenziswa kakhulu kwimveliso yeemoto, kunye ne-filler masterbatch, njengesongezo esisebenzayo esibalulekileyo, idlala indima ephambili ekunciphiseni iindleko kunye nokuphucula ukusebenza. Ukusetyenziswa kwe-filler masterbatch kwishishini leplastiki yeemoto ligxile kakhulu kwiindawo zangaphakathi zeemoto, amalungu angaphandle kunye namalungu asebenzayo.

• iiNdawo zangaphakathi zeemoto: Kubandakanywa iiphaneli zesixhobo, door panels, izihlalo zokuhlala, iindawo zokumisa iingalo, njl. Ezi nxalenye zineemfuno eziphezulu kwi-rigidity, ukumelana nobushushu, ivumba eliphantsi kunye nokukhuselwa kwendalo. Talc filler masterbatch and calcium carbonate filler masterbatch are the most commonly used products. Talc filler masterbatch can significantly improve the rigidity and heat resistance of polypropylene (PP) izixhobo, making the interior parts have good dimensional stability; calcium carbonate filler masterbatch has the advantages of low cost and good processing fluidity, which can reduce the production cost of interior parts. Umzekelo, ukongeza 6%-10% of talc filler masterbatch to PP instrument panels can improve the heat distortion temperature by 15-25℃, and reduce the production cost by 8%-12%.
• Automotive Exterior Parts: Including bumpers, fenders, door handles, njl. These parts are exposed to the outdoor environment for a long time, so they have high requirements on weather resistance, impact strength and UV resistance. The filler masterbatch used for exterior parts is mainly talc filler masterbatch or barium sulfate filler masterbatch, which is usually compounded with weather-resistant additives. Adding 4%-7% of talc filler masterbatch can improve the impact strength and rigidity of the exterior parts, enhance their resistance to external impact; barium sulfate filler masterbatch can improve the weather resistance and color retention of the exterior parts, making them not easy to fade and aging under the action of sunlight and rain.
• Automotive Functional Parts: Including air intake pipes, cooling system parts, battery casings, njl. These parts have high requirements on heat resistance, chemical resistance and mechanical properties. I-masterbatch ye-filler esetyenziselwa amalungu asebenzayo ikakhulu yi-glass fibre eyomeleziweyo yokuzalisa i-masterbatch okanye i-masterbatch ekhethekileyo ye-mineral filler.. Umzekelo, ukongeza 10%-15% yeglasi yefiber eyomeleziweyo yokuzalisa i-masterbatch kumbhobho wokungenisa umoya unokuphucula ukumelana nobushushu kunye noxinzelelo loxinzelelo lombhobho., ukuqinisekisa ukusebenza kwayo okuqhelekileyo phantsi kobushushu obuphezulu kunye noxinzelelo oluphezulu; Ukongeza i-barium sulfate filler masterbatch kwi-casing yebhetri inokuphucula ukumelana nemitha kunye nokuzinza kweekhemikhali zecasing., ukuqinisekisa ukhuseleko lwebhetri.

4.1.5 Ishishini lePlastiki yoMbane kunye noMbane:

Iimveliso ze-elektroniki kunye nezombane zineemfuno eziphezulu kwi-flame retardancy, ukugquma, ukuchaneka komda kunye nokumelana nobushushu bezinto zeplastiki. I-Filler masterbatch isetyenziswa ngokubanzi kwimveliso yeengxenye zeplastiki zeemveliso zombane kunye nezombane, ezifana neentambo zocingo kunye neentambo zeentambo, iibhokisi ze-transformer, izindlu zokudibanisa, njl.

• Iingcingo zocingo kunye neeCable Sheaths: Izingxobo zeplastiki zeengcingo kunye neentambo kufuneka zibe nokugquma kakuhle, nxiba ukumelana, ukunqanda amadangatye kunye nokumelana nemozulu. I-masterbatch ye-filler esetyenziselwa iintambo kunye neentambo zentambo ubukhulu becala yi-calcium carbonate filler masterbatch okanye i-masterbatch ye-flame-retardant filler masterbatch.. Adding 3%-6% ye-calcium carbonate filler masterbatch inokuphucula ukumelana nokunxiba kunye nokuqina kwesheath, ukunciphisa iindleko; flame-retardant filler masterbatch (njenge-magnesium hydroxide, i-aluminiyam hydroxide filler masterbatch) inokuphucula ukulibaziseka komlilo we-sheath, ukuthintela ukusasazeka komlilo kwimeko yesiphaluka esifutshane, ukuqinisekisa ukhuseleko lwesekethe.
• IiCasings zeTransformer kunye neZindlu eziDityanisiweyo: These parts need to have good insulation, heat resistance and dimensional accuracy. The filler masterbatch used is mainly talc filler masterbatch or glass fiber reinforced filler masterbatch. Adding 5%-8% of talc filler masterbatch can improve the heat resistance and dimensional stability of the parts, making them not easy to deform under long-term high temperature operation; glass fiber reinforced filler masterbatch can improve the impact strength and insulation of the parts, ensuring the normal operation of electronic and electrical products.

4.1.6 Agricultural Plastic Industry:

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

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

4.2 Usage Methods of Filler Masterbatch

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

4.2.1 Determination of Mixing Ratio:

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

• For plastic products with low performance requirements and high cost control requirements (such as ordinary plastic bags, iingxowa zenkunkuma), the mixing ratio can be 5%-20% (using low-to-medium filling calcium carbonate filler masterbatch);
• For plastic products with medium performance requirements (njengeefilimu zeplastiki, ordinary injection molding parts), the mixing ratio can be 2%-8% (using medium filling calcium carbonate, talc or barium sulfate filler masterbatch);
• For plastic products with high performance requirements (such as automotive parts, electronic product shells, high-grade films), the mixing ratio can be 1%-5% (using high-filling, high-performance talc, barium sulfate or glass fiber reinforced filler masterbatch);
• For transparent or semi-transparent plastic products (such as plastic bottles, transparent films), the mixing ratio should be controlled at 1%-3%, and barium sulfate or light calcium carbonate filler masterbatch with fine particle size (ngaphezulu 1250 umnatha) should be selected to avoid affecting the transparency of the products.

4.2.2 Mixing Method:

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

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

4.2.3 Adjustment of Processing Parameters:

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

• Temperature Adjustment: The addition of filler masterbatch will increase the viscosity of the mixture, so the processing temperature needs to be appropriately increased by 5-15℃ compared with the processing temperature of pure base plastic. Umzekelo, when processing PE plastic with calcium carbonate filler masterbatch, the processing temperature can be increased by 5-10℃; when processing PP plastic with talc filler masterbatch, the processing temperature can be increased by 10-15℃. It should be noted that the temperature should not be too high to avoid thermal decomposition of the base plastic and additives.
• Pressure Adjustment: Ukongezwa kwe-filler masterbatch kuya kwandisa ukuchasana ngexesha lokucubungula, ngoko uxinzelelo lokuqhuba (uxinzelelo lwe-extrusion, uxinzelelo lwenaliti) kufuneka yandiswe ngokufanelekileyo 10%-20%. Umzekelo, xa ukhupha imibhobho yeplastiki nge-filler masterbatch, uxinzelelo lwe-extrusion lunokwandiswa ngo 10%-15% ukuqinisekisa ukubumbana kunye nokuchaneka kobukhulu bemibhobho; xa ufaka iinxalenye zeplastiki kunye ne-filler masterbatch, uxinzelelo lwenaliti lunokwenyuka ngo 15%-20% ukuphepha iziphene ezifana nokungagcwali ngokwaneleyo kunye nokuncipha.
• Uhlengahlengiso lwesantya seScrew: Isantya se-screw kufuneka silungiswe ngokohlobo kunye nokuzaliswa kwemali ye-masterbatch. Ukuzalisa i-masterbatch ephezulu okanye i-masterbatch ene-dispersibility embi, isantya sokujija sinokunyuswa ngokufanelekileyo nge 10%-15% ukwandisa amandla okucheba kunye nesiphumo sokuxuba, ukuqinisekisa ukusasazwa okufanayo kwefayili; for low-filling masterbatch or masterbatch with good dispersibility, the screw speed can be kept unchanged or slightly reduced to reduce energy consumption and wear of equipment.

4.2.4 Precautions for Use:

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

• Moisture Prevention: Filler masterbatch (especially calcium carbonate, talc masterbatch) is easy to absorb moisture, which will cause bubbles, pinholes and other defects in the final product. Ngoko ke, the masterbatch should be stored in a dry, Isitora esipholileyo nesingena umoya, and should be dried before use (the drying temperature is 80-100℃, and the drying time is 2-4 iiyure).
• Compatibility: The carrier resin of the filler masterbatch should be consistent with or compatible with the base plastic of the product. Umzekelo, PE filler masterbatch should be used with PE base plastic, and PP filler masterbatch should be used with PP base plastic. If the carrier resin is incompatible with the base plastic, it will affect the compatibility between the masterbatch and the base plastic, resulting in poor dispersibility and reduced product performance.
• Uniform Mixing: The filler masterbatch and base plastic must be mixed uniformly. If the mixing is uneven, local agglomeration of the masterbatch will occur, okubangela iziphene ezifana namabala amhlophe, black spots and agglomeration in the product, affecting the appearance and performance of the product.
• Dosage Control: The dosage of filler masterbatch should not exceed the maximum filling amount applicable to the equipment and product performance. Excessive dosage will lead to poor dispersibility, low toughness, poor processing fluidity and other problems of the product; insufficient dosage will not achieve the effect of cost reduction and performance improvement.
• Storage Period: The filler masterbatch has a certain storage period (ngokubanzi 6-12 iinyanga). If the storage period is exceeded, the masterbatch may absorb moisture, agglomerate or the performance of additives may degrade, affecting the use effect. Ngoko ke, the masterbatch should be used within the storage period.

5. Common Problems and Solutions in Filler Masterbatch Production

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

5.1 Common Quality Problems of Filler Masterbatch and Their Solutions

5.1.1 Poor Dispersibility of Filler Masterbatch:

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

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

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

5.1.2 Uneven Particle Size of Filler Masterbatch:

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

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

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

5.1.3 Low Melting Index of Filler Masterbatch

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

Oonobangela:

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

Izisombululo:

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

5.1.4 Yellowing of Filler Masterbatch

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

Oonobangela:

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

Izisombululo:

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

5.1.5 High Moisture Content of Filler Masterbatch

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

Oonobangela:

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

Izisombululo:

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

5.2 Common Production Equipment Problems and Their Solutions

5.2.1 Extruder Blockage

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

Oonobangela:

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

Izisombululo:

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

5.2.2 Severe Wear of Extruder Screw and Barrel

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

Oonobangela:

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

Izisombululo:

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

5.2.4 Unstable Temperature Control of Extruder

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

Oonobangela:

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

Izisombululo:

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

6. Conclusion and Outlook

Filler masterbatch, as a key functional additive in the plastic processing industry, plays an irreplaceable role in reducing production costs, ukuphucula ukusebenza kwemveliso kunye nokuphucula ukusebenza kakuhle. With the rapid development of the global plastic industry and the continuous upgrading of downstream product requirements, the filler masterbatch industry is moving towards high performance, ukusebenza, imali yokuzalisa ephezulu, environmental protection and intelligence. Extrusion granulation technology, njengetekhnoloji ephambili yemveliso ye-filler masterbatch, directly determines the quality and competitiveness of the masterbatch. The performance of extruders is the key to ensuring the stable production of high-quality filler masterbatch.

We have developed a full range of twin-screw extruder products (HTS BASIC series, HTS PLUS series, HTS SUPER series, ZTE series, HTE series) according to the characteristics of filler masterbatch raw materials and processing requirements. I-extruders yethu ineenzuzo zokumelana nokunxiba okuphezulu, strong shearing and mixing capacity, ulawulo lobushushu oluchanekileyo, wide application range, high production efficiency and low energy consumption, which can meet the processing needs of various types and different filling amounts of filler masterbatch. By providing targeted extruder products and professional processing solutions, we help filler masterbatch manufacturers solve production pain points, improve production efficiency, qinisekisa umgangatho wemveliso, kwaye ufumane inzuzo yokukhuphisana kukhuphiswano oluqatha lwemarike.

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

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