Factors Affecting Formulation of Masterbatches

Hi friends. I hope you rememberme. Last time I wrote about plastic industry and masterbatches. This time I am going to throw some light on formation of masterbatches.

Frankly, unless you see for yourself the  manufacturing process of masterbatches, it is hard to imagine just how much of technology and hard work goes into getting the formulations right. We, most often don’t give a second thought to the packaging, marveling at the most at the attractive colors and designs that make give the product a hard-to-resist “pick-me-up-please” kind of look.

It took me a visit to RP industries a Delhi based masterbatch manufacturers & exporters, to open my eyes wide to the various factors affecting different aspects of formulation. A gist of whatever I learnt over there is here for you:

Formulations vary depending on whether a supplier is designing a new masterbatch or copying someone else’s. It is considered best to be involved at the color conception stage where it’s possible to optimize formulation choice. Their difference also depends upon whether they are manually designed or computer generated.

Depending on the formulations, the cost of masterbatches also differs. Sometimes formulations over specify performance, and thus become more expensive. Contrarily, they can generate borderline performance to minimize cost. Buying power, production costs and general operating costs, formulations, opacity and pigment loadings are other factors affecting the cost of masterbatches.

There are many factors which influence the performance of masterbatches such as processor machine type its size, capacity, screw-type. Some suppliers prefer to use extenders and some don’t. The ability of a color masterbatches to mix into the polymer varies depending upon its viscosity and flow.

Bulk density and specific gravity variations can occur if distinct base ingredients are used. This can cause further difference in the end result if gravimetric or volumetric dosers are used at the processor.

I was also made aware of the importance of asking customers before formulating about the specification, application and commercial parameters in order to craft a tailor-made masterbatch.

This is pretty much all I could understand, rest was some very technical blah blah. Hope, you guys can explain the procedures further in simpler language, so that novices like me can understand the whole process better.

 

Additive Masterbatches..The Color in Plastics

Hi all. I am an Indian student studying in 12^th standard in a New Delhi based school. I am also the editor of our school magazine. Last month I was writing for the article based on plastic industry. The focus of the article was on the environmental impact of the plastic.

During research for that article I got intrigued by the coloration process of the plastic. I then decided to give a new dimension to my article, about the coloration process and technologies involved. It made sense because harmful or not we can’t wish away the plastic from our lives, it is so damn useful, but we can make ourselves aware of the basics of manufacturing process so as to make use of the plastics more carefully.

With this objective in mind I decided to approach my principal with request to visit a manufacturer of international repute which can give me an idea of best practices in the industry. We decided upon visiting RPindustries R.P Industries the manufacturer and exporter of the additive masterbatches, the basic ingredient to color raw polymer economically during the plastics manufacturing process for all kinds of polymers.

Due to space crunch we could not squeeze the article in our magazine, but it would have been a terrible waste not to do anything with the research. Therefore through this series of postings I would like to make my work see the light of the day, and may be help some of you curious souls understand the plastic especially colored one.

Let’s start with description of masterbatch and its types.

Masterbatches are used to add colors and impart special properties to plastic products. Cost of masterbatch is hardly 1-2%in final plastic product but its quality is very important for durability and functional properties of the product. A Masterbatch contains polymers, additives and colorants specifically formulated together to provide either a general or specific function.

Master batch products are divided into two major types.

• The pigment master batch to color the plastic.
• The functional additive master batches make the plastic capable of certain performances like making them heat resistant, weather resistant etc. Some of the functional master batches are UV light stabilizers, antifog agents, antiblock agents, antistatic agents, etc.Interesting? Well read my next postings for more information on masterbatches, coloration process and UV Masterbatch.