Prick Pink Masterbatch Supplier

Prayke Hongmei shows you how to reduce the production cost of masterbatch? (Color Master please save)
Prak Red Plum is a professional manufacturer of masterbatch. How to control the production costs of masterbatch and expand profit margins is a top priority in production. Generally, for small batch masterbatch production, using a single-component pre-dispersal method is more economical. However, if large quantities are required, it is necessary to consider the additional cost of the single-component, compared to the savings in pure pigment usage during production.

Traditional production method for masterbatch

Most color masterbatches are primarily made from powdered pigments. The pigments required for a single color are thoroughly blended with powdered plastic raw materials using dispersing aids like waxes, and then the dispersion is completed in a twin-screw extruder, uniformly distributing within the plastic raw materials.

Note: The dispersion effect in the twin-screw extruder in the lab may not necessarily match the actual situation on the production line, so during production, it is essential to check the color value at the beginning and make the necessary adjustments.

2. Single-component color masterbatch production

The production of single-color masterbatch is completed in two steps. The first step is to produce a single component (first producing high-concentration masterbatch granules), followed by the production of the masterbatch. Dispersing pigments at the highest permissible concentration in plastic materials is referred to as the single-component method. Currently, organic pigments with a maximum concentration of up to 40-50% and inorganic pigments with a maximum concentration of up to 75% can be effectively dispersed in plastics through extrusion, achieving good dispersion results.

Note: Good dispersion quality refers to the very fine pigment particles in the plastic, which enable the best possible color penetration. On the other hand, pigment agglomerates larger than 5 micrometers are not permitted to avoid the formation of color spots.

The color adjustment, sampling, and masterbatch production in the lab are all performed by a single-screw extruder. Since the pigments are already dispersed, different single components only need to be melted and mixed in the single-screw extruder. Due to the identical dispersion quality in both the lab and actual production, the actual transferability of the raw material color values obtained in the lab is guaranteed in real production.

3. Cost factors in extrusion production
Extrusion production costs (including equipment, energy, labor, cleaning agents, and waste, etc.) depend on the type and size of the machine used, as well as the volume of the processing batch.

Twin-screw extruder granulation

The cost of dispersing organic pigments into plastics in a twin-screw extruder is considerable. Parallel co-rotating twin-screw extruders should have a length-to-diameter ratio of not less than 40. To ensure proper input, the extruder screw has several components that serve the blending function. Typically, such extruders produce relatively small quantities of masterbatches using organic pigments.

Inorganic pigments have a high density and are easier to disperse, resulting in significantly higher output when produced using twin-screw extruders. Consequently, the unit cost of dispersing inorganic pigments is lower than that of organic pigments. The highest pigment concentration and large-scale production with large machinery can minimize the unit cost of dispersing single-component pigments.

2. Single-Screw Extruder Granulating

Due to the single screw extruder not necessarily requiring dispersion, it may only need to melt and mix, making it much simpler in structure compared to the twin screw extruder. Not only are people more willing to purchase it, but it also boasts the following advantages: easy to clean, low production loss, easy to operate, granular feedstock is clean and dust-free, and mixing is quick.

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