As we have discussed before, in Polymer article, the material that composes plastic products is called polymeric substances. Now, we will focus on one of its important derivatives, known as masterbatch. It is crucial to know the suitable type of masterbatches for producing each plastic product. Therefore, we are going to discuss masterbatch types and applications in detail in this article.

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• What you will read in this article
• What is masterbatch?
• Types of Masterbatches
• Production of Masterbatch
• The Applications of Masterbatch
• Price and Purchase of Masterbatch

What is masterbatch?

The masterbatch is a type of concentrated mixture obtained from the combination of polymeric materials and colored pigments, which is presented in the form of granules (a powdered and crushed state of the polymer). Masterbatch is used to add specific and unique functionalities to the product or to color it. It can be said that it has applications in all plastic industries and is a crucial piece of the plastic production puzzle. It is also one of the highly demanded export products, and due to the fact that masterbatch manufacturers can add various functionalities during its production, it has become an appealing and essential product in the polymer field. We can divide this material into three categories: color masterbatch, additive masterbatch, and filler masterbatch.

Types of Masterbatches

Masterbatch plays a key role in enhancing the properties of plastic materials, ensuring improved performance, durability, and aesthetics. From achieving vibrant colors to adding functional benefits like UV resistance, flame retardancy, and cost-effectiveness, different types of masterbatch cater to a wide range of industrial needs. Masterbatch manufacturers design each variant specifically to optimize plastic formulations, making them more efficient and suitable for diverse applications. In the following sections, we’ll explore these types in more detail and their impact on modern manufacturing.

Color Masterbatch

We use this type of product to color plastic. Masterbatch producers combine polymer materials and the desired pigment to reach the colored one. Plastic producers commonly use white masterbatch and black masterbatch. By the help of this granule, you can add any color to your product, but it is important to ensure that the quality of the granule is at a good and standard level, because using low-quality materials may cause problems in the dyeing process or in color dispersion, or you may not achieve the desired color. However, we don’t only use them for coloring; they can also add special physical properties to the product or enhance the strength of the final product.

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Additive Masterbatch

This additive substance determines everything you expect from your final product! This masterbatch, as the name suggests, meets your desired unique characteristics by being added to the raw materials, where physical resistance and distortion properties are just a fragment of the features that we can mention. A few other features of this material are fire resistant, waterproofing, nanotechnology properties, and glossiness, among others.

Clarifier: Made usingpolypropylene (PP) polymer, its role is to clarify the plastic materials and is mostly used in nylon bags and films.

Cleaner: We use this product to clean the inside of the extruder, and with a small amount of it, we can clean our machine. This product has many applications in the production of foams and films.

Flame retardant: Producers add this masterbatch to the product to increase the thermal resistance threshold and prolong its melting time.

Anti-fog and anti-condensation: We mostly use this polymer in greenhouses because sometimes, duo to temperature changes, condensation forms on the surface of the film, and at times fogging causes, insufficient light reaches the products. Therefore, we use this compound to prevent these issues.

Antioxidant: You may have noticed that if we don’t use a plastic product for a long time and it remains in storage or under certain environmental conditions, it becomes faded and brittle. Producers use antioxidant masterbatch to prevent the oxidation of plastic in the presence of oxygen.

Anti-UV and UV protection: To protect plants and agricultural products from direct sunlight and harmful UV rays, we use anti-UV polymer film coatings.

Lubricant: By applying a layer of these materials, the plastic product gains slipperiness on its outer surface, preventing liquids and other substances from remaining on its surface.

The mentioned items are actually a small part of the vast variety of additive masterbatches. As we’ve mentioned above, because we can use various chemical bases in the production of masterbatches, one should expect a wide and extensive list of these substance. We have prepared a list of diverse products that you can access through this link.

Filler Masterbatch

Plastic producers use filler masterbatch, in the production to reduce costs. They use 20% of filler substance instead of 100% material X, for example, while the rest of the mixture consists of material X. This approach does not significantly change the quality of the product, but in cases where sourcing and using the raw material is costly, using filler masterbatch is an appropriate method. Additionally, this material, like additive masterbatch, can add desired physical properties to plastic products .

Calcium Carbonate: Calcium carbonate is produced in various qualities and percentages, and we mostly use it for white products. It also provides good sturdiness and resistance to the final product.

AdditiveFillerColorant Antioxidant MasterbatchCalcium Carbonate MasterbatchBlack Masterbatch UV Stabilizer MasterbatchTalc MasterbatchWhite Masterbatch Flame Retardant MasterbatchBarium Sulfate MasterbatchColor Masterbatch Antistatic MasterbatchKaolin Masterbatch Slip & Antiblock MasterbatchMica Masterbatch Anti-Bacterial MasterbatchGlass Bead Masterbatch Processing Aid Masterbatch Anti-Fog Masterbatch Anti-Slip Masterbatch

Production of Masterbatch

We produce this product in two general ways: either based on existing data sheets or according to the specific needs of the customer, effectively customizing the production process. The general steps for making masterbatch include the following:

Selecting Raw Materials: In the first stage of production, polymer raw materials such as virgin materials, colored pigments, and other chemicals are collected. Depending on the manufacturer’s goals, the raw materials may vary. 

Mixing: In this stage, we place the prepared raw materials inside a machine and thoroughly mix and combine them using a mixer. 

Extrusion: Then we feed the mixed materials into an extruder, where they melt under high heat and pressure, becoming soft and pliable. Further, through a hook inside the extruder, they take on a new shape and emerge at the end of the extrusion process in the form of long strands, resembling ropes.

Cooling: The materials have a very high temperature after extrusion, and to create cohesion and shock, we direct them through several rollers towards a water tank to gradually cool the masterbatch.

Cutting: Now that the masterbatch has cooled, it enters a crushing machine at the end of the water tank and it transformes into small granule pieces through blades, making it ready for packaging.

The Applications of Masterbatch

Many manufacturers recognize this substance as one of the additive materials in the plastic industry and it is of great importance to them. We can use various materials and chemicals in the production of masterbatch to add our desired characteristics, such as flexibility, physical resistance, waterproofing, heat resistance, cold resistance, and so on. However, it is also important to note that the amount of material that we use in the production is very low (sometimes it only constitutes 2% of the mixture) because, due to the high concentration of this product, we can achieve our desired results using a small percentage of masterbatch. Below, we name a few industries where this material is applied:

Packaging Industry: The packaging industry is one of the extensive industries in the world, and we can say that most packaging is made from plastic and polymeric materials, such as nylon bags, shopping bags, etc. But what role does masterbatch play in this process? One of its applications is adding anti-tearing properties to shopping bags, preventing them from tearing. Additionally, we use them in food packaging for physical protection as well as for long-term preservation against spoilage, among dozens of other applications.

Automotive Industry: Perhaps this section needs no explanation! Because we need to use masterbatch from start to finish in the car manufacturing process. Granules provide elasticity in tires and resistance to direct abrasion. For car body construction, in addition to painting and basic aspects, the strength against severe impacts, aerodynamic capabilities, and more are among the important applications of masterbatch in this industry.

Agriculture Industry: In the greenhouses, we use plastic films to protect agricultural products against cold and hot weather, maintain moisture, and most importantly, to protect them from dangerous ultraviolet rays that can spoil products over extended periods. This product can provide UV resistance and elasticity to protect plants.

Medical Industry: In the manufacturing of medical devices, we use masterbatches for sterilization and strengthening them, as well as for the production of prosthetic limbs and dentures.

Construction Industry: Masterbatches can create lightweight yet resilient structures that can withstand earthquakes and other challenges, while also saving costs. Additionally, plastic manufacturers use them in the construction of supplementary products such as pipes and fittings, doors and windows, electrical coverings, and insulation.

Textile Industry: Interestingly, we use plastic in the production of yarns and synthetic fibers. For dyeing and making durable quality threads, we can rely on the assistance of masterbatches!

Biodegradable Products: The release of plastic and polymer waste has caused many concerns in recent years, as the breakdown of plastic materials can take centuries! Therefore, by adding special masterbatches to plastic products and accelerating the degradation process, we hope to mitigate the environmental hazards and crises.

Price and Purchase of Masterbatch 

In industrial markets, manufacturers often face a large number of plastic raw material suppliers. This situation poses a significant challenge, especially for newcomers, as the abundance of suppliers makes it difficult to establish trust and collaboration, given the risks and time involved for producers. Therefore, in selecting a suitable supplier, several parameters must be considered, which we will discuss next:

Identifying Product Needs

Before anything else, you need to determine what type of materials (colored masterbatches, additives, or filler) with what features are suitable for your product. Factors to consider include:

Final application of the product: The first parameter is to ask yourself what type of product you intend to produce. Will you use the product in specific industries like packaging, automotive, or medical?

Required technical characteristics: You should specify your desired capabilities so that when purchasing and ordering, you know which masterbatch you need. For example, thermal resistance, mechanical properties, or UV resistance are notable considerations.

Compatibility with standards: Raw materials must comply with international standards such as ISO or FDA for specific applications.

Quality assessment of manufacturer products

Quality of materials is one of the most important criteria in selecting a manufacturer. Manufacturers can request product samples from suppliers to test their quality. Methods for assessing quality include:

International certifications: The manufacturer should have standards such as ISO (quality management) or ISO (environmental management).

Quality control laboratories: The manufacturer should have modern equipment to test the mechanical, chemical, and optical properties of the products.

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Long-term quality stability: Ongoing sampling and examination of received materials to assess quality uniformity.

Comparing price and added value

The price of raw materials plays an important role in the profitability of the business, but we should evaluate it alongside the added value. This parameter is one of the influential factors in purchasing masterbatches and raw materials. Considerations include:

Pricing transparency: Costs should include all details like transport and customs. Many times, parties have suffered losses and legal disputes due to unclear ordering and purchasing processes from the supplier.

Comparing quality-to-price ratio: The cheapest option is not always the best choice. Check whether the product’s quality corresponds to its price!

Provision of ancillary services: Services such as technical consulting or sample delivery can add more value to the collaboration. This also fosters greater trust and higher credibility for the supplier.

Sustainable supply capabilities and responsiveness

Ensuring a continuous supply of raw materials, particularly for mass production, is essential. Important points include:

Production capacity: The manufacturer must have the ability to produce the quantities you require. You should first discuss your required tonnage with the supplier to determine whether they can meet your desired production capacity.

Responsiveness to custom needs: It is the ability to adjust formulations of materials to meet your specific needs. As previously mentioned, the method of producing masterbatches can be twofold. The first case is when you want to produce a customized product based on customer orders, so you need to ensure that the supplier can produce materials with your desired formulation.

Delivery time: Check how quickly the supplier can deliver orders. In the manufacturing sector, planning and scheduling are among the most important parameters, so you should pay close attention to this issue.

After-sales service: Provide technical support or replace materials in case of problems. The company should be accountable for the products and services it offers and be able to guide you.

Evaluation of technology and innovation

A manufacturer that uses modern technologies can offer products with better performance and specific capabilities.

Research and Development (R&D): The manufacturer should have an active unit for innovation in its products.

Collaboration with global technologies :Manufacturers that use advanced machinery and modern techniques are usually better options.

In Suprapol we are ready to help & guide all producers around the world. For more information you can contact us via this link.

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Color Masterbatch: a Brief Guide

color masterbatch

What is Color Masterbatch

In the evolving world of plastics, color has become a crucial factor in determining the success of any product in terms of aesthetic, user experience and brand recognition. Color Masterbatch is a new type of polymer colorant, also known as color concentrates, which mainly consists of granules used for coloring plastics and producing batches with precise color matching.

Due to its great impact on the final products, color masterbatch has successfully achieved a global market sales revenue of 4.65 Billion Dollars in , and it is expected to reach a Compound Annual Growth Rate (CAGR) of 6.5% by the end of .

And for the importance of this matter and the great growth it has among the industry, we will offer you in this article a full brief of everything you need to know about color masterbatch and its diverse uses and benefits.

Most Common Applications of Color Masterbatch

Color masterbatch has become widely used in multiple industries for its great properties in enhancing visual appeal, color consistency and brand recognition. Top applications of color masterbatch are:

• Packaging: It is probably the most important area of application that everyone has encountered in their lives. This includes bottles, containers, films, bags, and flexible packages. 
• Automatives: Due to the fantastic visual aesthetic that color masterbatch provides, it is a quite common factor used in producing interior and exterior automotive parts, like dashboards, bumpers and trims.
• Consumer Goods: As color masterbatch allows for easier customization, it has become a great element in producing toys, cases, electronics, and appliances. 
• Medical Devices: Medical imaging and visibility is a very important factor for securing the safety of patients and medical staff, in which color masterbatch is a great tool to ease the process.
• Construction: Color masterbatch is easier to handle and use, hence it is efficient to use with additives to enhance the properties of the end products which is very important in the industry of construction. This includes pipes, fittings, panels, profiles, and more.

Producing Color Masterbatch

Color masterbatch is a concentrated mixture of pigments encapsulated in a carrier resin, used to add color to raw polymers. The process of manufacturing color masterbatch happens on multiple procedures:

Preparation of color masterbatch

The first procedure of manufacturing color masterbatch relies on preparing materials based on the end-use application. This means choosing the right carrier resin (typically Polyethylene (PE) and Polypropylene (PP)), and picking good quality pigments for the desired colors. Additives can also be prepared at this stage to ensure extra characteristics for the end product, like UV resistance.

Production of color masterbatch

After preparing materials, pigments and resin carriers are combined in a mixer where they get continuously blended to ensure even dispersion. A premix preparation can also be applied in a granular premix relying on extrusion or cutting. After that, the composition is melted to form a molten mixture, and is then extruded through an extruder to create continuous masterbatch strips. Eventually, the extruded strips are cooled and solidified into granules. The resulting granules are then uniformly cut based on the desired shapes and sizes.

Screening and Inspection of color masterbatch

Screening and inspecting are crucial procedures after producing a color masterbatch as they ensure that the manufactured masterbatch is even, uniform and with good quality. Screening can be applied through vibrating screens that spread granules based on sizes, or with magnetic separators and air classifiers. And to ensure great quality, certain procedures can be taken, for example,samples of masterbatch can be tested in laboratories to check for properties like color strength and dispersion quality. If the masterbatch requires a specific shading, Spectrophotometry can be a great way to measure the color of masterbatch against a standard. Another great technique is the MFI (Melt Flow Index), which measures the flow rate of the melted masterbatch to ensure that it will process perfectly during the plastic manufacturing processes. 

5 Things To Consider For Producing Color Masterbatch

Producing high-quality color masterbatch involves several critical considerations to ensure consistency, efficiency, and performance. Here are 5 factors you need to pay attention to:

Pigment Selection

Selecting the right pigments is one of the most important factors that determine the success of your production. Make sure you pick pigments with excellent dispersibility, lightfastness, heat stability and other properties to ensure vibrant and consistent colors. 

Carrier Resin Compatibility

The carrier resin must be compatible with your final product’s base polymer. This will ensure that your manufacturing process will achieve a uniform dispersion without risks of complications. 

Production Parameters

First of all, you need to ensure an even dispersion and a proper mixing of all your materials. Then you need to set some control parameters like temperature, pressure, speed and more, to best optimize the process. 

Quality Control

Consider establishing quality control measures such as Spectrophotometry and MFI to make sure that your resulting masterbatch meets the required specifications.

Regulatory Compliance

Ensure the masterbatch complies with industry standards and regulations, especially for applications like food packaging and medical devices.

Top 7 Purposes and Benefits Of Using Color Masterbatch

1- Perfect Color Dispersion

Using high quality color masterbatch ensures a great color consistency throughout the final product and the full set of products in general, with noticeably lesser risks of inconsistent dispersion, streaks, and color variation.

2- Attractive Visual Appeal

Color masterbatch provides vibrant and intense colors that remain vivid over time, which highly elevates the product aesthetic, making it more appealing.

3- Customization

Thanks to the improved technology solutions like Spectrophotometry and computer-aided color matching (CACM), people can now produce color masterbatch that precisely match their needed color samples and requirements.

4- Cost-Effective Solutions

Using color masterbatch is quite more economical than using pre-colored polymers as it reduces the need for large amounts and inventories of colored materials, which is not only cost-effective, but also more sustainable and eco-friendly.

5- Ease Of Use

Colored masterbatch granules are easy to work with and handle in mixers and extruders, and they also have lower risks of incompatibility with base resins, which simplifies the overall manufacturing process.

6- Marketing and Brand Recognition

Many great companies rely on color as a significant marketing tool, for which they use color masterbatch to produce their packaging such as in bottles, bags and covers. Using colors has proven to have a great impact on customers’ decisions of buying.

7- Production Efficiency

Relying on color masterbatch does not only improve the visual appeal and secure great quality, but it also guarantees a quicker production process in lesser time with lesser waste and reduced risks.  

Final thoughts about color masterbatch

If you work in the plastic industry and need color masterbatch, ensure you get your batches from a trusted supplier so guarantee great qualities and ease of production of your end product without risks.

We at Carbokene FZE offer high quality color masterbatch, manufactured in our laboratories under high quality control and standards, with extra inspection and testing to ensure you the best quality and the exact requested color for your application. Contact us to get a price quotation!

Contact us to discuss your requirements of plastic masterbatch. Our experienced sales team can help you identify the options that best suit your needs.

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