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Ultimate Guide for Filler Masterbatch


Filler Masterbatch : A brief Description

Filler masterbatch are known by various names such as pp filler compound , calcium carbonate filler, talc filler, PE Filler, filler masterbatches, filler compound , plastic filler dana etc.It has been considered best for reducing cost of any plastic product. It just not reduces cost also modifies its properties. These have been made using a special process of blending or extruding known as compounding extrusion. It involves mixing of carrier resin such as PE , PP, HD with Additives and Fillers i.e Calcium carbonate powder , Talc Powder , Baso4 Powder(Barium Sulphate Powder Masterbatch), Naso4 Powder(Sodium Sulphate Powder Masterbatch. We are also the leading exporter of filler masterbacth based of calcium carbonate powder, Talcum powder, Baso4 Powder, Sodium sulphate powder.





What is Filler masterbatch calcium base?

Calcium Carbonate Filler masterbatch:Calcium carbonate filler masterbatch is manufactured by using fine grade calcium carbonate powder . Different grades of caco3 fillers are manufactured to cater different industries which include blown film, blow moulding, injection moulding, woven sack, non woven etc. The offered masterbatches are widely utilized in polymer and plastic industry due to their remarkable quality.it improves whitening effect, Heat resistance, Bio-degradable, High opacity. It is used in plastic production to reduce cost, increase the heat resistance and durability for the product, increase the flexibility for printing and opacity thus reduce the colour masterbatch and make really big saving for material cost. A great solution of cost saving in production, enhance and improve strength, smoothness, mechanical properties of final plastic products such as films, sheets, yarns, woven sacks, bottles, boxes, containers..etc.



What is Transparent masterbatch?

Talc Based Filler Masterbatch (Transparent filler masterbatch):Transparent Filler Masterbatch are based of Talcum powder . It is transparent in nature and widely used in blowmoulding and blown film industry.These type of Filler masterbatch are highly loaded with talcum powder and are very well suited for PE Films , Woven Sacks, Mouldinds, thermoforming etc. One of the good solution for cost saving in production, enhance and improve strength, smoothness, mechanical properties of final plastic products such as films, sheets, yarns, woven sacks, bottles, boxes, containers..etc




What is Barium Sulphate masterbatch ?

Barium Sulphate Filler masterbatch: Baso4 Filler masterbatch are the most suitable for PE film blown molding, injection and extrusion molding - Loading from 10% up to 40% depending on the quality requirement of final product or on the processing technology - A great solution of cost saving in production, enhance and improve strength, smoothness, mechanical properties of final plastic products such as films, sheets, yarns, woven sacks, bottles, boxes, containers..etc . It has Carrier resin of LLDPE and it is Compatible with HDPE, LDPE, LLDPE film blown molding, injection and extrusion molding, blown molding.

- For LLDPE agricultural film, mulching film;

- For HDPE,LDPE rolling bags, shopping bags, high standard transparency blowing products, can be used to take place of virgin material;

- For HDPE,PP specular injection molded parts



What is Sodium Sulphate Filler Masterbatch ?

Naso4 Filler masterbatch is a transparent masterbatch. It is made of superfine Naso4 powder. It is of very fine Quality and greatly reduce the cost and has a very little effect of transparency. It can be used in various types of industries such as hdpe films, LDPE Films, PP Sheets, PP Boards, injection moulded products etc. Sodium sulphate transparent filler masterbatch contains anhydrous sodium sulphate powder, resin and additives, can be widely used in plastic film blowing, blow molding, injection, pipe, sheet etc. Plastic products keep high tensile, stability, glossiness under high adding ratio of the masterbatch. It is also a kind of filler masterbatch with advantages of high performance, low cost and eco-friendly.

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Filler Masterbatch Applications

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

Advantages of Filler Masterbatch

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

Fillers are widely used among plastic industry for cost reduction and for improving the property of the end product.

Usage of Filler Masterbatches in Different Industry


Filler Masterbatch for non woven fabric industry:



These filler masterbatches for non woven are pp based consist of fine grade Calcium Carbonate extruded with polymer and additives, allowing higher loading compared to other filler masterbatches. It is used to manufacture pp non woven fabric , PP Spunbond non woven fabrics. 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.



Filler masterbatch for woven sack industry:

Filler masterbatch for Woven Sacks, HDPE Bags, PP/HD Tapes, Transparent Lamination & LD liners. Woven sack is a very big industry involving huge consumption of fillers. It meets all Technical requirements for balancing high speed, Elongation, Productivity and above all cost reduction.we also export filler masterbatches for woven sack. Filler masterbatches for Antifibrilliation.

Filler masterbatch for Raffia and pp woven bags: We are leading manufacturer, trader, supplier and exporter of filler masterbatch for pp woven bags.


Filler masterbatch for Cement Bags: We are leading manufacturer, trader, supplier and exporter of filler masterbatch for cement bags. Qualities High loading for HDPE /PP gives Considerable Cost reduction. Production Increase Increases production more than 10% compared to any other filler in the market.


Filler masterbatches for Geo Textile: We are leading manufacturer, trader, supplier and exporter of filler masterbatch for geo textile.


Filler Masterbatches for HDPE Tarpaulin: We are leading manufacturer, trader, supplier and exporter of filler masterbatch for HDPE Tarpaulin. calcium Carbonate Filler Masterbatch for PP/HD RAFFIA plant, HDPE Lamination Plant, PE Blown Films Blown Films, Woven Sacks, Raffia, Injection Molding, Blow Molding, Roto Molding and other Purposes.Qualities of our filler masterbatch are:

  • No delaminating at high dosage
  • Increases mat effect better flexibility

  • Filler masterbatches for Jumbo bags : We are leading manufacturer, trader, supplier and exporter of filler masterbatch for Jumbo bags. Can be processes at High speed, Higher impact and without water carrying

  • No dust formation on tape plant as mere and looms
  • Lowers mean and tear of machine part
  • Increases out of tape plant by 5.7%
  • Dosage recommended 5.15%. as per denier

  • Filler masterbatches for Leno Bags: We are leading manufacturer, trader, supplier and exporter of filler masterbatch for Leno bags.


    Filler masterbatch for carry bags or polythene: Our products are produced with the innovation to meet the requirement of HD/HM carry bags. we are leading manufacturer, trader, supplier and exporter of plastic filler masterbatch for carry bags.




    Filler Masterbatch for blown Film industry:

    Filler masterbatch for blown Film Industry: we are leading manufacture, exporter of Filler masterbatches for polythene, Shopiing Bags, Garbage bags masterbatch, Filler masterbatch for lamination film .The most common method of producing shopping bags, garbage bags, carry bags, plastic bags or plastic sheets is blown film extrusion. Blown Film Extrusion can be used for the manufacture of co-extruded, multi-layer films for high barrier applications such as food packaging. HM, HDPE, LDPE, PP and LLDPE are the most common resins in use, but a wide variety of other materials can be used with these resins or as single layers in a multi-layer film structure. Blown film can be used either in tube form (e.g. for plastic bags and sacks) or the tube can be slit to form a sheet. So to reduce the cost and improve the properties of the blown film extrusion process and also the properties of the end product , it is always preferable to use filler masterbatches in the product


    Various Products made using Filler masterbatches for Industry packaging are shrink film, stretch film, bag film or container liners, Filler masterbatches for Consumer packaging are packaging film for frozen products, shrink film for transport packaging, food wrap film, packaging bags, or form, fill and seal packaging film), Filler masterbatches for Laminating film (e.g. laminating of aluminium or paper used for packaging for example milk or coffee), Filler masterbatches for Barrier film (e.g. film made of raw materials such as polyamides and EVOH acting as an aroma or oxygen barrier used for packaging food, e. g. cold meats and cheese), films for the packaging of medical products, Filler masterbatches for Agricultural film Such as greenhouse film masterbatch, crop forcing film masterbatch, silage film masterbatch, silage stretch film, mulch film masterbatch). So we are the leading manufacturer , supplier , Exporter of Filler masterbatches for Single Layer, Multilayer Films whether used to manufacture carry bags, garbage bags, or any type of packaging products




    Filler Masterbatch for Blow moulding:

    We are the leading manufacturer , supplier , Exporter of Filler masterbatches for HDPE blow moulding, Filler masterbatch for L arc Drum, Filler Masterbatch for Water Tank, Roto water Tank masterbatch or powder.



    Filler Masterbatch for Injection Moulding

    We are the leading manufacturer , supplier , Exporter of Filler masterbatches for injection moulding products.

    Usage 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.


    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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