How can we reduce the production cost of masterbatch?

A masterbatch of professional manufacturers, how to control the production cost of masterbatch? To expand the profit margins? Is the most important production work.Usually for small quantities of masterbatch, through the single-component pre-dispersed way to produce more economical, However, if the amount required is large, one-component extra costs must be taken into account relative to the savings that the pure pigment produces in production.

First, the traditional mode of production of color masterbatch

Most masterbatches are mainly made of powdered pigments The pigments required for a single color are thoroughly blended with the powdered plastic raw materials by dispersing aids such as wax and the like and then dispersed in a twin-screw extruder, evenly Distribution in the plastic raw materials.

Figure: Masterbatch

Note: The effects of dispersion in a laboratory twin-screw extruder are not necessarily the same as those on the production line, so color values ​​must be checked at the very beginning and corrected as necessary.

Second, with a single component production masterbatch

The production of single-color masterbatches is done in two steps, the first of which is the production of one-component masterbatches, followed by the production of masterbatches. The dispersion of pigments in the plastic masterbatches at the highest allowable concentration is called a single At present, organic pigments with a maximum concentration of 40-50% and inorganic pigments with a maximum concentration of 75% can be dispersed into the plastic by extrusion to obtain good dispersion.

Figure: Masterbatch

Note: good dispersion quality refers to the plastic pigment particles are very delicate, to get the best possible color penetration, on the other hand, does not allow more than 5 microns pigment agglomeration, so as to avoid the formation of stains.

One-component color conditioning and sampling in the laboratory and masterbatch production are done by a single-screw extruder because the pigment is already dispersed and the different single components are melted in a single-screw extruder and Due to the same quality of dispersion in laboratory and in actual production, the actual transferability of raw material color values ​​obtained in the laboratory can be guaranteed in actual production.

Third, the production of extrusion cost factor

The production costs of extrusion (equipment costs, energy, labor, cleaning agents and scrap etc.) depend on the machine type and size used and the size of the batch processed.

1. Twin-screw extruder granulation

Organic pigments In the twin-screw extruder, the cost of dispersing into the plastic is not high.The aspect ratio of the parallel twin-screw extruder is not less than 40, and in order to ensure the proper input, , The general use of this extruder to produce a smaller amount of organic pigments Masterbatch.

Inorganic pigments High density, easier to disperse, so the production with the twin-screw extruder production is much higher, so the unit of inorganic pigment dispersion costs lower than the cost of organic pigments.Maximum pigment concentration and large machines mass production, can make a single group Unit of pigment dispersion costs to a minimum.

2. Single-screw extruder granulation

Since single-screw machines do not have to be dispersed and may only need to be melted and blended, they are structurally simpler than twin-screw extruders. Not only are they more willing to buy, but they also have the following advantages: ease of cleaning, low production loss, Operation, granular raw materials clean, dust-free, fast mixing.

3. Choose the type of extruder based on the order quantity

small order(<1t)

Smaller machines are generally used for processing small lot sizes from 25 to 1000 kg. In view of the fact that single screw extruders have been described above, batches of up to 500 kg are processed in small extruders (eg 45 mm screw diameter) The most obvious advantage is that the additional cost of one-component production is compensated over that of the powdered pigment, which gives the masterbatch manufacturer the ideal flexibility (rapid response unit) due to the very fast color change.

Larger orders (> 3t)

If the masterbatch production exceeds 3 tonnes, the cost of extrusion with single-screw and twin-screw extruders is quite comparable, and the most economical way to do this is based on the recipe.If inorganic pigments (such as TiO2) and organic pigments are compounded The material to be dispersed in the twin-screw extruder, the organic pigment portion can be added as a single component, so long as the distribution of inorganic pigments in it.) Since the organic pigments do not need redispersion, inorganic pigments can be Higher output speed is decentralized.

2016 GoodChinaBrand | ICP: 12011751 | China Exports