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1. The traditional production method of color masterbatch
Most color masterbatches are mainly made of powdered pigments. The pigments required for a single color are fully blended with powdered plastic raw materials through dispersing additives, such as wax, etc., and then dispersed in a twin-screw extruder, and are evenly distributed in the plastic raw materials.
2. Use a single component to produce color masterbatch
The production of single-color masterbatch is completed in two steps. The first step is to produce single-component (high-concentration masterbatch first), and then the masterbatch. Dispersing the pigment in the plastic raw material at the maximum allowable concentration is called a one-component method. At present, organic pigments with a maximum concentration of 40-50% and inorganic pigments with a maximum concentration of 75% can be dispersed into plastics by extrusion to obtain a good dispersion effect.
3. The cost factor of extrusion production
The production cost of extrusion (equipment cost, energy, labor, cleaning agent, waste, etc.) depends on the type and size of the machine used and the size of the processing batch.
1. Twin-screw extruder granulation
The cost of dispersing organic pigments into plastics in a twin-screw extruder is expensive. The length-to-diameter ratio of the parallel co-rotating twin-screw extruder is not less than 40. In order to ensure proper input, the extruder screw has several components for kneading function. This kind of extruder generally produces relatively small amount of organic pigments. .
Inorganic pigments have high density and are easier to disperse, so the output is much higher when produced with a twin-screw extruder. Therefore, the cost of dispersion per unit of inorganic pigments is lower than that of organic pigments. The maximum pigment concentration and mass production of large machines can minimize the dispersion cost of single-component unit pigments.
3. Choose the type of extruder according to the order quantity
Small order ("1t)
Smaller machines are generally used when processing small batches of color masterbatches from 25 to 1000 kg. In view of the above-mentioned advantages of a single-screw extruder, the advantage of using a small extruder (such as a screw diameter of 45 mm) to process batches of up to 500 kg is the most obvious. Compared with powdered pigments, the additional cost of one-component production is compensated. Since the color can be changed very quickly, the color masterbatch manufacturer has obtained the ideal flexibility (quick response unit).
Larger order (》3t)
If the output of color masterbatch exceeds 3 tons, the production cost of single-screw and twin-screw extruder is equivalent. At this time, the most economical way must be determined according to the formula. If the inorganic pigment (such as: TiO2) and organic pigment compound are to be dispersed in a twin-screw extruder, the organic pigment part can be added in the form of a single component, so that only the inorganic pigment is distributed). Since organic pigments do not need to be re-dispersed, inorganic pigments can be dispersed at a higher output speed.