MASTERBATCH

MASTERBATCH

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INTRODUCTIONMasterbatch is a mixture that consists of rubber or plastic with one or more compounding ingredients in definite proportions but higher concentrations than in a normal mix and that is used for convenience in compounding.Masterbatch is a solid product (normally of plastic, rubber, or elastomer) in which pigments or additives are optimally dispersed at high concentration in a carrier material. The carrier material is compatible with the main plastic in which it will be blended during molding, whereby the final plastic product obtains the color or properties from the masterbatch.

How masterbatch is madeIn simple terms, manufacture is a two-stage process: gathering ingredients and then mixing them together by applying heat and shear to produce an homogenized pellet. Generally high or low speed mixers are used to produce a pre-mix of the additives which is then compounded on roller mills, kneaders, single or twin screw extruders. Even distribution (dispersion) and development (breaking down) of the additives throughout the carrier are essential. This processing depends on several key elements: formulation, quality of raw materials, quality of mixing and compounding plant. Finally, the finished masterbatch is pelletised (die-face or strand cut) or ground.

Using masterbatchMasterbatch can be introduced to the processors' base polymer on the production line in a number of ways, the most successful methods being volumetric or gravimetric dosing. In both techniques, the masterbatch is added directly into the polymer stream immediately before processing. Volumetric dosing has the advantage of relatively low capital investment but requires calibrating every time the batch or colour is changed (depending on the bulk density of the material). Graviametric dosing is extremely accurate, but plant is expensive.

Types of MasterbatchesWHITE MASTERBATCHESCOLOUR MASTERBATCHESBLACK MASTERBATCHESADDITIVE MASTERBATCHESFILLER MASTERBATCHES

WHITE MASTERBATCHES

Application:

Multilayer/ Monolayer FilmBlow/ Rotational/ Injection MoldingLaminationNon Woven ApplicationPipe extrusion

COLOUR MASTERBATCHES

Application:

PP Filaments and FibersPP NON-WOVEN FabricBelow moulded Bottles and drumsInjection moldings specially for Chair, Crates, housewares items made from plastics like HDPE, PP and HIPS. Pipes for irrigation and Telecom ducting applications.

BLACK MASTERBATCHES

Application:

Garbage/ Shopping BagAutomotive/ Injection/ Blow/ Rotational MoldingMono FilamentHDPE PipeCableCritical Film Application

ADDITIVE MASTERBATCHES

Types:

Optical brightener masterbatchAnti block/ Antioxidant masterbatchSilicone masterbatch/Slip masterbatchPolymer processing aid masterbatchNucleating masterbatch/Antistatic masterbatchUV masterbatch

FILLER MASTERBATCHES

Application:

PP and PE woven sacksMono and multi layer filmsBlow moldingInjection moldingPS sheets

End UseInjection molding, blow molding, profile extrusion, sheet extrusion, film extrusion, cast film, fibers and calendared sheet processes commonly employ masterbatch.A basic method of determining whether you will benefit from using masterbatch is to consider that small lots of coloured compound invariably carry a surcharge. Further, if you are using several colours in the same base polymer, especially if it is an engineering polymer, you should explore the cost of using masterbatch. Also, look at the cost of stock holding tones of coloured compounded material and weigh this up against using the space saved by installing a plant that contributes to profit. Although masterbatch can cost from 7 to 25 per kilo, it has the potential to save hundreds of pounds per tone against compounded materials.

Current Market of MasterbatchAccording toIndia Masterbatch Market Forecast & Opportunities, 2018,the Masterbatchvolume sales in India are expected to grow at 23% CAGR till 2018. The market for Masterbatch is driven by the growth in its end user industries as well as the increasing penetration of plastic products in the Indian market. However, use of plastics is being regulated by Ministry of Environment & Forests, Government of India, as solid plastic waste impacts the environment adversely and also causes blockage of gutters, sewerage system and drains. With the development of bio-additives, usage of masterbatches holds positive prospects for the manufacturing of bio-degradable plastics. Other important innovations such as development of anti-microbial masterbatches, flame retardant masterbatches, antioxidant masterbatches is set to drive the market for masterbatches across various end user industries.

The leading players in Masterbatches market in IndiaPlastiblends IndiaClariant ChemicalsPoddar PigmentsPlastichemix Ampacet Corporation.