What is filler masterbatch and how it is applied in plastic industry?

filler masterbatch PolyFill

Filler masterbatch is widely applied in many aspects in the plastic industry. So what exactly is filler masterbatch and how is it applied into plastic manufacture? Let’s discover in the article below!

1. What is filler masterbatch?

filler masterbatch PolyFill
Filler masterbatch is the mixture of CaCO3, plastic carrier and additives

Filler masterbatch is the combination of CaCO3, primary plastic resin and other special additives in accordance with customer’s demand. The production of filler masterbatch includes 4 steps:

  • Step 1: CaCO3, additives and plastic resin are mixed together by high-speed mixer. 
  • Step 2: The mixture above is completely melted at high temperature.
  • Step 3: That mixture is then cooled and put into a screw extruder, pushed forward and pressed into the mold. 
  • Step 4: The output of the extruder is cut into small pieces. They are filler masterbatch applied into plastic manufacture.

Related: What is calcium carbonate filler manufacturing process?

2. Why filler masterbatch?

First of all, primary plastic is made up of high molecular polymers, which are constituted of monomers. To create primary plastic, humans combine natural components including cellulose, rubber,… or Ethin, Benzol, Ethene gas, and most importantly – kerosene together. Thus, using 100% primary plastic in plastic manufacture has the following disadvantages:

Firstly, primary plastic is non eco-friendly. It takes hundreds of years for products made of primary plastic to be completely decomposed under natural conditions.

Secondly, kerosene – the main component of primary plastic largely depends on foreign suppliers, which ends up with a relatively high price of finished products. Besides, due to the instability of kerosene supply, primary plastic is easily influenced by negative effects of foreign market.

filler masterbatch PollyFill
The most important benefit of filler masterbatch is cost saving

Thirdly, kerosene is a non-renewable resource, thus contributing to the unsustainable and unstable development of firms which takes kerosene as the main input material. 

With a view to providing customers with an appropriate solution to address the root of the production expense problem, filler masterbatch was born.

Related news: How thousands of plastic firms cut cost by filler masterbatch?

3. What are the advantages of filler masterbatch?

So, how exactly plastic firms benefit from filler masterbatch? 

  • Product’s cost decrease: One of the main components of filler masterbatch is CaCO3, which is famous for its rich and high-quality reserve worldwide. This will definitely reduce production cost, stabilize the amount of input materials and significantly improve product’s competitiveness.
  • Physical properties enhancement: Rigidity and plasticity increase, shrinkage decrease. 
  • Flexible applications: Thanks to the suitable toughness and stable chemical properties, filler masterbatch can be easily cut into small pieces or crushed into powder. It can also be mixed with other plastic resin to create new products with more functionalities.
  • Forming enhancement: Filler masterbatch plays a vital role in adequate heat distribution in blow film or raffia, thus getting rid of bubbles on plastic surface situations. 

4. How filler masterbatch is applied in the plastic industry?

Thanks to its outstanding advantages regarding functionality and price, filler masterbatch has been widely applied into many industries. 

Injection molding

Injection molding is a common technology based on two main phases: extruding melted plastic mixture and pressing it into the mold for forming. This method is used to create many plastic products including rice cooker lid, toilet lid, buckets, baskets, boxes, toothbrush, plastic toys,…

The injection molding products have these following advantages:

Injection molding
  • Manufacturing lead time decrease due to the good thermal conductivity of CaCO3.
  • Input material expenses reduce thanks to the reasonable price of CaCO3, which is significantly more economical than primary plastic.
  • Energy saving due to the decrease of manufacturing lead time.
  • Stability increase during the product forming process.
  • Carbon footprint decrease thanks to the replacement of primary plastic with CaCO3.
  • Product’s physical properties increase (flexibility, rigidity,…)
  • Product’s tear resistance increase regardless of its thickness. 
  • Product’s printability increase. 

Related news: Common fillers used in injection molding

Extrusion

One of the most popular plastic manufacturing methods is extrusion. After being mixed together, input materials go into the extruder through the hopper. This combination is then melted under extremely high temperature and extruded by a mould clamping cylinder in the form of fibers. The cross section of these depends on the form of the mould clamping cylinder (commonly square or round). The plastic fibers are then cooled by water or fan on the assembly line and cut into small pieces for packaging.  

Extrusion is a common method to produce plastic products such as PVC pipes, straws, gutters,… thanks to its simple technology. The application of filler masterbatch into extrusion helps: 

extruder
  • Reduce production cost thanks to the reasonable price of CaCO3 compared to primary plastic, thus decreasing product’s price and driving competitiveness. 
  • Enhance rigidity and Cải thiện độ cứng và khả năng chịu lực cho thành phẩm.

Blow molding

Blown molding is a common plastic manufacturing technology, especially in producing packaging (thin-film packaging, biodegradable packaging, paper packaging, packaging roll film, waste packaging,…). To create packaging film, materials mixture enters the extruder through the hopper. After being melted, it goes through an annular slit die and is formed as a thin tube. The tube is then cooled by the air ring and continues moving upwards until it passes through nip rolls, where it is flattened. This lay-flat tube is then taken back down via more rollers. The edges of the lay-flat are slit off to produce two flat film sheets and wound up onto reels.

blown film machine
Blown molding machine

Filler masterbatch is used in blow molding to improve the rigidity, control heat, enhance the turbidity and most importantly, cut production expense.

5. PolyFill filler masterbatch 

Thanks to its advantages, this component has been widely applied in many fields with a view to optimizing production cost and to enhancing product’s competitiveness as well. Our most popular products including:

  • PP filler: the combination of PP resin, high-quality CaCO3 and additives. 
  • PE filler: is produced with PE resin, high-quality CaCO3 and additives.
  • Transparent filler masterbatch: the mixture of inorganic transparent powder as BaSO4 or Na2SO4 in PP/PE resin and other additives. 
  • HD filler: includes polyolefin carrier, CaCO3 and other additives. 
  • HIPS filler: contains high portion of pure CaCO3 mixed with additives and plastic resin

For further information and samples, please contact us HERE!

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