What is the cause of die build-up during masterbatch extrusion? How to solve the problem of masterbatch processing defects?

Colour masterbatches play a vital role in the plastic products manufacturing industry, which can not only provide uniform and vivid colours, but also ensure the stability of the products in the production process. However, there are still a lot of difficulties to be solved in the production of colour masterbatches, such as the dispersion of colour masterbatch colour powder and the accumulation of material in the die of extrusion process. The production process is the core link to achieve high quality colour masterbatches, mainly including melt mixing, extrusion, pelleting and other steps.

Production process of colour masterbatch:

1. Melt mixing: The prepared mixture is heated to the melting temperature of polyethylene so that the pigment and resin are fully integrated. This step is usually carried out in a twin-screw extruder which provides better shearing and mixing.

2. Extrusion: The molten polyethylene mixture is extruded through the die of the extruder to form a uniform strip of masterbatch. The temperature control and screw speed during the extrusion process directly affect the quality of the product.

3. Pelletising: The extruded strips are cooled and then cut into small particles by the pelletiser. The uniformity and consistency of particle size are important factors to ensure the dispersion and use of colour masterbatch.

4. Inspection and packaging: The finished masterbatches need to go through strict quality inspection, including colour test, melting point test, etc., to ensure that the performance of each batch of colour masterbatches meets the requirements. After that, it should be packed and stored according to the requirements.

Image: https://a132.goodao.net/uploads/R-C-30.jpg

Quality control is an integral part of the entire production process. This includes quality inspection of raw materials, monitoring of parameters during the production process and performance testing of the final product. The market competitiveness of colour masterbatch products can be significantly improved by implementing strict quality control measures.

Problems during extrusion of colour masterbatches

Some masterbatch manufacturers said: in the colour masterbatch extrusion process is prone to the phenomenon of die build-up of material, which seriously affects the quality of the product, the production of masterbatch is a complex process, each link needs to be precisely controlled to ensure that the product can meet the high standard of quality requirements.

The main reasons for the accumulation of material in the die mouth of masterbatch in the extrusion process are as follows: poor compatibility of colour powder and base material, easy agglomeration of part of the colour powder after mixing, differences in the fluidity of the colour powder and resin during the extrusion process, and the viscosity of the melt is large, and at the same time, there is a viscous effect between the metal extrusion equipment and the resin system, which leads to the accumulation of material in the die mouth due to the presence of dead material in the equipment and the peeling off of the colour powder and the thermoplastic resin in the die mouth during the extrusion process.

PFAS-free PPA processing aids [https://www.siliketech.com/100-pure-pfas-free-ppa/], Environmentally friendly and efficient processing solutions

To solve this defect, the interaction between the resin melt and the metal equipment needs to be weakened. It is recommended to use SILIMER 9300 PFAS-free PPA instead of fluorinated PPA processing aids, SILIMER 9300 adopts the modified group which can be combined with metal screw more strongly to replace the role of fluorine in PPA, and then use the low surface energy characteristics of silicone to form a layer of silicone film on the surface of the metal equipment to achieve isolation effect, so this reduces die build-up, extends equipment cleaning cycles, improves process lubrication and improves product quality.

PFAS-free PPA SILIMER-9300 is a silicone additive containing polar functional groups, PFAS-free PPA SILIMER 9300 can be premixed with masterbatch, powder, etc., can also be added in proportion to produce masterbatch. It can significantly improve processing and release, reduce die build-up and improve melt rupture problems, so that the product reduction is better. At the same time, PFAS-free PPA SILIMER 9300 [https://www.siliketech.com/pfas-free-and-fluorine-free-polymer-processing-aidsppa-silimer-9300-product/] has a special structure, good compatibility with the matrix resin, no precipitation, no impact on the appearance of the product and surface treatment.

If you encounter processing problems or product defects during the processing of colour masterbatches, please contact SILIKE and we will provide you with customised processing solutions! By optimising production processes and continuously improving technology, colour masterbatches manufacturers can better meet the market demand for high quality masterbatches.

Contact us Tel: +86-28-83625089 or via email: amy.wang@silike.cn

website: www.siliketech.com [https://www.siliketech.com/] to learn more.

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This release was published on openPR.