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Calcium Filler Masterbatches

Shivam Polychem Colors Filler masterbatches are concentrates of Calcium Carbonate (CaCO3) or Talc in a polymer base. They offer a convenient way of incorporating CaCO3 and Talc in thermoplastics without contamination by dust. They have perfect dispersion and optimized flow properties ensuring easy processing. The CaCO3 and talc grades used in our filler masterbatches are of excellent quality allowing much higher loading compared to conventional filler masterbatches.

Download Filler Masterbatches For Extrusion Films & Guide

PP Filler Masterbatches Applications

Raffia Tape
PE Carry/Shopping bags
Blow Molding
Injection Molding
Tarpaulin
Strapping

Key Advantages

Cost Reduction
Improves printability and rigidity.
Imparts slip properties
Enhance tear resistance
Increases the Output.
Reduces fibrillation and
splitting tendency on tapes
under mechanical stress

Among main benefits of calcium carbonate concentrates are cost savings, productivity gains, better products quality and environmental advantages.

What is calcium carbonate filler masterbatch?

Calcium carbonate (CaCO3) filler masterbatch or filler master batch is a concentrated mixture of calcium carbonate and other additives which is processed through a heat process into a carrier polymer resin such as PP , LD , LLDPE, or other which is then cooled and cut into granules (pellets) making CaCO3 masterbatch a solid additive for plastics. Opaque Filler /Milky Filler Masterbatches are Calcium Carbonate based Filler Masterbatches for Raffia Tapes (woven sacks), lamination, Moulding, Blown film.

Usage of Calcium Carbonate Masterbatch

 
  •    RAFFIA TAPES :- A wide range of fillers for raffia is offered by us for different applications
  •    HDPE & PP,Low/High denier Fabric.
  •    Lino Bags
  •    FIBC
  •    Tarpaulins
  •    Blown Film:-Used to make liners/carry bags opaque, increase strength and allows loading upto 60%
  •    Furniture:- Compound of strength and economic results
  •    Blow moulding:- For containers,barrels and other articles.
  •    Injection Moulding

Features

The main use of filler masterbatches lies in tapes, which is to provide anti-fibrillation (also known as anti-splitting) properties. There are other advantages as

 
  •    Higher stiffness
  •    Easier processing
  •    Improved weaving ability
  •    Improved anti-blocking properties
  •    Improved weld ability and printability
  •    Reduction of white masterbatch requirement
  •    Lower raw materials cost, as they are more economic than polymer resins.

Useful effect of Calcium Carbonate Masterbatches

Calcium carbonate masterbatch alone is normally not used for coloring plastics and, thus, is different from white masterbatches and color masterbatches. However when used together with white TiO2 based masterbatch it not only increases whiteness due to its natural color but also facilitates white pigment dispersion in the polymer matrix contributing to higher opacity.

 
  •    Calcium carbonate concentrates usually contain from 60% to as high as 90% of CaCO3 in the polymer matrix and are commonly based on polyolefin (PE or PP) resins, though other polymers (PS, EPS, ABS etc.) can be filled as well.
  •    Calcium carbonate filler masterbatches is the most effective cost-saving solution for worldwide plastic processors.
  •    CaCO3 filler masterbatch not only cuts down plastic production costs by replacing a part of virgin polymer during extrusion, injection and blow molding, but also increases output, improves production conditions as well as a number of physical and chemical properties of finished plastic products.
  •    Today advanced calcium carbonate concentrates not only fill but also impart other properties to (improve) plastics. In this case they rather act as functional additives than simply common fillers, and may be referred to as additive masterbatches.

Calcium carbonate filler for nonwoven materials

At Shivam we offer variousl grades of CaCO3 filler mastrebatch for non-woven fabric.

There are a number of benefits of use of CaCO3 fillers in non-woven fabric intended for hygiene, medical, personal care, geotextile, industrial and many other applications.

Adding filler CaCO3 masterbatch into nonwoven materials can improve matte, enhance opacity, increase strength, and provide a cotton-soft feel for comfort, all while reducing your carbon footprint.

A filler masterbatch disperses well in resins and incorporates easily during extrusion.

 
  •    Calcium carbonate Filler masterbatch is modifying fiber surface so that containing CaCO3 non-woven material is softer than the one with only polypropylene (PP). Micro roughness reduces surface luster giving a more matte appearance to the fabric.
  •    Calcium carbonate Filler masterbatch Increases surface area gives improvements in air filtration and oil absorption.
  •    Filler masterbatches Due to natural whiteness CaCO3 will provide good color in fabrics, with limited yellowness. Increased opacity in fibers leads to improved covering power of the web.
  •    Filler masterbatch Increases thermal conductivity of CaCO3 allows for faster throughput or reduced processing temperatures leading to increased productivity or energy savings.
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Calcium Carbonate Filler Masterbatch in Injection Moulding

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Calcium carbonate masterbatches based on PP are widely used in plastics industry for manufacturing furniture and household appliances, containers, boxes, buckets and so on.

Among the main processing and product quality benefits of use of CaCO3 Filler masterbatch in injection-moulded products are

 
  •    lower shrinkage
  •    better flexural stiffness,
  •    higher thermal conductivity
  •    higher impact resistance.

As a new market trend, calcium carbonate filled PP Masterbatch proved to be a good substitute for polystyrene and ABS in applications where scratch-resistance is not a requirement. There is no need to modify existing injection molding machines or significantly change machine settings. Depending on existing formulation and specific product application plastic processor can add up to 50% of filler masterbatch into PP resin.

Calcium Carbonate Masterbatch for Extrusion of Films and Sheets

Adding CaCO3 into original polymer formulations is the most economical way to improve the properties of LDPE, LLDPE and HDPE films and sheeting.

The following product benefits will be achieved:

 
  •    Higher blocking and slip resistance.
  •    Greater tensile strength of film after stretching.
  •    Improved mated surface for printing.
  •    Food Contact Use" compliance due to absence of toxic components.
  •    Higher quality of folding and creasing.
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Calcium Carbonate in Blown HDPE Film

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Many interesting developments have taken place in the film industry over the past few years due to new improved resins and the increased capability of extrusion lines.

Technical progress must however be subject to the cost factor and the use of mineral modifiers, especially calcium carbonate can play an important role. Most polymers are ductile but may become brittle under certain circumstances.

Calcium carbonate filler for extrusion of yarn and twine

One of the main issues the producers of weaving tapes (yarn) and twine face during production is a so called fibrillation effect – an uncontrolled splitting of stretched PP/PE yarn (tape). Using calcium carbonate in the composition helps to reduce or completely avoid fibrillation. Slight modification of your original formula by adding 3-4% of calcium carbonate filler masterbatch is enough to solve the problem.

Other benefits from using of CaCO3 filler in flat PP/PE yarn production

 
  • Improved vertical tearing resistance and tensile strength of PP flat yarn in PP woven bags.
  • Anti-slip effect and facilitating winding.
  • Greater tensile strength of the yarn after stretching.
  • Stiffed yarn makes products firmer and more stable.
  • Higher lifetime of cutting blades because the amount of abrasive titanium dioxide as well as anti-blocking and anti-slip additives can be reduced.
  • Self-cleaning of extruder and dies
  • Increased output.
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