Filler Masterbatch To ti ni ilọsiwaju Awọn laini iṣelọpọ Granulation ati Ohun elo Imọ-ẹrọ Extrusion

Pẹlu awọn dekun idagbasoke ti awọn agbaye ṣiṣu ile ise, ibeere fun awọn ọja ṣiṣu n pọ si lojoojumọ, ati awọn ibeere fun iṣẹ ọja, iṣakoso iye owo ati aabo ayika tun n di okun sii ati siwaju sii. Filler masterbatch, bi aropo iṣẹ bọtini ni ṣiṣu processing, ti lo ni ọpọlọpọ awọn aaye ti iṣelọpọ ṣiṣu nitori awọn anfani rẹ ti idinku awọn idiyele iṣelọpọ, imudara iṣẹ ṣiṣe ọja ati mimuṣe ṣiṣe ṣiṣe. A ti pinnu lati pese awọn laini iṣelọpọ granulation ti ilọsiwaju ati awọn extruders ti o ga julọ fun ọpọlọpọ awọn oriṣi ti kikun masterbatch, gbigbekele iriri ọlọrọ ni iwadii imọ-ẹrọ extrusion ati idagbasoke ati iṣelọpọ, lati pese ìfọkànsí, awọn solusan iṣelọpọ daradara ati igbẹkẹle fun awọn aṣelọpọ masterbatch kikun, ran katakara mu gbóògì ṣiṣe, rii daju didara ọja, ati ki o jèrè anfani ifigagbaga ni idije ọja imuna.

Nkan yii yoo dojukọ aaye ti kikun masterbatch, ni-ijinle elaborating lori awọn ipilẹ agbekale, isọri, gbóògì ilana ti filler masterbatch, awọn mojuto ipa ti extrusion ọna ẹrọ ni awọn oniwe-granulation gbóògì, awọn anfani ti jara extruder wa ati aṣamubadọgba ìfọkànsí wọn si kikun masterbatch processing, bakannaa awọn aaye ohun elo pato, awọn ọna lilo ati awọn iṣoro ti o wọpọ ati awọn solusan ni iṣelọpọ. Yoo ṣe afikun awọn aye imọ-ẹrọ alaye, awọn alaye ilana ati awọn aaye irora ile-iṣẹ lati ṣe alekun akoonu naa, pade ibeere kika ọrọ ti 3000-4000 awọn ọrọ, ati pese itọkasi okeerẹ ati ọjọgbọn fun awọn ile-iṣẹ ti o yẹ ati awọn oṣiṣẹ ni ile-iṣẹ masterbatch kikun.

1. Akopọ ti Filler Masterbatch Industry ati Awọn abuda Ọja

1.1 Ipo lọwọlọwọ ati Aṣa Idagbasoke ti Filler Masterbatch Industry

Ni awọn ọdun aipẹ, ìṣó nipasẹ awọn dekun idagbasoke ti ibosile ise bi apoti, ikole, ọkọ ayọkẹlẹ, itanna ati ojoojumọ aini, ọja Masterbatch kikun agbaye ti ṣafihan aṣa idagbasoke iduroṣinṣin. Filler masterbatch jẹ iru ohun elo akojọpọ eyiti o ṣe nipasẹ dapọ, yo, extruding ati granulating inorganic fillers (gẹgẹ bi awọn kaboneti kalisiomu, talc, barium imi-ọjọ, ati be be lo.) pẹlu polima ẹjẹ (bi polyethylene, polypropylene, polyvinyl kiloraidi, ati be be lo.) ati awọn afikun ti o yẹ (gẹgẹ bi awọn dispersants, compatibilizers, lubricants, ati be be lo.) ni ipin kan. Iṣẹ akọkọ rẹ ni lati dinku idiyele iṣelọpọ ti awọn ọja ṣiṣu lakoko imudarasi tabi mimu iṣẹ ipilẹ ti awọn ọja ṣiṣu.

Gẹgẹbi awọn iṣiro data ti o yẹ, awọn agbaye kikun masterbatch oja iwọn ti koja 20 bilionu owo dola Amerika, ati pe o nireti lati ṣetọju oṣuwọn idagbasoke ti 6%-9% ni awọn ọdun diẹ to nbọ. Lára wọn, kalisiomu kaboneti (CaCO3) Masterbatch kikun jẹ iru ọja ti a lo julọ julọ, iṣiro fun diẹ ẹ sii ju 60% ti lapapọ filler masterbatch oja, atẹle nipa talc kikun masterbatch, barium imi-ọjọ (BaSO4) filler masterbatch and other special filler masterbatches. The Asia-Pacific region is the world’s largest filler masterbatch production and consumption market, iṣiro fun diẹ ẹ sii ju 50% ti agbaye oja ipin, which is mainly due to the rapid development of the plastic processing industry in China, India ati awọn orilẹ-ede miiran, the huge demand for cost reduction and performance improvement of plastic products, and the continuous improvement of industrial supporting capacity.

The development trend of the filler masterbatch industry is mainly reflected in four aspects: akọkọ, ga išẹ ati 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, lile, ooru resistance, weather resistance and barrier properties of plastic products, ati idagbasoke awọn aṣeto kikun kikun iṣẹ ṣiṣe pataki gẹgẹbi idaduro ina, antistatic ati antibacterial; keji, ga nkún iye ati ti o dara dispersibility. Labẹ ipilẹ ile ti idaniloju iṣẹ ṣiṣe ọja, jijẹ iye kikun ti awọn ohun elo inorganic le dinku awọn idiyele iṣelọpọ siwaju, eyi ti o fi awọn ibeere ti o ga julọ sori dispersibility ti filler masterbatch-pipa ti o dara julọ le rii daju pe kikun ti pin ni deede ni matrix ṣiṣu, yago fun hihan funfun to muna, dudu to muna tabi agglomeration ni ik ọja; kẹta, Idaabobo ayika ati idoti kekere. Pẹlu okun ti awọn eto imulo aabo ayika agbaye ati ilọsiwaju ti imọ aabo ayika, Awọn olupilẹṣẹ Masterbatch kikun ti n gba awọn afikun ore ayika ati awọn ilana iṣelọpọ, atehinwa itujade ti ipalara oludoti, ati idagbasoke masterbatch kikun kikun ibajẹ lati ṣe deede si aṣa idagbasoke ti awọn pilasitik alawọ ewe; kẹrin, itetisi ati ṣiṣe ti ẹrọ iṣelọpọ. Ni ibere lati pade awọn ti o tobi-asekale, lemọlemọfún ati awọn iwulo iṣelọpọ didara giga ti kikun masterbatch, awọn aṣelọpọ nigbagbogbo n ṣafihan awọn laini iṣelọpọ granulation ti ilọsiwaju ati awọn eto iṣakoso oye, imudarasi iṣelọpọ iṣelọpọ, idinku awọn idiyele iṣẹ ati aridaju iduroṣinṣin didara ọja.

Lodi si yi lẹhin, extrusion granulation ọna ẹrọ, bi imọ-ẹrọ mojuto ti iṣelọpọ masterbatch kikun, ti di bọtini lati pinnu didara ti kikun masterbatch ati ifigagbaga ti awọn ile-iṣẹ. Awọn iṣẹ ti extruders taara yoo ni ipa lori dispersibility, patiku apẹrẹ, atọka yo ati awọn itọkasi bọtini miiran ti kikun masterbatch. Awọn extruders ọjọgbọn wa ati awọn laini iṣelọpọ granulation fun kikun masterbatch ti wa ni idagbasoke ni idahun si awọn abuda ti ile-iṣẹ ati ibeere ọja, eyiti o le yanju awọn aaye irora ni imunadoko ni iṣelọpọ masterbatch kikun (gẹgẹ bi awọn talaka dispersibility, uneven patiku iwọn, kekere nkún iye, ga agbara agbara, ati be be lo.) ati iranlọwọ awọn ile-iṣẹ lati ṣaṣeyọri didara giga ati iṣelọpọ daradara.

1.2 Isọri ti Filler Masterbatch ati Awọn abuda Pataki Rẹ

Filler masterbatch le pin si awọn oriṣi oriṣiriṣi gẹgẹbi iru kikun, ti ngbe resini, aaye ohun elo ati kikun iye. Iru kọọkan ti kikun masterbatch ni awọn abuda alailẹgbẹ tirẹ ati awọn oju iṣẹlẹ to wulo. Atẹle jẹ ifihan alaye si isọdi ti o wọpọ ati awọn abuda pataki ti masterbatch kikun:

1.2.1 Isọri nipa Filler Iru:

Eyi ni ọna isọdi ti o wọpọ julọ fun masterbatch kikun. Ni ibamu si awọn iru ti inorganic kikun, o le wa ni o kun pin si kalisiomu kaboneti (CaCO3) kikun masterbatch, talc kikun masterbatch, barium imi-ọjọ (BaSO4) kikun masterbatch, ati awọn miiran pataki kikun masterbatches (gẹgẹ bi awọn kaolin kikun masterbatch, erogba dudu kikun masterbatch, gilasi okun kikun masterbatch, ati be be lo.).

• Carbonate kalisiomu (CaCO3) Filler Masterbatch: O jẹ masterbatch kikun ti a lo pupọ julọ pẹlu idiyele ti o kere julọ. Awọn kikun jẹ o kun ina kalisiomu kaboneti tabi eru kalisiomu kaboneti. Ina kalisiomu kaboneti ni o ni itanran patiku iwọn, ti o dara dispersibility ati ki o ga funfun, eyiti o dara fun awọn ọja ṣiṣu pẹlu awọn ibeere giga lori irisi ati didara (gẹgẹbi awọn fiimu ṣiṣu, abẹrẹ igbáti awọn ọja); eru kalisiomu kaboneti ni o ni ga líle, ti o dara yiya resistance ati kekere owo, eyi ti o dara fun awọn ọja ṣiṣu pẹlu awọn ibeere giga lori rigidity ati iṣakoso iye owo (gẹgẹbi awọn baagi hun, igbanu apoti, paipu, ati be be lo.). Masterbatch kikun kaboneti kalisiomu ko le dinku awọn idiyele iṣelọpọ nikan, sugbon tun mu awọn rigidity, ooru resistance ati onisẹpo iduroṣinṣin ti ṣiṣu awọn ọja, ati ki o ni kan awọn lubricating ipa, eyi ti o le mu awọn processing fluidity ti pilasitik.
• Talc Filler Masterbatch: Awọn kikun ni talc lulú pẹlu siwa be. Talc lulú ni awọn ohun-ini ẹrọ ti o dara, ooru resistance ati kemikali iduroṣinṣin. Masterbatch filler Talc jẹ lilo ni akọkọ ni polypropylene (PP) ṣiṣu awọn ọja, eyi ti o le significantly mu awọn rigidity, otutu ipalọlọ ooru ati agbara ipa ti awọn ọja PP, ati pe o gbajumo ni lilo ninu awọn ẹya ara ẹrọ, awọn ikarahun ohun elo ile, awọn paipu ṣiṣu ati awọn aaye miiran ti o nilo iṣẹ giga.
• Sulfate Barium (BaSO4) Filler Masterbatch: Awọn kikun jẹ barium sulfate lulú, eyi ti o ni ga funfun, ti o dara akoyawo, inertness kemikali ati ipanilara resistance. Barium sulfate filler masterbatch dara fun awọn ọja ṣiṣu pẹlu awọn ibeere giga lori akoyawo, funfun ati iduroṣinṣin kemikali (gẹgẹbi awọn fiimu ṣiṣu, ṣiṣu igo, egbogi ṣiṣu awọn ọja, ati be be lo.), ati pe o tun le ṣee lo ninu awọn ọja ṣiṣu ti o ni ẹri itankalẹ (gẹgẹbi ohun elo aabo iṣoogun, iparun agbara ọgbin awọn ẹya ẹrọ, ati be be lo.).

1.2.2 Isọri nipa ti ngbe Resini:

Ni ibamu si iru resini ti ngbe ti a lo, Masterbatch kikun le ti pin si polyethylene (PE) kikun masterbatch, polypropylene (PP) kikun masterbatch, polyvinyl kiloraidi (PVC) kikun masterbatch, terephthalate polyethylene (PET) kikun masterbatch, ati be be lo. Yiyan ti resini ti ngbe jẹ ipinnu nipataki nipasẹ iru awọn ọja ṣiṣu isalẹ. Fun apere, Masterbatch kikun PE dara fun awọn ọja ṣiṣu PE (gẹgẹbi awọn fiimu ṣiṣu, baagi, paipu); Masterbatch kikun PP dara fun awọn ọja ṣiṣu PP (gẹgẹbi awọn baagi hun, abẹrẹ igbáti awọn ẹya ara, ọkọ ayọkẹlẹ awọn ẹya ara); Masterbatch kikun PVC jẹ o dara fun awọn ọja ṣiṣu PVC (gẹgẹbi awọn paipu PVC, awọn profaili, awọn aṣọ-ikele).

1.2.3 Iyasọtọ nipasẹ aaye Ohun elo:

Ni ibamu si awọn ohun elo aaye ti ibosile ṣiṣu awọn ọja, kikun masterbatch le pin si masterbatch kikun kikun fiimu, abẹrẹ-ite kikun masterbatch, extrusion-ite kikun masterbatch, fe igbáti-ite kikun masterbatch, ati be be lo. Fimu-ite kikun masterbatch nilo itọka ti o dara, ga fineness ko si si impurities, lati rii daju pe fiimu ti o fẹ ko ni awọn aaye funfun, dudu to muna tabi pinholes, ati ki o bojuto ti o dara akoyawo ati toughness; Masterbatch kikun ipele abẹrẹ nilo ito ti o dara ati iwọn patiku aṣọ, lati ṣe deede si ilana imudọgba abẹrẹ iyara ati rii daju ifarahan ati deede iwọn ti awọn ọja abẹrẹ; extrusion-ite kikun masterbatch nilo iduroṣinṣin igbona ti o dara ati awọn ohun-ini ẹrọ, to adapt to the high-temperature and high-pressure extrusion process of pipes, profiles and other products.

1.2.4 Classification by Filling Amount:

According to the filling amount of inorganic fillers, filler masterbatch can be divided into low-filling masterbatch (filling amount 30%-50%), medium-filling masterbatch (filling amount 50%-70%) and high-filling masterbatch (filling amount 70% ati loke). The filling amount is determined according to the performance requirements of downstream products and the processing capacity of equipment. High-filling masterbatch has more obvious cost reduction effect, but it has higher requirements on the dispersibility of fillers and the performance of extruders—only high-performance extruders can ensure the uniform mixing and melting of high-filling materials, avoiding agglomeration and poor processing fluidity.

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

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

Extrusion granulation technology is the core technology of filler masterbatch production, which integrates mixing, yo, irẹrun, dispersion and granulation. It has the advantages of high production efficiency, ti o dara ọja didara, lagbara adaptability to aise ohun elo ati ki o jakejado ohun elo ibiti. In the production of filler masterbatch, extrusion granulation technology is mainly used to realize the uniform dispersion of inorganic fillers in the polymer carrier, melt and plasticize the mixture, and then extrude and granulate to form granular filler masterbatch with uniform size, good fluidity and stable performance. The quality of extrusion granulation directly determines the key performance indicators of filler masterbatch, such as dispersibility, particle size and melting index.

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

The raw materials of filler masterbatch mainly include three parts: inorganic fillers (such as CaCO3, talc, BaSO4), polymer carriers (bii PE, PP, PVC) ati awọn afikun (gẹgẹ bi awọn dispersants, compatibilizers, lubricants, antioxidants, ati be be lo.). Awọn abuda ti awọn ohun elo aise jẹ ohun ti o yatọ, eyi ti o fi siwaju pataki awọn ibeere fun extrusion ẹrọ:

Ni akọkọ, awọn inorganic fillers ni ga líle, ko dara ibamu pẹlu polima ẹjẹ, ati ki o rọrun lati agglomerate. Julọ inorganic fillers (such as CaCO3, talc) jẹ hydrophilic, nigba ti polima ẹjẹ ni o wa hydrophobic, eyiti o yori si ibaramu ti ko dara laarin awọn kikun ati awọn gbigbe. Ti didapọ ati irẹrun ko ba to, awọn fillers yoo agglomerate, eyi ti ko le wa ni iṣọkan tuka ni awọn ti ngbe, Abajade ni ko dara didara ti kikun masterbatch. Ni afikun, Lile giga ti awọn ohun elo inorganic yoo fa yiya to ṣe pataki si dabaru ati agba ti extruder lakoko ilana extrusion, eyi ti o nbeere dabaru ati agba ti extruder lati ni lalailopinpin giga resistance resistance.

Keji, Awọn adalu kikun masterbatch ni o ni ga iki ati ko dara fluidity. Afikun ti nọmba nla ti awọn ohun elo inorganic yoo mu iki ti adalu pọ si ni pataki, din awọn processing fluidity, ati ki o beere fun extruder lati ni agbara gbigbe ti o lagbara ati agbara irẹrun lati rii daju ilọsiwaju didan ti yo, dapọ ati extrusion.

Kẹta, iwọn otutu processing jẹ dín. Awọn resini ti ngbe oriṣiriṣi ni awọn aaye yo oriṣiriṣi ati iduroṣinṣin gbona. Fun apere, aaye yo ti PE jẹ 100-130 ℃, aaye yo ti PP jẹ 160-170 ℃, ati PVC jẹ rọrun lati decompose ni awọn iwọn otutu giga (loke 160 ℃). Nitorina, ohun elo extrusion nilo lati ni agbara iṣakoso iwọn otutu deede lati rii daju pe adalu ti yo ni kikun laisi jijẹ gbigbona., and to avoid the decomposition of additives and the deterioration of product performance.

Based on the above characteristics, single-screw extruders are not suitable for large-scale and high-quality production of filler masterbatch. Nitori awọn nikan-skru extruder ni o ni a dín rirẹ ibiti o, Agbara fifa ti ko dara ati pe ko si ipa ti ara ẹni. When processing high-viscosity and high-filler mixtures, o rọrun lati fa ikojọpọ ohun elo, blockage ati uneven dapọ ni extruder agba, resulting in poor dispersibility of filler masterbatch, uneven particle size and unstable product quality. Ni afikun, the single-screw extruder has high energy consumption when processing high-filler materials, and the screw and barrel are severely worn, which increases the production cost and equipment maintenance cost of enterprises.

Twin-dabaru extruders, ti a ba tun wo lo, ni awọn anfani ti o han gbangba ni iṣelọpọ masterbatch kikun ati pe o ti di ohun elo akọkọ fun kikun masterbatch extrusion granulation. Twin-skru extruders ni a anfani rirẹ-ori ibiti o, ipa fifa diẹ ti o munadoko ati ipa-mimọ, eyi ti o le yanju awọn iṣoro ti ko dara ibamu, agglomeration irọrun ati omi ti ko dara ti awọn ohun elo aise kikun masterbatch. Ibaṣepọ ati yiyi ti awọn skru ibeji le ṣe ipilẹṣẹ agbara rirun ti o lagbara ati ipa ilọkun, eyi ti o le ni kikun fọ awọn agglomerates ti inorganic fillers, ṣe awọn fillers iṣọkan tuka ni polima ti ngbe, ati rii daju dispersibility ati iduroṣinṣin ti ọja naa. Ni afikun, Twin-dabaru extruder ni o ni ti o dara otutu Iṣakoso išedede, lagbara adaptability to aise ohun elo, ati ki o le orisirisi si si awọn processing ti o yatọ si orisi, o yatọ si nkún oye akojo ti filler masterbatch, ati pe o ni ṣiṣe iṣelọpọ giga ati agbara agbara kekere.

2.2 Ilana Ṣiṣẹ ti Filler Masterbatch Extrusion granulation

Ilana granulation extrusion ti kikun masterbatch jẹ ilana ti ara ati ilana kemikali eka, eyiti o jẹ pẹlu ibaraenisepo ti awọn ifosiwewe pupọ gẹgẹbi iwọn otutu, titẹ, rirun agbara ati akoko. Ilana iṣẹ pato ati ṣiṣan ilana jẹ bi atẹle:

Ni akọkọ, aise ohun elo pretreatment. Awọn ohun elo aise ti kikun masterbatch (inorganic fillers, ti ngbe resini, awọn afikun) nilo lati wa ni pretreated lati rii daju awọn didara ti ik ọja. Awọn igbesẹ kan pato pẹlu: 1) Itọju gbigbe: Awọn ohun elo aiṣedeede (such as CaCO3, talc) nigbagbogbo jẹ hydrophilic ati pe o ni iye kan ti ọrinrin. Ti akoonu ọrinrin ba ga ju, yoo ni ipa lori ipadapọ ati dispersibility ti awọn ohun elo, ati paapa fa nyoju ninu awọn extruded masterbatch. Nitorina, awọn fillers nilo lati wa ni gbẹ ni kan togbe (gẹgẹ bi awọn kan gbona air togbe, a igbale togbe) lati dinku akoonu ọrinrin si isalẹ 0.5%. 2) Crushing ati sieving: Resini ti ngbe (bii PE, PP) is crushed into small particles or powder with a particle size of 20-40 apapo, which is conducive to uniform mixing with fillers and additives. Inorganic fillers are also sieved to remove impurities and large particles, ensuring the fineness and uniformity of fillers. 3) Iwaju: According to the formula ratio, the dried fillers, carrier resin particles and additives (dispersants, compatibilizers, lubricants, ati be be lo.) are put into a high-speed mixer for premixing. The mixing speed is generally 800-1200 rpm, and the mixing time is 5-10 iseju. The purpose of premixing is to make the additives evenly adhere to the surface of fillers and carrier resin, improve the compatibility between fillers and carrier, and lay a foundation for subsequent extrusion mixing. The dispersant is a key additive in premixing, which can form a protective film on the surface of the filler, reduce the surface energy of the filler, idilọwọ awọn kikun lati agglomerating, ati ki o mu awọn dispersibility ti awọn kikun ninu awọn ti ngbe resini.

Keji, ono ati gbigbe. Adalu iṣaaju naa ni a fi ranṣẹ si olutọpa ifunni ti twin-skru extruder nipasẹ atokan skru tabi atokun igbanu.. Iyara ifunni nilo lati jẹ aṣọ ati iduroṣinṣin, eyi ti o baamu pẹlu iyara dabaru ati iyara extrusion ti extruder, lati rii daju pe awọn ohun elo wọ inu iho extrusion ni iduroṣinṣin ati yago fun ikojọpọ ohun elo tabi ifunni ti ko to. Ẹrọ ifunni ti extruder nigbagbogbo ni ipese pẹlu iṣẹ ṣiṣe ilana iyara iyipada igbohunsafẹfẹ, eyi ti o le ṣatunṣe iyara ifunni ni ibamu si ipo iṣelọpọ gangan.

Kẹta, yo, dapọ ati irẹrun. Awọn ohun elo ti nwọle iho extrusion ti twin-skru extruder ti wa ni titari siwaju nigbagbogbo nipasẹ awọn skru yiyi. Iho extrusion ti wa ni kq ti a dabaru ati ki o kan agba, ati awọn iwọn didun ti awọn extrusion iho maa dinku pẹlú awọn axis itọsọna. Nigbati awọn skru yiyi, awọn ohun elo ti wa ni maa fisinuirindigbindigbin labẹ awọn iṣẹ ti awọn skru ati awọn agba, ati awọn titẹ ni extrusion iho maa posi (gbogbo 3-15MPa). Ni akoko kan naa, Awọn ohun elo naa wa labẹ agbara rirẹ ti o lagbara ati agbara ija ti ipilẹṣẹ nipasẹ iṣipopada ibatan laarin awọn skru ati agba, bi daradara bi laarin awọn dabaru ofurufu.

Agbara rirẹ ati agbara ija le fọ ni kikun awọn agglomerates ti awọn ohun elo eleto, ṣe awọn fillers iṣọkan tuka ni yo o ti ngbe resini, ati igbelaruge idapọ ati ibamu laarin awọn kikun ati awọn ti ngbe. Agbara edekoyede tun le ṣe ina iwọn ooru kan, eyi ti o ti wa ni idapo pelu awọn ita alapapo ti awọn agba (itanna alapapo tabi nya alapapo) lati ṣe awọn ti ngbe resini maa yo ati plasticize. Awọn agba ti extruder ti wa ni maa pin si 3-6 awọn apakan iṣakoso iwọn otutu (ono apakan, yo apakan, dapọ apakan, homogenizing apakan, ati be be lo.), ati iwọn otutu ti apakan kọọkan jẹ iṣakoso ni deede gẹgẹbi iru resini ti ngbe ati kikun. Fun apere, nigba processing PE ti ngbe kikun masterbatch, Iwọn otutu ti apakan ifunni jẹ 80-100 ℃, apakan yo jẹ 120-140 ℃, awọn dapọ apakan ni 140-150 ℃, ati awọn homogenizing apakan jẹ 130-140 ℃; nigbati o nṣiṣẹ PP ti ngbe kikun masterbatch, the temperature of each section is 20-30℃ higher than that of PE carrier.

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

Karun, cooling and cutting. The extruded strips are sent to a cooling device (such as a water tank, an air-cooled conveyor) fun dekun itutu. Ni gbogbogbo, iwọn otutu itutu agbaiye jẹ 20-30 ℃, ati awọn itutu akoko ni 2-5 iseju. Itutu agbaiye ni kiakia le jẹ ki awọn ila di mimọ ni kiakia, ṣetọju apẹrẹ ati iwọn ti awọn ila, ki o si yago fun abuku. Lẹhin itutu agbaiye, awọn ila ti wa ni rán si a granulator fun gige. Awọn granulator ni ipese pẹlu kan Rotari ọbẹ, eyiti o le ge awọn ila naa sinu masterbatch filler granular pẹlu iwọn aṣọ (awọn patiku iwọn ni gbogbo 2-5mm, eyi ti o le wa ni titunse gẹgẹ onibara aini). Iyara ti ọbẹ iyipo jẹ ibamu pẹlu iyara gbigbe ti awọn ila lati rii daju pe iwọn patiku ti masterbatch jẹ aṣọ..

Ẹkẹfa, waworan ati apoti. Masterbatch kikun granular ge ti wa ni fifiranṣẹ si iboju gbigbọn fun ibojuwo, eyi ti o le yọ unqualified patikulu (bii ti o tobi ju, ju kekere tabi agglomerated patikulu) and ensure the uniformity of the product. The qualified masterbatch is then sent to an automatic packaging machine for packaging. Awọn pato apoti le ṣe atunṣe ni ibamu si awọn aini alabara (such as 25kg/bag, 50kg/apo), and the packaging should be sealed and moisture-proof to prevent the masterbatch from absorbing moisture and affecting the quality. Lẹhin ti apoti, awọn ọja ti wa ni ipamọ ni kan gbẹ, itura ati ki o ventilated ile ise.

2.3 Key Factors Affecting Filler Masterbatch Extrusion Granulation Effect

The effect of extrusion granulation directly affects the quality of filler masterbatch. There are many factors affecting the granulation effect, o kun pẹlu aise awọn ohun elo abuda, formula ratio, premixing effect, extrusion sile ki o si kú ori be. 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 Awọn abuda Ohun elo Raw:

Iru, patiku iwọn, moisture content and purity of raw materials have a great impact on the granulation effect. Fun apere, the particle size of inorganic fillers directly affects the dispersibility and fineness of the masterbatch. The finer the particle size of the filler (ni gbogbogbo 800-2000 apapo), 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, ni ipa lori iwuwo ati awọn ohun-ini ẹrọ ti ọja naa. Mimo ti awọn ohun elo aise tun ṣe pataki pupọ; impurities ni aise ohun elo (gẹgẹ bi awọn okuta, awọn irin, eruku) kii yoo ni ipa lori didara masterbatch nikan, sugbon tun wọ dabaru ati agba ti extruder, ati paapaa fa idinamọ ẹrọ.

2.3.2 Ilana agbekalẹ:

Iwọn agbekalẹ ti kikun masterbatch (awọn ipin ti kikun, ti ngbe resini ati additives) jẹ bọtini lati pinnu iṣẹ ṣiṣe ati idiyele ọja naa. Iwọn kikun ti kikun yẹ ki o pinnu ni ibamu si awọn ibeere iṣẹ ti ọja isalẹ ati agbara sisẹ ti ẹrọ naa.. Iwọn kikun ti o ga julọ yoo ja si dispersibility ti ko dara, kekere toughness ati ko dara processing fluidity ti masterbatch; Iwọn kikun ti o kere ju yoo dinku ipa idinku iye owo. The type and dosage of additives also need to be reasonably matched. Fun apere, the dispersant dosage is generally 1%-3% of the filler dosage; too little dispersant will lead to poor dispersibility of the filler, and too much dispersant will affect the compatibility between the masterbatch and the downstream plastic products, and reduce the mechanical properties of the products. The compatibilizer is used to improve the compatibility between the filler and the carrier resin; the dosage is generally 0.5%-2%, which can significantly improve the dispersibility and mechanical properties of the masterbatch. The lubricant is used to reduce the friction between the materials and the screw, barrel and die head, improve the processing fluidity, and prevent the materials from sticking to the equipment; the dosage is generally 0.3%-1%.

2.3.3 Premixing Effect:

Premixing is the foundation of extrusion granulation. The uniformity of premixing directly affects the dispersibility of the filler in the carrier resin. If the premixing is uneven, the additives cannot be uniformly adhered to the surface of the filler and carrier, resulting in local agglomeration of the filler, uneven mixing of the materials during extrusion, and poor quality of the masterbatch. Lati rii daju awọn premixing ipa, o jẹ pataki lati šakoso awọn dapọ iyara, dapọ akoko ati dapọ otutu. The mixing speed is generally 800-1200 rpm, awọn dapọ akoko ni 5-10 iseju, ati awọn dapọ otutu ti wa ni dari ni 40-60 ℃ (iwọn otutu ti o yẹ le mu imudara ti awọn afikun pọ si ati igbelaruge idapọ aṣọ).

2.3.4 Extrusion paramita:

Extrusion parameters are the most important factors affecting the granulation effect, o kun pẹlu dabaru iyara, extrusion otutu ati extrusion titẹ.

• Iyara dabaru: The screw speed generally ranges from 150 si 600 rpm. Awọn ti o ga ni dabaru iyara, ti o pọju agbara irẹwẹsi ati agbara ija ti a gba nipasẹ awọn ohun elo, the better the mixing and dispersing effect of the filler, ati awọn ti o ga gbóògì ṣiṣe. Sibẹsibẹ, ti o ba ti dabaru iyara jẹ ga ju, akoko ibugbe ti awọn ohun elo ti o wa ninu iho extrusion jẹ kukuru pupọ, resulting in incomplete melting of the carrier resin, insufficient mixing of the materials, and uneven particle size of the masterbatch; ti o ba ti dabaru iyara jẹ ju kekere, agbara rirun ati ija ija ko to, the filler cannot be fully dispersed, and the production efficiency is low. The screw speed should be adjusted according to the filling amount and type of filler masterbatch—for high-filling masterbatch, a higher screw speed is needed to ensure sufficient shearing and mixing.
• Extrusion otutu: The extrusion temperature is divided into multiple sections (ono apakan, yo apakan, dapọ apakan, homogenizing apakan, kú ori apakan), and the temperature of each section needs to be precisely controlled according to the type of carrier resin and filler. Iwọn otutu ti apakan ifunni jẹ kekere (slightly higher than the melting point of the carrier resin), which is mainly to prevent the materials from caking and ensure smooth feeding; iwọn otutu ti apakan yo jẹ alabọde, which is mainly to promote the melting and plasticization of the carrier resin; the temperature of the mixing section is higher, which is mainly to enhance the shear and mixing effect, and promote the uniform dispersion of the filler; the temperature of the homogenizing section is slightly lower than the mixing section, 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 strips.
• Extrusion Ipa: The extrusion pressure is generally 3-15MPa. Awọn titẹ ninu awọn extrusion iho wa ni o kun nipasẹ awọn funmorawon ipin ti awọn dabaru, awọn kú iho iwọn ati ki o dabaru iyara. Awọn ti o ga awọn extrusion titẹ, the better the mixing and dispersing effect of the materials, and the denser the masterbatch particles. Sibẹsibẹ, if the pressure is too high, yoo mu agbara agbara ati yiya ti ẹrọ naa pọ si, and even cause the die head to block; ti o ba ti awọn titẹ jẹ ju kekere, the materials cannot be fully compressed and mixed, the masterbatch particles are loose, and the performance is unstable.

2.3.5 Kú Head Be:

Awọn kú ori be o kun pẹlu awọn nọmba, apẹrẹ ati iwọn ti kú ihò. The shape of the die hole determines the cross-sectional shape of the extruded strips (gẹgẹ bi awọn ipin, onigun mẹrin), and the size of the die hole determines the initial diameter of the strips and the final particle size of the masterbatch. Awọn kere kú iho iwọn, ti o tobi ni extrusion titẹ, the better the mixing and dispersing effect, ṣugbọn agbara iṣelọpọ yoo dinku; the larger the die hole size, the lower the extrusion pressure, the lower the production efficiency, but the particle size of the masterbatch is larger. Awọn nọmba ti kú iho yoo ni ipa lori isejade agbara; the more the number of die holes, ti o ga agbara iṣelọpọ, ṣugbọn o jẹ dandan lati rii daju pe pinpin titẹ jẹ iṣọkan, so as to avoid uneven thickness of the strips and uneven particle size of the masterbatch.

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

A ti gun a ti npe ni iwadi, development and production of high-performance extruders and granulation production lines, and have accumulated rich experience in the field of filler masterbatch processing. According to the characteristics of filler masterbatch raw materials (high hardness, poor compatibility, ga iki) ati processing awọn ibeere (good dispersibility, uniform particle size, high filling amount), we have developed a series of twin-screw extruders specially suitable for filler masterbatch production. Our extruders have the advantages of high wear resistance, strong shearing force, kongẹ otutu iṣakoso, stable performance and low operating cost, which can meet the processing needs of various types, o yatọ si nkún oye akojo ti filler masterbatch (CaCO3, talc, BaSO4, ati be be lo.), and help enterprises improve production efficiency, ensure product quality and reduce production costs.

3.1 Main Advantages of Our Extruders for Filler Masterbatch Production

3.1.1 High Wear Resistance, Long Service Life:

Aiming at the problem that inorganic fillers (such as CaCO3, talc) have high hardness and easy to wear the screw and barrel, we adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components of the extruder. The screw and barrel are made of imported wear-resistant alloy steel (such as 38CrMoAlA), and after nitriding treatment or bimetallic composite treatment, the surface hardness can reach ≥65 HRC, which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by the friction between the high-hardness filler and the components. This greatly extends the service life of the screw and barrel, reduces the frequency of component replacement, and reduces the maintenance cost of the equipment. Ni afikun, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, jade alaye yiya Iroyin, and put forward targeted replacement and maintenance suggestions, ensuring that customers only replace components when necessary, avoiding unnecessary waste.

3.1.2 Strong Shearing and Mixing Capacity, Excellent Dispersibility:

The key to filler masterbatch production is to ensure the uniform dispersion of fillers. Our twin-screw extruders adopt an intermeshing co-rotating twin-screw structure, pẹlu kan reasonable dabaru ipolowo, lead and compression ratio design. Ibaṣepọ ati yiyi ti awọn skru ibeji le ṣe ipilẹṣẹ agbara rirun ti o lagbara ati ipa ilọkun, eyi ti o le ni kikun fọ awọn agglomerates ti inorganic fillers, ṣe awọn fillers iṣọkan tuka ni yo o ti ngbe resini, and ensure the dispersibility of the masterbatch. The screw is designed with a modular structure, and different screw elements (such as conveying elements, dapọ eroja, 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. Fun apere, when processing high-filling CaCO3 masterbatch, we can configure more shearing elements to enhance the shearing effect and ensure the uniform dispersion of the filler; when processing talc masterbatch which requires high mixing uniformity, we can configure more mixing elements to improve the mixing effect.

3.1.3 Iṣakoso iwọn otutu deede, Stable Performance:

Our extruders adopt advanced intelligent temperature control systems, which can realize precise control of the temperature of each section of the barrel and the die head. The temperature control accuracy can reach ±1℃, which can ensure that the carrier resin is fully melted without thermal decomposition, and the additives are not decomposed, ensuring the stability of the product performance. The temperature control system is equipped with a real-time monitoring and alarm function. If the temperature of any section exceeds the set range, Eto naa yoo funni ni kiakia itaniji ni akoko, and even automatically adjust the heating power or shut down the equipment if necessary, lati yago fun ikuna ẹrọ ati awọn iṣoro didara ọja. Ni afikun, 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 Wide elo Ibiti, Strong Flexibility:

Our extruder series can adapt to the processing needs of various types of filler masterbatch, including CaCO3 filler masterbatch, talc kikun masterbatch, BaSO4 filler masterbatch, ati awọn miiran pataki kikun masterbatches. The filling amount can be adjusted from 30% si 80%, which can meet the different cost and performance requirements of customers. The modular design of the extruder (dabaru, agba, kú orí, ati be be lo.) makes the replacement of components more convenient and quick. When customers need to adjust the product type or filling amount, they only need to replace the corresponding components, lai a ropo gbogbo ẹrọ, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. Ni afikun, our extruders can also be matched with different auxiliary equipment (gẹgẹbi awọn alapọpọ iyara-giga, agbẹgbẹ, coolers, granulators, screening machines, packaging machines) to form a complete automatic granulation production line, realizing continuous production from raw material pretreatment to product packaging.

3.1.5 Ṣiṣe iṣelọpọ giga, Low Energy Consumption:

Wa twin-skru extruders ni ga gbóògì ṣiṣe, eyi ti o ga ju ti awọn extruders ẹyọkan. The production capacity of our extruders ranges from 100kg/h to 3000kg/h, eyiti o le pade awọn iwulo iṣelọpọ ti awọn irẹjẹ oriṣiriṣi ti awọn ile-iṣẹ (kekere, alabọde ati ki o tobi). Eto awakọ iyipo giga-giga ati apẹrẹ dabaru iṣapeye ti extruder le mu imunadoko agbara gbigbe ati ṣiṣe ṣiṣu ti awọn ohun elo., idinku akoko ibugbe ti awọn ohun elo ninu iho extrusion ati imudarasi ṣiṣe iṣelọpọ. Ni akoko kan naa, the extruder adopts an energy-saving design, such as a high-efficiency motor, a heat recovery device, ati be be lo., which can reduce the unit energy consumption by 15%-25% akawe pẹlu arinrin extruders, helping enterprises reduce production costs.

3.1.6 Easy Operation and Maintenance:

Our extruders adopt a PLC intelligent control system and a touch screen operation interface, eyi ti o rọrun ati ogbon inu, rọrun lati ṣiṣẹ. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of filler masterbatch, wọn nikan nilo lati pe agbekalẹ ti o baamu ati awọn paramita, lai tun ṣatunṣe, which saves time and improves production efficiency. The modular design of the equipment makes the maintenance more convenient. Awọn dabaru, agba, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Wa lẹhin-tita iṣẹ egbe yoo pese ọjọgbọn fifi sori, Ifiranṣẹ ati awọn iṣẹ ikẹkọ fun awọn onibara, aridaju wipe awọn onibara le lo awọn ẹrọ laisiyonu.

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, pẹlu HTS Ipilẹ jara, HTS PLUS jara, 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 Ipilẹ Series Extruders: Cost-Effective Choice for Medium and Small-Scale Enterprises.

Awọn extruders jara HTS BASIC jẹ ọna ọja ti o munadoko-owo ni ominira ni idagbasoke nipasẹ wa, which are specially designed for filler masterbatch processing enterprises with medium and small production scales or initial entry into the industry. Yi jara ti extruders nlo alabọde-torque gearboxes lati asiwaju European awọn olupese, eyiti o ni awọn anfani ti iṣẹ iduroṣinṣin, kekere ariwo, ga ṣiṣe ati ki o gun iṣẹ aye. 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), ati ni akoko kanna, o ni a reasonable owo, eyiti o le ṣe iranlọwọ fun awọn ile-iṣẹ lati dinku idiyele idoko-owo akọkọ.

Ni awọn ofin ti apẹrẹ igbekale, awọn HTS BASIC jara extruders gba a ibeji-skru ni afiwe be, pẹlu kan dabaru opin orisirisi lati 30mm to 65mm, ati ipin funmorawon ti 4 ~ 8, which can be adjusted according to the type and filling amount of filler masterbatch. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. Extruder ti ni ipese pẹlu eto iṣakoso PLC ati wiwo iṣẹ iboju ifọwọkan, which can realize automatic feeding, laifọwọyi otutu iṣakoso, iṣakoso titẹ laifọwọyi ati gige gige laifọwọyi, and is simple and easy to operate.

The production capacity of the HTS BASIC series extruders ranges from 100kg/h to 500kg/h, which is suitable for medium and small-sized filler masterbatch processing enterprises that mainly produce common filler masterbatch (such as CaCO3 masterbatch for plastic films, woven bags). 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, kú ori, ono awọn ẹrọ, drying devices and post-processing equipment according to their own product types, gbóògì agbara ati isuna, ki o le fẹlẹfẹlẹ kan ti gbóògì ila dara fun ara wọn aini.

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

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

Awọn extruders jara HTS PLUS ni iwọn ila opin kan ti o wa lati 65mm si 110mm, ipin funmorawon ti 5 ~ 10, ati iwọn iyara dabaru ti 200 ~ 600 rpm. Dabaru ati agba gba itọju akojọpọ bimetallic, eyi ti o ni ti o ga yiya resistance ati ipata resistance, ati ki o le orisirisi si si awọn processing ti ga-lile fillers (gẹgẹ bi awọn eru kaboneti kalisiomu, talc) ati awọn ohun elo ti o ga julọ. Extruder ti ni ipese pẹlu eto iṣakoso oye to ti ni ilọsiwaju, eyiti o le mọ iṣakoso kongẹ ti awọn aye imukuro ati ibojuwo akoko gidi ti data iṣelọpọ. Awọn sakani agbara iṣelọpọ lati 500kg / h si 2000kg / h, eyiti o dara fun alabọde ati awọn ile-iṣẹ kikun kikun iwọn-nla ti o lepa iṣẹ giga ati iye kikun kikun.

Ni afikun, the HTS PLUS series extruders have a stronger mixing and shearing capacity, which can fully disperse the high-filling fillers in the carrier resin, ensuring the dispersibility and stability of the masterbatch. It is especially suitable for the production of filler masterbatch used in automotive parts, awọn ikarahun ohun elo ile, 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, erogba dudu, barium imi-ọjọ) ati awọn ohun elo ti o ga julọ (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, mimo ni oye gbóògì isakoso.

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, lagbara isọdi, 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, ati iwọn iyara dabaru ti 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, Awọn ile-iṣẹ nilo lati ṣe akiyesi ni kikun awọn iwulo iṣelọpọ tiwọn, ọja orisi, filling amount, isuna ati awọn ifosiwewe miiran lati rii daju pe ohun elo ti a yan le pade awọn iwulo iṣelọpọ gangan ati mu awọn anfani eto-aje ti o pọju. Awọn atẹle jẹ diẹ ninu awọn imọran yiyan pato:

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. Fun apere, if the enterprise mainly produces low-to-medium filling CaCO3 masterbatch (filling amount ≤60%) and common PE/PP carrier masterbatch, the HTS BASIC series or ZTE series extruders are suitable; if the enterprise produces high-filling masterbatch (filling amount ≥60%), talc masterbatch or BaSO4 masterbatch, the HTS PLUS series extruders are recommended; if the enterprise produces high-end, special filler masterbatch (such as glass fiber reinforced masterbatch, ina-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 Ṣe ipinnu Agbara iṣelọpọ ti Extruder Ni ibamu si Iwọn iṣelọpọ:

Awọn ile-iṣẹ yẹ ki o yan extruder pẹlu agbara iṣelọpọ ti o yẹ ni ibamu si iwọn iṣelọpọ tiwọn ati ibeere ọja. Ti iwọn iṣelọpọ ba kere (ojoojumọ o wu kere ju 1 pupọ), the ZTE series or HTS BASIC series extruders with production capacity of 50-300kg/h are suitable; ti iwọn iṣelọpọ ba jẹ alabọde (ojoojumọ o wu 1-5 toonu), the HTS BASIC series or HTS PLUS series extruders with production capacity of 300-1000kg/h are suitable; ti iwọn iṣelọpọ ba tobi (ojoojumọ o wu diẹ sii ju 5 toonu), it is recommended to choose the HTS PLUS series, HTS SUPER series or HTE series extruders with production capacity of more than 1000kg/h.

3.3.3 Consider the Wear Resistance of the Equipment:

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

3.3.4 Ṣe akiyesi Imudara-iye ti Ohun elo naa:

Awọn ile-iṣẹ ko yẹ ki o san ifojusi nikan si idiyele idoko-owo akọkọ ti ẹrọ naa, ṣugbọn tun ṣe akiyesi idiyele iṣẹ ṣiṣe igba pipẹ (gẹgẹbi lilo agbara, iye owo itọju, apoju iye owo). Fun apere, 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 San ifojusi si Iṣẹ Lẹhin-Tita ti Ohun elo naa:

Iṣẹ lẹhin-titaja ti ohun elo jẹ pataki fun iṣẹ deede ti laini iṣelọpọ. Awọn ile-iṣẹ yẹ ki o yan awọn aṣelọpọ pẹlu awọn eto iṣẹ lẹhin-tita pipe, eyi ti o le pese ọjọgbọn fifi sori, ifiṣẹṣẹ, ikẹkọ, itọju ati apoju awọn iṣẹ ipese. A ni a ọjọgbọn lẹhin-tita iṣẹ egbe, which can respond to customer needs in a timely manner (provide solutions within 24 wakati) and send technicians to the site for maintenance if necessary, aridaju iṣẹ deede ti laini iṣelọpọ.

3.3.6 Wo Irọrun ati Imugboroosi ti Ohun elo naa:

Pẹlu awọn iyipada ti ibeere ọja, enterprises may need to adjust their product types and filling amounts. Nitorina, nigbati yiyan extruders, awọn katakara yẹ ki o ro irọrun ati expandability ti ẹrọ naa. Wa extruders gba a apọjuwọn oniru, eyiti o le ni idapo larọwọto ati igbegasoke ni ibamu si awọn iwulo ti awọn ile-iṣẹ, imudarasi irọrun ati expandability ti ẹrọ, ati idinku iye owo iyipada ẹrọ.

4. Application Fields and Usage Methods of Filler Masterbatch

Filler masterbatch, bi aropo iṣẹ bọtini ni ṣiṣu processing, has a wide range of application fields, covering various fields such as plastic packaging, ikole, ọkọ ayọkẹlẹ, itanna, 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, iṣiro fun diẹ ẹ sii ju 50% of the total application amount. Filler masterbatch is widely used in the production of plastic films, awọn baagi ṣiṣu, woven bags, igbanu apoti, packaging containers and other packaging products.

• Plastic Films: Including plastic thin films, thick films, stretch films, greenhouse films, ati be be lo. The filler masterbatch used for plastic films is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires good dispersibility, ga fineness ko si si impurities, lati rii daju pe fiimu ti o fẹ ko ni awọn aaye funfun, dudu to muna tabi pinholes, and maintains good transparency, toughness and tensile strength. Adding an appropriate amount of filler masterbatch can not only reduce the production cost of the film, sugbon tun mu awọn rigidity, heat resistance and dimensional stability of the film, and reduce the shrinkage rate of the film. Fun apere, in the production of plastic shopping bags, fifi 1%-3% of CaCO3 filler masterbatch can reduce the cost by 5%-10% without affecting the toughness and load-bearing capacity of the bags.
• Plastic Bags: Including shopping bags, vest bags, garbage bags, food packaging bags, ati be be lo. 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, simenti, chemical products and other goods; packaging belts are used for the bundling of goods. The filler masterbatch used for woven bags and packaging belts is mainly heavy calcium carbonate filler masterbatch or talc filler masterbatch, which requires high rigidity and wear resistance. Adding 5%-10% of filler masterbatch can improve the rigidity, tensile strength and wear resistance of woven bags and packaging belts, reduce the cost, and extend the service life of the products.
• Packaging Containers: Including plastic bottles, plastic barrels, plastic boxes, ati be be lo. The filler masterbatch used for packaging containers is mainly barium sulfate filler masterbatch or light calcium carbonate filler masterbatch, which requires good transparency and chemical stability. Adding an appropriate amount of filler masterbatch can reduce the cost and improve the rigidity and impact strength of the containers.

4.1.2 Plastic Construction Industry:

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

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

4.1.3 Plastic Injection Molding Industry:

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

• Plastic Daily Necessities: Including plastic bowls, plastic plates, plastic cups, plastic baskets, plastic buckets and other daily necessities. The filler masterbatch used for these products is mainly calcium carbonate filler masterbatch, which has low cost and good safety. Adding 2%-5% of filler masterbatch can reduce the cost and improve the rigidity and impact strength of the products, making them not easy to break.
• Plastic Toys: Including various plastic toys for children. The filler masterbatch used for plastic toys is mainly light calcium carbonate filler masterbatch or barium sulfate filler masterbatch, which requires high safety, ti kii-majele ti, 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 (loke 1250 apapo) 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, ati be be lo. 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. Fun apere, in the production of automotive interior parts (such as instrument panels, enu paneli), fifi 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), fifi 3%-5% of glass fiber reinforced filler masterbatch can improve the impact strength and dimensional accuracy of the shells, enhancing the durability of the products.

4.1.4 Automotive Plastic Industry:

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

• Automotive ilohunsoke Parts: Including instrument panels, enu paneli, seat cushions, armrests, ati be be lo. These parts have high requirements on rigidity, ooru resistance, low odor and environmental protection. Talc filler masterbatch and calcium carbonate filler masterbatch are the most commonly used products. Talc filler masterbatch can significantly improve the rigidity and heat resistance of polypropylene (PP) ohun elo, 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. Fun apere, fifi 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 Ode Parts: Including bumpers, fenders, enu kapa, ati be be lo. 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, ati be be lo. These parts have high requirements on heat resistance, chemical resistance and mechanical properties. The filler masterbatch used for functional parts is mainly glass fiber reinforced filler masterbatch or special mineral filler masterbatch. Fun apere, fifi 10%-15% of glass fiber reinforced filler masterbatch to the air intake pipe can improve the heat resistance and pressure resistance of the pipe, ensuring its normal operation under high temperature and high pressure; adding barium sulfate filler masterbatch to the battery casing can improve the radiation resistance and chemical stability of the casing, ensuring the safety of the battery.

4.1.5 Electronic and Electrical Plastic Industry:

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

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

4.1.6 Agricultural Plastic Industry:

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

4.2 Usage Methods of Filler Masterbatch

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

4.2.1 Determination of Mixing Ratio:

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

• For plastic products with low performance requirements and high cost control requirements (such as ordinary plastic bags, garbage bags), the mixing ratio can be 5%-20% (using low-to-medium filling calcium carbonate filler masterbatch);
• For plastic products with medium performance requirements (gẹgẹbi awọn fiimu ṣiṣu, 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 (gẹgẹbi awọn ẹya ara ẹrọ, 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 (loke 1250 apapo) 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 (bii PE, PP, PVC). The specific steps are: akọkọ, 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. The mixing speed is generally 500-800 rpm, and the mixing time is 3-5 iseju. Lẹhin ti o dapọ, the mixture can be directly sent to the extruder or injection molding machine for processing. The advantages of dry mixing are simple operation, ga ṣiṣe, 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. Nitorina, 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, titẹ, dabaru iyara) 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. Fun apere, when processing PE plastic with calcium carbonate filler masterbatch, the processing temperature can be increased by 5-10℃; when processing PP plastic with talc filler masterbatch, the processing temperature can be increased by 10-15℃. It should be noted that the temperature should not be too high to avoid thermal decomposition of the base plastic and additives.
• Pressure Adjustment: The addition of filler masterbatch will increase the resistance during processing, so the processing pressure (extrusion titẹ, injection pressure) needs to be appropriately increased by 10%-20%. Fun apere, when extruding plastic pipes with filler masterbatch, the extrusion pressure can be increased by 10%-15% to ensure the compactness and dimensional accuracy of the pipes; when injecting plastic parts with filler masterbatch, the injection pressure can be increased by 15%-20% to avoid defects such as insufficient filling and shrinkage.
• Screw Speed Adjustment: The screw speed should be adjusted according to the type and filling amount of the masterbatch. For high-filling masterbatch or masterbatch with poor dispersibility, the screw speed can be appropriately increased by 10%-15% to enhance the shear force and mixing effect, ensuring the uniform dispersion of the filler; for low-filling masterbatch or masterbatch with good dispersibility, the screw speed can be kept unchanged or slightly reduced to reduce energy consumption and wear of equipment.

4.2.4 Precautions for Use:

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

• Moisture Prevention: Filler masterbatch (especially calcium carbonate, talc masterbatch) is easy to absorb moisture, which will cause bubbles, pinholes and other defects in the final product. Nitorina, the masterbatch should be stored in a dry, itura ati ki o ventilated ile ise, and should be dried before use (the drying temperature is 80-100℃, ati akoko gbigbe ni 2-4 wakati).
• Ibamu: The carrier resin of the filler masterbatch should be consistent with or compatible with the base plastic of the product. Fun apere, PE filler masterbatch should be used with PE base plastic, and PP filler masterbatch should be used with PP base plastic. If the carrier resin is incompatible with the base plastic, it will affect the compatibility between the masterbatch and the base plastic, resulting in poor dispersibility and reduced product performance.
• Uniform Mixing: The filler masterbatch and base plastic must be mixed uniformly. If the mixing is uneven, local agglomeration of the masterbatch will occur, resulting in defects such as white spots, black spots and agglomeration in the product, affecting the appearance and performance of the product.
• Dosage Control: The dosage of filler masterbatch should not exceed the maximum filling amount applicable to the equipment and product performance. Excessive dosage will lead to poor dispersibility, low toughness, poor processing fluidity and other problems of the product; insufficient dosage will not achieve the effect of cost reduction and performance improvement.
• Storage Period: The filler masterbatch has a certain storage period (ni gbogbogbo 6-12 osu). If the storage period is exceeded, the masterbatch may absorb moisture, agglomerate or the performance of additives may degrade, affecting the use effect. Nitorina, 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.

Awọn okunfa: 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.

Awọn ojutu: 1) Select inorganic fillers with fine and uniform particle size (ni gbogbogbo 800-2000 apapo), and sieve the fillers before use to remove large particles and agglomerates; 2) Increase the dosage of dispersant appropriately (within the range of 1%-3% of the filler dosage) or replace with a dispersant compatible with the filler and carrier resin; 3) Optimize the premixing process, increase the mixing speed (800-1200 rpm) and mixing time (5-10 iseju), 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.

Awọn okunfa: 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.

Awọn ojutu: 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.

Awọn okunfa:

• 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.

Awọn ojutu:

• 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 (fun apere, 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).

Awọn okunfa:

• The thermal stability of the carrier resin is poor, and thermal decomposition occurs at high processing temperatures;
• The additives (gẹgẹ bi awọn dispersants, lubricants) 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.

Awọn ojutu:

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

Awọn okunfa:

• 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.

Awọn ojutu:

• Extend the drying time of the filler (drying temperature 80-100℃, drying time 3-5 wakati), 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, itura ati ki o ventilated ile ise, 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.

Awọn okunfa:

• 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 (gẹgẹ bi awọn okuta, awọn irin), 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.

Awọn ojutu:

• Stop the machine immediately, ge si pa awọn ipese agbara, 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.

Awọn okunfa:

• The filler has high hardness (gẹgẹ bi awọn eru kaboneti kalisiomu, 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, agba;
• The screw and barrel are made of materials with poor wear resistance.

Awọn ojutu:

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

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.

Awọn okunfa:

• 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.

Awọn ojutu:

• 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, imudara iṣẹ ṣiṣe ọja ati mimuṣe ṣiṣe ṣiṣe. 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, iṣẹ ṣiṣe, high filling amount, Idaabobo ayika ati oye. Extrusion granulation technology, bi imọ-ẹrọ mojuto ti iṣelọpọ masterbatch kikun, 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 jara, HTS SUPER series, ZTE series, HTE jara) according to the characteristics of filler masterbatch raw materials and processing requirements. Our extruders have the advantages of high wear resistance, strong shearing and mixing capacity, kongẹ otutu iṣakoso, jakejado ibiti o ohun elo, 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, rii daju didara ọja, ati ki o jèrè anfani ifigagbaga ni idije ọja imuna.

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; ti a ba tun wo lo, 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. Ni akoko kan naa, 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.