Uses and Advantages of Filler Masterbatches in the Plastic Industry

Filler masterbatch is a concentrated calcium carbonate or talc in a polymer base. Nowadays these are highly used in plastic industries. The use of fillers has improved economic benefits. The filler masterbatch is a compound of calcium carbonate powder to improve plastic’s moldability and stability. The use of this raw material is to replace a part of virgin polymer that is very expensive. So, it reduces cost up to great extent. Plastic manufacturers enjoy cost saving with the use of fillers. Also, it improves production conditions and increases output.

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The plastic resins are blended with fillers. They can increase plastic heat deflection temperature. And it reduces thermal expansion. It also changes other features that serve to be beneficial. Earlier plastic cups, tables, chairs, etc. were made up of injection molding. In injection molding, the producers melt the plastic and inject it into the mold. Then they allow it to cool and finally pop out the products. The producers tend to choose popular types of plastics such as PP. But to gain more benefits with good quality fillers are a good way. So, instead of using 100% PP plastic, they reduce its amount. They mix some amount of PP with fillers and other additives. If they want to make it more hard they can add glass fiber. Since the fillers are cheaper than pure PP. So, the output is assured with good quality and less cost.

Use of filler masterbatch:

Calcium carbonate of fillers is widely used to make polythene heavy bags. It hardens the plastic and offers good quality. So, it is also used for PE liquid packaging film. Also, sanitary product bags are made up using fillers. Other usage areas are PE handbags, agricultural films, PE garbage bags, etc. The fillers can be in the production of pipe extrusion and plastic footwear. Using Caco3 filler masterbatches can improve several characters of plastic. It improves low-temperature impact. Also, provides resistance strength and offers better dimension stability. It is suitable for 8-12 micron film.

Advantages of filler:

Apart from cost reduction, fillers offer good quality products too. It does not comprise the quality of the output product. Also, it improves several characters of plastic products. The following are some product characteristics of using fillers.

  • The use of fillers improves anti-heating and rigidity. It hardens the material. Also, it improves the tightness property.
  • It removes the surface light from plastic products. It allows a sub-light effect.
  • The use of carbonate fillers improves the surface anti-friction. It reduces the anti-slip properly of plastic products.
  • It reduces the shrinkage ratio of plastic products. So, it brings stability of size in final products.
  • It reduces pollution because it is degradable.
  • The fillers reduce fire heating quantity. Thus, it does not cause air pollution.
  • It advances the surface printing property of plastics.
  • The filler masterbatch provides breathe-free film products.
  • It improves the heat-conducting property of molding to reduce the period.
  • Lastly, it reduces the application ratio of white color masterbatch.

You can find filler masterbatches for several purposes like:

  1. PE filler masterbatch for blowing film, extrusion coating, etc.
  2. PP filler for PP woven sacks, PP non-woven, and PP Rafia.
  3. Transparent filler for extrusion molding.
  4. HIPS filler for foam PS tableware and sheets.
  5. Fillers for laminated or multi-layer film PP and HDPE pipe.

The use of fillers in plastic products enhances hardness and heat steadiness. It also adds inflexibility. Minerals are also used in fillers. Commonly used fillers are calcium carbonate, talc, silica, clay, mica, and alumina trihydrate. Alumina trihydrate gives plastic flame blocking. Because it decomposes into water and alumina above 220 degrees Celsius. However, its low decomposition limits its use in resins such as polyethylene.

Clay fillers improve electrical properties. Mica boosts the mechanical properties of resins. Glass beads, silica, and talc usually weaken the plastics. Hardness value varies from 1 for talc to 7 for silica. The size and shape of fillers impact the mechanical property of the plastic. Fibers and prismatic particles increase both tensile and flex strength. Fillers in the shape of cubes and spheres raise none of the properties. Flakes or plate-like structures can reinforce strength in two directions.

A filler’s material size also impacts the properties. The particles with larger sizes create greater stress in plastics. So, the smaller ones improve the strength more than the larger ones. Variation in particle size varies from 20:1 to 40:1. The fillers’ surface also has an impact on plastic properties. The surface and degree of wetting determine the viscosity of the flowing resin while molding. Well-wetted fillers flow more easily. Mineral fillers with a length to width ratio below 10:1 have a large impact on isotropic or uniform shrinkage. The low aspect ratio fillers also improve moldability.

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