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Black masterbatch is a color concentrate raw material produced through processes such as injection molding, consisting of carbon black, carriers, and additives.
Composición
Black Masterbatch se compone de los siguientes componentes:
Resinas base: Such as ABS/PE/PP/PS/PVC, PET/PA/PBT, TPE/TPR/EVA, etc., serving as the carrier for the pigment and additives.
Pigmentos: Primarily carbon black, which is an inorganic pigment known for its excellent light-absorbing properties and UV stability, providing a deep black color and high tinting strength.
Carbon Black Lubricant: Used to facilitate the processing of the carbon black and the plastic carrier. It reduces friction during mixing and extrusion, ensuring a smoother production process.
Carbon Black Dispersant: Helps in the uniform distribution of carbon black particles within the plastic carrier, preventing agglomeration and ensuring consistent color and physical properties throughout the plastic product.
Aditivos: May include processing aids like PE wax to improve flowability and mold release, antioxidants to protect against thermal degradation during processing, and zinc stabilizers (ZnSt) for improved UV resistance and heat stabilization during manufacturing and end-use.
El granulador de masterbatch negro mezcla la resina y el negro de carbón a través del equipo cuando la resina se funde. Bajo la función de adictivo, el negro de carbón se dispersa uniformemente en la resina para formar un masterbatch negro con alta concentración.
Aplicación y clasificación del negro de humo
Carbon black, the core component of black masterbatch, has over 30 varieties in China according to international classification standards. These are mainly divided into two categories: rubber and non-rubber.
Rubber Carbon Black: Primarily used to enhance the wear resistance of rubber tires, extending their service life.
Non-rubber Carbon Black: Widely used in plastics, but with only a few types truly suited for application.
Trough carbon black is extensively used in the plastics industry due to its abundant sources, high purity, and small particle size. It is further classified into:
High pigment carbon black (particle size 9-17mm)
Medium pigment carbon black (particle size 18-25mm)
Low pigment carbon black (particle size 26-37mm)
The diversity of varieties leads to significant price differences among carbon blacks.
The Role and Selection of Carrier Resin
The carrier resin serves as the substrate for carbon black in black masterbatch. Typically, the choice of carrier resin aligns with the raw material used in plastic products to ensure compatibility and performance. It can be a general-purpose plastic but must be compatible with the final plastic product.
For example:
For PS (polystyrene) plastic products, the carrier for black masterbatch is PS.
For polyethylene plastic products, the carrier is polyethylene. However, LDPE (high pressure polyethylene) is generally preferred due to its strong carbon black carrying capacity and good processability.
Other polyethylenes such as HDPE and LLDPE can only produce low concentration black masterbatch.
For PP (polypropylene) plastic products, only black masterbatches with PP and LDPE as carriers are used, excluding those with HDPE, LLDPE, or other plastics as carriers. Of course, there are also black masterbatches that utilize recycled materials as carriers. This method of production not only ensures good compatibility with plastic raw materials but also maintains product quality and performance.
Aplicaciones
● Automotive Manufacturing: In the automotive industry, black masterbatch is used to produce various black plastic components such as interior panels, dashboards, door handles, and exterior trims. The good mechanical properties and weatherability provided by black masterbatch make it very suitable for these high-demand applications.
● Electronics and Appliances: Black masterbatch is commonly used in the manufacturing of casings for electronic products and household appliances, such as phone cases, TV enclosures, air conditioner parts, etc. It not only ensures the aesthetics of the products but also provides the necessary functionality like heat resistance and antistatic properties.
● Construction Materials: In building materials, especially the manufacture of PVC doors and windows, black masterbatch is used to provide a uniform black color as well as to enhance the material’s weatherability and durability.
● Packaging Materials: Black masterbatch is also very common in the production of plastic packaging materials, such as black plastic bags and containers. These materials require good optical characteristics and mechanical strength, which can be provided by black masterbatch.
● Agriculture and Gardening: In agriculture and gardening applications, black masterbatch is used to manufacture mulch film, flower pots, and other gardening supplies. Its weatherability and UV protection characteristics make it an ideal choice for outdoor use.
● Sports and Leisure: Sports facilities and outdoor recreational products, such as artificial turf for sports fields, outdoor furniture, and playground equipment, often use black masterbatch to meet the ideal color and performance standards.
● Textiles and Apparel: Certain types of black masterbatch can be used for fiber coloring, producing black textiles and clothing.
Introduction to Carbon Black Masterbatch Extruders
Carbon black masterbatch production involves several types of extruders including twin screw and triple screw extruders, as well as processes that utilize Banbury mixing methods. These machines have distinct features in terms of mixing, dispersing, and pelletizing carbon black.
1. Twin Screw Black Masterbatch Extruder
After initial mixing with a blender, the material is further mixed and dispersed in the twin-screw extruder. The twin-screw barrel facilitates thorough mixing and dispersing of the material, which is then pelletized using an extruder water ring head or another type of pelletizer. Since the twin screw is a fully enclosed meshing conjugated screw, it is challenging to feed carbon black into the twin screw host easily. This results in a relatively lower output, with general carbon black concentrations in the masterbatch ranging from 25-32%.
2. Triple Screw Black Master Granulato
Following blender mixing, the material proceeds into the three-screw extruder. The triple screw extruder offers ample melting and dispersion mixing, with a broad mixing range and enhanced mixing effects. Due to two meshing areas, the mixing range of the triple screw increases exponentially, leading to more uniform dispersion. The yield is also higher, thus the general carbon black concentration of the masterbatch can reach 40-45%.
3. Banbury Mixing Method
The material is mixed by a blender and then kneaded by a Banbury mixer before being fed into a twin-screw extruder via a feeder. After water ring or underwater pelletizing, the masterbatch generally has a carbon black concentration of 40-45%. However, because the Banbury mixer is an intermittent processing unit, it must be unloaded after each mixing cycle, which leads to high labor intensity, high energy consumption, and significant dust generation.
4. Production of Plastic Raw Materials
The carbon black masterbatch granulator can also be utilized in the production of plastic raw materials such as stone paper, PVC, low smoke halogen-free cable materials, internal and external shielding cable materials, chlorinated polyethylene, functional masterbatches, color masterbatches, heat shrinkable materials, PP+carbon black low smoke halogen-free series, etc.
These different machines and techniques have their own advantages and limitations, and choosing the right equipment depends on specific application requirements and expected production efficiency.
Technical Characteristics of Carbon Black Masterbatch Granulator
El granulador de masterbatch de negro de humo es un equipo esencial en la industria del plástico, y sus características técnicas son fundamentales para garantizar la calidad del producto y la eficacia de la producción. Estas son algunas de las características clave de esta máquina:
1. Customized Production Process Route
Unique Production Process Route for Different Grades of Black Masterbatch: A combination of equipment and process is specified for different grades of black masterbatch, offering customized equipment for customers and providing the most cost-effective combination of equipment.
Integrated Unit Process Chain Control Functions: This includes acousto-optic fault alarms and rapid fault locking features, ensuring stability and controllability of the production process.
2. Material and Attention to Detail
Stainless Steel Construction: All units that come into contact with materials are made of stainless steel, focusing on detail to ensure the equipment’s perfection and reliability.
Energy-Saving and Durable: The equipment design focuses on energy-saving and durability to reduce long-term operating costs.
3. Precision of Temperature Control System
Precise Temperature Control: The accuracy of the temperature control system ensures the sensitivity of materials to temperature, avoiding any potential loss in quality.
4. Screw Structure and Mixing Effectiveness
Special Screw Structure: With a rational distribution of mixing sections and high wear-resistant materials, the special screw structure effectively ensures the mixing effect of carbon black.
Automated Feeding and Mixing System: According to customer requirements, the entire process from raw material feeding to conveying to mixing can achieve automatic control, saving labor and reducing dust pollution.
5. Barrel, Screw, and Die
Modular Barrel and Screw Design: The barrel is made of bimetal material, and the screw can offer various high wear-resistant materials for customers to choose from based on their requirements.
Die Design: The die adopts a manual screen changing device, making the honeycomb filter plate easy to clean and nets quick to change, preventing leakage in the die.
6. Automated Feeding and Mixing System
Automated Feeding: Catering to customer needs, the entire process from raw material feeding to conveying to mixing can be automated, which saves labor and reduces dust pollution.
Especificaciones del producto
| Extrusora de doble husillo serie GTE-B | ||||||
| Modelo | Diámetro (mm) | Hacer/Di | Máx. L/D | Velocidad (rpm) | Potencia (kilovatios) | Producción (kg/h) |
| GTE 52B | 51.4 | 1.55 | 68 | 600 | 55 | 150~250 |
| GTE 65B | 62.4 | 1.55 | 68 | 600 | 90 | 200~350 |
| GTE 75B | 71.4 | 1.55 | 68 | 600 | 132 | 400~600 |
| GTE 85B | 81 | 1.55 | 68 | 600 | 250 | 600~900 |
| GTE 95B | 93 | 1.55 | 68 | 600 | 315 | 800~1200 |
| GTE1208 | 116 | 1.55 | 68 | 500 | 450 | 1300~2000 |
| GTE 135B | 133 | 1.55 | 68 | 500 | 900 | 2500~4000 |
| Extrusora de doble husillo serie GTE-C | ||||||
| Modelo | Diámetro (mm) | Hacer/Di | Máx. L/D | Velocidad (rpm) | Potencia (kilovatios) | Producción (kg/h) |
| GTE 52C | 51.4 | 1.55 | 68 | 600 | 90 | 250~350 |
| GTE 65C | 62.4 | 1.55 | 68 | 600 | 160 | 400~600 |
| GTE 75C | 71.4 | 1.55 | 68 | 600 | 250 | 700~1000 |
| GTE 85C | 81 | 1.55 | 68 | 600 | 280 | 800~1200 |
| GTE 95C | 93 | 1.55 | 68 | 600 | 450 | 1300~2000 |
| GTE 120C | 116 | 1.55 | 68 | 500 | 550 | 1500~2200 |
| GTE 135C | 133 | 1.55 | 68 | 500 | 1200 | 3500~5000 |
| Extrusora de doble husillo serie GTE-D | ||||||
| Modelo | Diámetro (mm) | Hacer/Di | Máx. L/D | Velocidad (rpm) | Potencia (kilovatios) | Producción (kg/h) |
| GTE 52D | 51.4 | 1.55 | 68 | 600 | 110 | 300~500 |
| GTE 65D | 62.4 | 1.55 | 68 | 600 | 250 | 700~1000 |
| GTE 75D | 71.4 | 1.55 | 68 | 600 | 315 | 800~1200 |
| GTE 85D | 81 | 1.55 | 68 | 600 | 355 | 1000~1600 |
| GTE 95D | 93 | 1.55 | 68 | 600 | 550 | 1500~2200 |
| GTE 120D | 116 | 1.55 | 68 | 600 | 900 | 3000~4500 |
| GTE 135D | 133 | 1.55 | 68 | 600 | 1800 | 5500~8000 |