Leistritz Masterbatch
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MASTERBATCH PRODUCTION Extruders and extrusion lines

MASTERBATCH – THE GRAIN MAKES THE DIFFERENCE ONE GENERALLY DISTINGUISHES BETWEEN THREE MB GROUPS: ↗ Color Masterbatch → is used to color plastic products ↗ Additive Masterbatch → ensures certain chemical and physical properties of the final products (e.g. UV-stabilization, flame-retardant, anti-static) Small, but with a major impact Plastic pellets with a high share of pigments and/or additives that is much greater than in the final application are called masterbatches. In later process steps such as injection molding, film or fiber production, these are added to the raw polymer to color...

COLOR MASTERBATCH Knowledge of the right color Color masterbatches can be divided up into roughly the following types: Color masterbatches largely consist of individual color pigments that are combined to produce a specific target color. Other components may include effect pigments, dispersing agents and additives. Their production places great demands on the dispersion process because raw materials with different properties have to be optimally ↗ Mono batches or "Single Pigment Concentrates" (SPC): Masterbatches from a certain pigment and a supporting base; wax and/or dispersing agents are...

FILLER MASTERBATCH Low-cost polymer substitute Highly-filled masterbatches contain more than 50 % by weight of fillers that are dispersed in a polymer matrix. Different process set-ups are possible depending on the type and amount of filler. The most common fillers include calcium carbonate or talcum. Filler masterbatches are primarily used to optimize and increase the stiffness, reduce shrinkage and improve the surface appearance of the final product. Application example: CaCO₃ (70 – 85%) in polyolefin There are two main reasons why CaCO₃ is used in plastic: it acts as a functional filler...

PREMIX PROCESS Metered addition of a premix The process set-up shown here is suitable to produce both a masterbatch of mono pigments (SPC = Single Pigment Concentrate) as well as customized masterbatches of powder mixtures. All components are mixed in advance if the premix process is used. The quality of the masterbatch is determined largely by the preceding mixing process. This is why this process step is extremely important: if the premix is not good, e.g. if agglomerates have formed, this fault cannot be remedied in the extrusion process. ADVANTAGES OF THE PREMIX PROCESS Example of a...

SPLIT-FEED PROCESS Material feed through several dosing units As an alternative to premix, both mono as a well as customized masterbatches can be produced by the splitfeed process. The material flows are hereby separated. Through a separation into two or more material flows, the split-feed process allows processing of shearsensitive pigments (e.g. effect pigments) or pigments with a great tendency to compact (e.g. certain phathalo pigments) too. The energy needed to melt the polymer is introduced directly into the polymer - without the pigment - in the split-feed process. The pigment...

CUSTOM COLORING AUXILIARY EQUIPMENT For fast and optimized processes This term describes the color adjustment by means of a mixture of various standard colors, so-called mono batches. With the help of gravimetric, multi-component feeding (usually between five and eight components), a color of the customer's choice is produced from pre-defined standard colors. The extrusion line set-up is similar to that for the premix process. already in the mono batch need more distributive than dispersive mixing. They can be colored more gently in a wide variety of different shades. Here again, a twin...

THE IDEAL MASTERBATCH EXTRUDER ZSE iMAXX – in the new design and for widely varying batch sizes Twin screw extruders cover over complete drive unit ZSE MAXX process part with OD/ID = 1.66 and torque density = 12,5 Nm/cm³ ZSE 18 MAXX Spec. torque density (Nm/cm³) up to max. Through the combination of a high, free screw volume (OD/ID = 1.66) and a high torque (up to 15 Nm/cm³) the ZSE MAXX twin screw extruders have very high throughputs for masterbatch production. Single screw Twin screw SCREW CLEANING Dispersion zone 40 optimum user friendliness maximum ease of cleaning cooling device...

EXTRUSION TECHNOLOGY Available for you all over the world Leistritz Advanced Technologies Corp., Somerville, NJ Headquarters Leistritz Extrusionstechnik GmbH, Nuremberg Leistritz Machinery (Taicang) Co., Ltd., Taicang Leistritz Italia Estrusione, Castellanza Leistritz France Extrusion, Ceyzeriat ↗↗ Leistritz Extrusionstechnik GmbH | Markgrafenstraße 36-39 | 90459 Nuremberg | Germany T +49 911 4306-0 | extruder@leistritz.com