Masterbatch; Introduction and features

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.

• 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 using polypropylene (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.

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 9001 (quality management) or ISO 14001 (environmental management).

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

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.

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Conclusion

In this article, we aimed to provide a complete explanation of masterbatch and its applications in the industry. We also discussed its features and various classifications. Polymer materials have always been among the most widely used products in the world. The diversity and abundance of this industry are countless, and in this article, we only mentioned a few brief points. However, if you are interested in learning more about the properties and various applications of polymers, you can read more about it here! If you need advice on how to order and purchase, you can contact our experts via this link. We will respond to you as soon as possible.