CALCIUM CARBONATE FILLER MASTERBATCH AND 4 MOST POPULAR APPLICATIONS

Filler masterbatch, especially calcium carbonate (calcium carbonate) masterbatch, is considered one of the most superior materials in the plastics manufacturing industry. Calcium carbonate filler masterbatch has countless applications with a large number of products made from them. Below are the outstanding features and 4 most popular applications of this type of masterbatch.

1. WHAT IS FILLER MASTERBATCH MADE FROM CALCIUM CARBONATE ?

Calcium carbonate filler masterbatch is a mixture containing a large amount of fine calcium carbonate (CaCO3) powder mixed with a portion of primary plastic and a few appropriate plastic additives. This mixture is heated at high temperature until it melts into liquid form. After the ingredients in the mixture are mixed together, the mixture will be raw until solidified and passed through an extruder and finally chopped into small plastic particles. These plastic beads are the filler master batch. CaCO3 masterbatch is widely applied as a filler used in the manufacturing and production of plastic products. They have the function of partially replacing input materials, helping manufacturers save costs and reinforcing many features of the product made at the same time.

Calcium carbonate filler masterbatch is naturally white but it cannot be used as a colorant for plastics (because the whiteness is not enough). However, when combined with white masterbatch containing titanium dioxide (TiO2), they play an active role in increasing whiteness and facilitating white pigments to be evenly dispersed in the resin mixture. As a result, the finished product will achieve higher opacity than usual.

2 What outstanding features does Calcium carbonate filler masterbatch have?

Calcium carbonate powder makes up the majority of the masterbatch mixture, usually ranging from 60% to a maximum of 90%. They are most compatible with polyolefin plastics (PP, PE) but can still be mixed with some other common plastics such as PS, ABS, PVC, EPS, etc. This type of masterbatch filer was originally designed to be used as a filler providing an economical and economical solution to the entire plastics industry around the world. However, over time, as the need to use multi-purpose materials is increasing, today they no longer simply play the role of a filler but are gradually becoming a special plastic additive. has the function of improving the physical and chemical properties of the base resin. In general, thanks to the appearance of masterbatch, the quality of products made from plastic has improved significantly.

3. Overview of applications of calcium carbonate filler masterbatch

Overall, the varieties in the application of calcium carbonate masterbatch are too numerous to count and it would be difficult to list them all. Some of the most prominent applications include blowing HDPE film, raffia tape, tarpaulin production, High Density (HD) and Low Density (LD) fabrics from PP/PE plastic, LDPE/LLDPE/HDPE films. , plastic interior/exterior, etc. However, these applications can be divided into several main groups based on the production method or the origin of the base resin. In this article we divide them according to production method criteria.

4. Using CaCO3 filler masterbatch in nonwoven fabric production

The range of fields with products made from calcium carbonate nonwoven fabrics is very large, ranging from medical and personal care to hygiene, geotextiles (fabrics with the ability to absorb, separate , filtration, protection, reinforcement and drainage used in engineering industries such as irrigation, transportation, environment). The benefits of using the plastic additive calcium carbonate filler masterbatch in nonwoven fabric production include:

• Improve product surface by

• Reducing the gloss effect makes the surface more matte and opaque, leading to increased coverage of the fabric structure

• Gives the product a natural white color without yellowing

• Improve material texture by

• Creates a soft and gentle feel like cotton, avoiding fingerprints when touched

• Create extremely small micro-sized ventilation holes to filter air and absorb oil

• Enhances thermal conductivity and mechanical strength

• Contributes to lowering processing temperatures, from which manufacturers can achieve higher productivity as well as simultaneously save energy and production costs

• Easily combined with many different base resins (thanks to good dispersion ability) and can be processed and shaped by many methods

5. Processing calcium carbonate filler masterbatch by injection molding method

Calcium carbonate masterbatch mixed with PP-based plastic is the perfect solution for the production of household items such as furniture, containers, containers, bottles, jars, baskets, etc. through injection molding method. The proportion of CaCO3 in the PP plastic mixture can be up to 50%. However, the exact formula for each production line should be carefully thought out and largely depends on the specific requirements.

Besides calcium carbonate filler masterbatch with PP-based plastic, other options for primary plastic sources include PS (polystyrene) and ABS plastic. These are used where surface scratches are acceptable. Products made from a mixture of PP and CaCO3 plastic through injection molding achieve thermal conductivity, better impact resistance, more flexibility, and less shrinkage. .

6. Apply CaCO3 filler masterbatch to extrusion of plastic sheets and films

With some special man-made materials such as LDPE, LLDPE or HDPE, calcium carbonate filler masterbatch can be added directly to virgin plastic and these mixtures will act simultaneously as plastic filler and plastic industry additive in production of plastic films and sheets. Basically, they provide greater non-stick and anti-slip properties. The surface of the finished product will achieve a suitable opacity for printing. The tensile strength of finished products is also improved allowing their shape and structure to provide complete protection even when they are stretched. Furthermore, this material is safe for food contact as it does not contain any toxic ingredients.

7. Calcium carbonate masterbatch is also found in spunbond and braided fibers

CaCO3 filler masterbatch is said to be the perfect solution to help manufacturers partially reduce or completely avoid the problem of fibers and fibers falling apart. Yarn unraveling is one of the most common problems manufacturers face in plastic filament and filament tape production processes. It causes the plastic structure to separate uncontrollably when the PP/PE fiber is stretched. By adding only a small amount (3 – 4% of the total amount of raw materials) of the plastic additive calcium carbonate into the production of flat PP/PE yarn, not only the problem of fraying and fraying is solved but also brings Some other benefits for this material include:

• Improves tensile strength and resistance to tearing and fraying of spun yarns, braided yarns and woven fabrics after being stretched

• Provides anti-slip and anti-stick effect, facilitating the next winding step

• Improves the weaveability, weldability and printability of the material

• Improves the hardness of products making them stiffer and more stable

• Less damage to machinery, especially cutting blades (by replacing the amount of titanium dioxide, anti-adhesive and anti-slip substances used, which can cause abrasive effects on cutting blades). In general, the life of the machinery is extended.

• Increase productivity

• Partially replaces the need to use white masterbatch, thus helping manufacturers save costs

• Reduce input material costs because calcium carbon filler masterbatch is much cheaper than other primary plastics

• Easier handling

• Provides self-cleaning effects on other materials (like dyes) and machines (like extruders)