Basic Introduction

The full name of masterbatch is masterbatch, also known as color species. Masterbatch is mainly used in plastics. To achieve a certain color effect in plastic or rubber products.

Masterbatch is an aggregate made by uniformly attaching an extraordinary amount of pigment to a resin. Masterbatch is also known as color species. Masterbatch is a new type of special colorant for polymer materials, also known as pigment preparation. It is composed of three basic elements: pigment or dye, carrier and additive. It is an aggregate obtained by uniformly attaching an extraordinary amount of pigment or dye to a resin. It can be called a pigment concentrate, so its tinting power is higher than the pigment itself.

Advantages

Using masterbatch has the following advantages:1. Make the pigment have better dispersibility in the product: Masterbatch is an aggregate made by uniformly attaching an extraordinary amount of pigment to a resin. In the production process of masterbatch, the pigment must be refined to improve the dispersibility and tinting power of the pigment. The carrier of the special masterbatch is the same as the plastic type of the product, and has good matching. After heating and melting, the pigment particles can be well dispersed in the plastic of the product. 2. It is conducive to maintaining the chemical stability of the pigment: if the pigment is used directly, the pigment will absorb water and oxidize due to direct contact with the air during storage and use. After being made into a masterbatch, the resin carrier isolates the pigment from the air and moisture, which can keep the quality of the pigment unchanged for a long time. 3. Ensure the stability of the color of the product: the masterbatch particles are similar to the resin particles, which is more convenient and accurate in measurement. They will not adhere to the container during mixing, and the mixing with the resin is also more uniform. Therefore, the stability of the added amount can be guaranteed, thereby ensuring the stability of the color of the product. 4. Protect the health of operators: Pigments are generally powdery, which are easy to fly when added and mixed. If inhaled by the human body, it will affect the health of the operator. 5. Keep the environment clean and do not contaminate utensils: 6. Simple process, easy color change, saving time and raw materials: Since the pigment is directly exposed to the air during storage and use, it will absorb moisture, oxidize, and agglomerate. Direct use will cause color spots on the surface of plastic products, dark hue, easy color fading, and cause dust during mixing, affecting the health of operators. The masterbatch is mechanically processed during the production process, and the pigment is refined. The pigment and the resin carrier and dispersant are fully mixed to isolate the pigment from air and moisture, thereby enhancing the weather resistance of the pigment, improving the dispersibility and tinting power of the pigment, and making the hue bright. Since the masterbatch is similar in shape to the resin particles, it is more convenient and accurate in measurement, and will not adhere to the container during mixing, thus saving the time of cleaning the container and the machine, as well as the raw materials used for cleaning the machine.

Basic ingredients

1. Pigments or dyes Pigments are divided into organic pigments and inorganic pigments. Commonly used organic pigments are: phthalocyanine red, phthalocyanine blue, phthalocyanine green, fast red, macromolecular red, macromolecular yellow, permanent yellow, permanent purple, azo red, etc. Commonly used inorganic pigments are: cadmium red, cadmium yellow, titanium dioxide, carbon black, iron oxide red, iron oxide yellow, etc. 2. The carrier is the matrix of the masterbatch. Special masterbatch generally chooses the same resin as the product resin as the carrier, and the compatibility of the two is the best, but the fluidity of the carrier should also be considered. 3. The dispersant promotes the uniform dispersion of the pigment and no longer agglomerates. The melting point of the dispersant should be lower than that of the resin, and it has good compatibility with the resin and good affinity with the pigment. The most commonly used dispersants are: polyethylene low molecular wax and stearate. 4. Additives such as flame retardant, brightening, antibacterial, antistatic, antioxidant and other varieties. Unless the customer requires it, the masterbatch generally does not contain the above additives.

Varieties and grades

The following methods are commonly used to classify masterbatches: Classification by carrier: such as PE masterbatches, PP masterbatches, ABS masterbatches, PVC masterbatches, EVA masterbatches, etc. Classification by use: such as injection masterbatches, blow molding masterbatches, spinning masterbatches, etc. Each variety can be divided into different grades, such as: 1. High-grade injection masterbatches: used for cosmetic packaging boxes, toys, electrical appliance housings and other high-grade products. 2. Ordinary injection masterbatches: used for general daily plastic products, industrial containers, etc. 3. High-grade blown film masterbatches: used for blow molding coloring of ultra-thin products. 4. Ordinary blown film masterbatches: used for blow molding coloring of general packaging bags and woven bags. 5. Spinning masterbatches: used for spinning coloring of textile fibers, masterbatches have fine pigment particles, high concentration, strong tinting power, good heat resistance and light resistance. 6. Low-grade masterbatches: used to manufacture low-grade products with low requirements for color quality, such as trash cans, low-grade containers, etc. 7. Special masterbatch: It is a masterbatch made by using the same plastic as the carrier according to the plastic type specified by the user for the product. For example, PP masterbatch and ABS masterbatch use PP and ABS as the carrier respectively. Universal masterbatch: It also uses a certain resin (usually PE with a low melting point) as the carrier, but it can be used for the coloring of other resins except its carrier resin. 8. Universal masterbatch Universal masterbatch is relatively simple and convenient, but it has many disadvantages. It is recommended that users use special masterbatch. The heat resistance level of special masterbatch is generally adapted to the plastic used for the product. It can be used at normal temperature. However, it will cause different degrees of discoloration in the following cases: one is that the temperature exceeds the normal range, and the other is that the downtime is too long. 9. Compared with granulation coloring, masterbatch coloring has the following advantages: 9.1. Coloring and product processing are completed at one time, avoiding the heating process of granulation coloring on the plastic, which is good for protecting the quality of plastic products. 9.2. It simplifies the production process of plastic products. 9.3. Save a lot of electricity

Universal masterbatch and special masterbatch

Special masterbatch: It is a masterbatch made by using the same plastic as the carrier according to the plastic type specified by the user for the product. For example, PP masterbatch and ABS masterbatch use PP and ABS as the carrier respectively. Universal masterbatch: It also uses a certain resin (usually PE with a low melting point) as the carrier, but it can be used for coloring other resins except its carrier resin. Universal masterbatch is relatively simple and convenient, but it has many disadvantages. It is recommended that you use special masterbatch. Why do many companies not produce universal masterbatch? Most of the regular masterbatch companies in the world generally do not produce universal masterbatch. Universal masterbatch has many disadvantages. In fact, the "universal" range of universal masterbatch is very narrow, and the technical indicators and economic benefits are also poor, which are specifically manifested in: 1. The predictability of coloring effect is poor. Masterbatch is used for coloring. The pigment of universal masterbatch will show different colors in different plastics, so the predictability of coloring effect is poor. 2. Affects other properties of plastic products, especially strength. Products are prone to deformation and distortion, which is more obvious for engineering plastics. 3. High cost. In order to be "universal", general masterbatches often use pigments with higher heat resistance grades, which causes waste. In addition to coloring, can masterbatches also have flame retardant, brightening, antistatic, antioxidant, and UV resistance functions? Masterbatches can have some of these functions at the same time if the factory requires it. Sometimes, although the customer has not made any requirements, the masterbatch company will also recommend users to add some additives according to the needs of the product, such as adding certain additives to the masterbatch, such as brighteners. Of course, this will increase the cost of the product.

Heat resistance

The heat resistance grade of special masterbatches is generally compatible with the plastic used for the product, and can be used at normal temperature. However, different degrees of discoloration will occur in the following situations: one is that the temperature exceeds the normal range, and the other is that the downtime is too long. What is the difference between granulation coloring and masterbatch coloring? Compared with granulation coloring, masterbatch coloring has the following advantages: 1. Coloring and product processing are completed at one time, avoiding the heating process of plastics by granulation coloring, which is good for protecting the quality of plastic products. 2. Make the production process of plastic products as simple as possible. 3. Save a lot of electricity. Will the products colored with masterbatch not fade? There is no product that will never fade. Products colored with masterbatch may still fade, but the degree is different for different grades of products, some are more obvious, and some are difficult to detect. Notes 1. How to use masterbatch? The use of masterbatch is very simple. Just mix it with resin particles according to the specified ratio and stir it manually. The following issues should be noted in the operation of the equipment: 1.1. The mixing chamber of the injection molding machine or extruder generally has multiple temperature zones, among which the temperature near the blanking port should be slightly higher. This is to make the masterbatch melt quickly after entering the mixing chamber and mix it evenly with the plastic resin as soon as possible, which is conducive to the masterbatch pigment being in a good dispersion state in the product. 1.2. Applying back pressure to the injection molding machine appropriately can improve the mixing effect of the screw and facilitate the dispersion of the pigment. The side effect of applying back pressure is to slow down the injection speed. 1.3. Properly increasing the die head temperature of the extruder can increase the brightness of the product. 2. How to determine the proportion of masterbatch? The basis for determining the proportion of masterbatch is to obtain a satisfactory coloring effect. As long as the surface color of the product is uniform and there are no stripes and spots, it can be recognized. The proportion of masterbatch can be selected as follows: 1:100 Unless the mixing performance of the equipment is very good, it is easy to cause uneven dispersion of pigments. It is generally not recommended for customers to use this ratio. However, due to price pressure, some customers especially want to use masterbatch with this ratio. For the sake of customers, more concentrated masterbatch with such a low ratio is produced, and the dispersion of pigments can generally meet the requirements. 1:50 is used for plastic products with general coloring requirements, and PE and PP masterbatches mostly use this ratio. 1:33--1:25 is used for PO products with higher coloring requirements, and ABS products with lower coloring requirements or general 1:20 is used for advanced plastic products, including PO and ABS, which can be widely used in injection molding, blow molding, spinning and other processes. 1:20 and above are generally used for coloring of advanced cosmetic containers, and are mostly used in small injection molding machines. 3. How to calculate the cost of masterbatch? The weight of the masterbatch itself should be deducted when calculating the cost of masterbatch coloring. For example: 2 kg of masterbatch is added to 100 kg of plastic resin. At this time, the total weight is 102 kg. Assuming that the price of resin is 10 yuan/kg and the price of masterbatch is 20 yuan/kg, the cost of 102 kg of plastic products due to the use of masterbatch is: 2 kg ¡Á (20 yuan/kg-10 yuan/kg) = 20 yuan. The cost of using masterbatch in every 100 kg of plastic products is: 20 yuan/102 kg ¡Á 100 kg = 19.61 yuan. 4. Will the use of masterbatch increase product costs? In most cases, it is true. However, in some cases, it is more economical to use masterbatch than toner, because the colorist can achieve the coloring effect of higher-priced pigments through a combination of several lower-priced pigments. The following two phenomena should also be considered: 1. In many cases, the pigments used by plastic product manufacturers when matching with toner are not the most economical, and due to lack of familiarity with pigments, repeated experiments during color matching cause waste of manpower and materials, which is very common. This problem does not exist when using masterbatch. 2. The grades of products colored with masterbatch and products colored with color powder are completely different, and their selling prices are also higher. The higher selling prices are often higher than the increased costs of using masterbatch, so masterbatch can create "profits". From this perspective, in some cases, it is more "economical" to use masterbatch than toner. 5. Do masterbatch need to be dried before use? Masterbatch generally does not need to be dried and can be used directly, but ABS and NY masterbatch are exceptions, which should be dried according to conventional processes. How long is the shelf life of masterbatch? Masterbatch can be stored for a long time. The pigment in the masterbatch is dispersed and fixed in the carrier resin and is in a closed state. Even if it is stored for a long time, its quality will not change. But it should be stored in a dry and cool environment. 6. Can several different masterbatch be used to prepare colors? Generally, companies often use several masterbatch to prepare specific colors for small-volume customers. However, without the guidance of the company's technical personnel, customers cannot use several masterbatch combinations on their own initiative, and they cannot mix masterbatch produced by different companies to avoid incompatibility and cause losses. Will the use of masterbatch affect other properties of the product? Some pigments have an impact on the flame retardant effect of the product. When used in flame retardant products, it should be pointed out to the masterbatch manufacturer. Does the mold have an impact on the use of the masterbatch? In order to fully display the coloring effect of the masterbatch, the mold must have the corresponding quality, especially the surface must be very smooth.

Common defects of masterbatch

1. Under sunlight, there are stripes of pigment in the product. This problem needs to be considered from two aspects: the physical and mechanical properties of the plastic and the plastic molding process: 1.1 The temperature of the injection molding equipment is not well controlled, and the masterbatch cannot be fully mixed with the resin after entering the mixing chamber. 1.2 The injection molding machine does not add a certain back pressure, and the mixing effect of the screw is not good. 1.3 The dispersion of the masterbatch is not good or the plasticization of the resin is not good. The process can be debugged as follows: 1. Slightly increase the temperature of the mixing chamber near the blanking port 2. Apply a certain back pressure to the injection molding machine. If the above debugging is still not good, it may be a problem of dispersion or matching of the masterbatch and resin, and the masterbatch manufacturer should be contacted for resolution. 2. After using a certain masterbatch, the product seems to be easier to break. This may be due to the poor quality of the dispersant or additive selected by the manufacturer, resulting in poor diffusion and miscibility, which affects the physical and mechanical properties of the product. 3. After using according to the proportion in the masterbatch manual, the color is too dark (too light). Although this problem is simple, there are many possibilities, specifically: 3.1. The masterbatch has not been carefully tested, and the pigment is too little or too much. 3.2. The measurement is inaccurate during use. There are a large number of Chinese companies, especially small and medium-sized enterprises, that measure arbitrarily. 3.3. There is a problem with the matching of the masterbatch and the resin. This may be due to improper selection of the carrier of the masterbatch, or the manufacturer may change the resin variety at will. 3.4. The machine temperature is improper, and the masterbatch stays in the machine for too long. Processing procedures: First, check whether the resin variety matches the masterbatch and whether the measurement is accurate. Secondly, adjust the machine temperature or speed. If there is still a problem, contact the masterbatch manufacturer. 4. With the same masterbatch, resin and formula, why do the products injected by different injection molding machines have different colors? This is often caused by the injection molding machine. Different injection molding machines have different mechanical states due to different manufacturing, use time or maintenance conditions, especially the difference in the closeness between the heating element and the barrel, which makes the dispersion state of the masterbatch in the barrel different, and the above phenomenon will occur. 5. After changing to another brand of resin, the color of the same masterbatch and formula has changed. Why is this? The density and melt index of different brands of resin will be different, so the performance of the resin will be different, and the compatibility with the masterbatch will also be different, resulting in color changes. Generally speaking, as long as the density and melt index are not much different, the color difference will not be too big, and the color can be corrected by adjusting the amount of masterbatch. 6. Will the pigment migration during the storage of the masterbatch affect the quality of the product? Some masterbatch pigment content (or dye) is very high. In this case, migration is normal. Especially for masterbatch with dye added, serious migration will occur. But this does not affect the quality of the product, because after the masterbatch is injected into the product, the pigment is at a normal color concentration in the product. 7. Why do some injection products have poor gloss? There are several possibilities: 7.1. The nozzle temperature of the injection molding machine is too low 7.2. The mold finish of the injection molding machine is not good 7.3. The molding cycle of the product is too long 7.4. The masterbatch contains too much titanium dioxide 7.5. The masterbatch is not dispersed well 8. After a period of time, some plastic products will fade. The basic pigments used by the manufacturer are of poor quality and drift occurs. 9. Why is ABS masterbatch particularly prone to color differences? Different brands of ABS produced in various countries have large color differences. Even for the same brand of ABS, each batch may have color differences. Of course, color differences will also occur after coloring with masterbatch. This is caused by the characteristics of ABS, and there is no complete solution internationally. However, this color difference is generally not serious. When using ABS masterbatch, users must pay attention to this characteristic of ABS. Performance of pigments. 1. Heat resistance: Pigments of PVC and PE can withstand temperatures of 160-180 degrees Celsius. Pigments of ABS and PS can withstand temperatures of 250-280 degrees Celsius. Pigments of PP, PA, and PET can withstand temperatures above 280 degrees. Generally, the heat resistance time of pigments is required to be 4-10 minutes. Usually, the higher the use temperature, the shorter the heat resistance time. Phthalocyanine blue pigment can withstand temperatures of 325 degrees Celsius and changes color in 10 minutes. 2. Migration: The migration resistance of pigments refers to: when colored plastic products are in long-term contact with other solid, liquid, gas, and other substances or work in a certain environment, they may have physical and chemical reactions with the above substances, which is manifested as the migration of pigments from the inside of the plastic to the free surface of the product, or to the adjacent plastic or solvent. Migration resistance rating standard: Level 1 Level 2 Level 3 Level 4 Level 5 Severe migration Significant migration There is migration Slight migration No migration 3. Most inorganic pigments have good light resistance. 4. Weather resistance refers to the color stability of pigments under natural conditions. 5. Titanium dioxide is divided into: anatase type (A) titanium dioxide rutile type (R) titanium dioxide Titanium dioxide can improve hiding power, weather resistance, fading resistance, etc. When the concentration of titanium dioxide is low, the whiteness of PP increases with the increase rate of its content. When the concentration exceeds 1.5%, the whiteness no longer increases. From 1%-8%, the whiteness only increases by 2.8%. This shows that after exceeding a certain concentration range, increasing the amount of titanium dioxide does not improve the whiteness. In order to further improve the whiteness, fluorescent whitening agent can be used. Only a small amount of fluorescent whitening agent can significantly improve the tinting power of titanium dioxide. Titanium dioxide, also known as titanium dioxide, can effectively scatter visible light in plastics to give them whiteness, brightness and opacity. The concentration of titanium dioxide in PP\\\\\\\\ ABS is 1%; in PVC it is 4%; as the amount of titanium dioxide increases, its hiding power gradually increases, and tends to be balanced when the concentration is greater than 8%. In general, the finer the titanium dioxide particles, the higher its tinting power and the stronger its hiding power. 6. Cadmium yellow has strong tinting power, excellent light resistance and weather resistance, and does not migrate or bleed (toxic pigment). This product can be used as a yellow colorant for plastics. It has bright colors, excellent light resistance, heat resistance, solvent resistance, water resistance and alkali resistance, but it is not acid-resistant, coloring, and its hiding power is not too high. 7. Ultramarine has the effect of whitening and toning. It can remove the yellow light in white products.

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