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The Importance of Masterbatches, their types and market size

Masterbatches give color and many desired qualities to the plastic material. The color can range from black, white, and red to transparent colors and shades. The heat resistance, UV protection and other qualities to the final plastic products are provided by the use of appropriate masterbatch.  To give any desired color to the plastic products, pigments or additives are needed. These master batches provide the pigment. These pigments come in black, color and white. The mixing of these pigments gives birth to different colors. The masterbatch can be of plastic or rubber.

Basically, there are two types of masterbatch. The color masterbatch and additive masterbatch. The color masterbatch gives color to the plastic product. The additive masterbatch adds other properties like resistance or decide the texture of the plastic. Additive masterbatch also give anti –static, anti fouling, and lubrication qualities to the plastic. In addition to the basic colors, the manufacturers also give lot of shades and special effects to the plastic. These special effect can be marble, pearl, metallic, sparkle, granite, and phosphorescent. Masterbatch come in granular and rough cut form.  The granular form can be in pellets and mini pellets. The rough cut form comes in shreds and tiny chucks.

It is estimated that the market for masterbatches will grow up to 12 billion in next 4 years. The global masterbatch market Masterbatches Manufacturer & Supplier is segmented on the basis of color, region and application. The color component of the masterbatches is expected to play the major role in accelerating the growth of the market. This is because color of the master batch has many unique properties. The properties of the color help a plastic material to find role in various applications and industries. The color aspect of the masterbatch is fueled by the need for the final product users and makers to differentiate the product.  Almost all final products make rely on color for their marketing strategy. The brand of one company is differentiated from other by the use of particular color in logo and company branding.

Generally the growth will happen in the major developing countries and countries in south East Asia.  The growth of economy of these regions will expand the plastic industry. This expansion in plastic industry will lift the demand for masterbatches.  The change in manufacturing industry, where plastic is replacing the use of steel in consumer good is major accelerator of the demand for plastic as raw material. Since, the consumers goods are made with different colors and properties, the demand for masterbatches is bound to increase. The slowdown of world economy is not going Black Masterbatches Manufacturer in India  to have major downward impact on the demand of masterbatches. The reason is that the consumer goods industry will continue to grow to cater to the needs of growing population in developing countries. The shift towards use of plastic in consumer industry will increase the demand for color pigments such as masterbatches.

Types of masterbatches and their uses

Masterbatchesa are widely used in the plastic industry to add color and other desired properties to the plastic items. The addition of masterbatches is very important for the durability and many functional properties of the final product made with plastic. A materbatche may contain polymer, colorant, or additives formulated together specially to give special property or general properties to the product.

Masterbatches are divided into two parts. They are: pigment masterbatches and functional additive masterbatches. Pigment masterbatches add color to the plastic items. The functional masterbatches are used to add some properties to the final plastic products like, heat resistance quality or weather resistance quality. Some examples of functional masterbatches are: antilog agents, anti static agents and anti UV agents.

White masterbatches come with excellent whiteness and opacity. White masterbatches are made into fine films, tapes, blow molded plastic components and they can also be used with pigments for bright and clean shades. The quality manufacturers made white masterbatches without any molecular waxes and are highly filled.  The white masterbatches find application in single and multiple RF films, Non filaments, PP, HDPE Tapes and filaments, laminated tarpaulin, blow molded items and injections.

Black masterbatches Black Masterbatches Manufacturer in India are widely used because of their cost effectiveness, coloring ability and performance. They are used in large number of plastic as additive to get the desired results as protection from UV rays, desired color and conductivity. The tone exhibited by the carbon black range from alcohol blue to warm brown. These masterbatches finds its applications in plastic and engineering industry, laminated tarpaulin, PE films, telecom duct pipes, HDPE pipes for agriculture, PP fiber and filaments and rotomouled tanks.

Additive masterbatches are used to improve the heat conductivity of the plastic materials so that molding period time is reduced. It also improves the tightness and rigidity of the products while removes the surface light from the products.  These additive masterbatches can be made in various specifications. Some of the additive are : additive like optical brighter , flame retardant , UV stabilizer , anti static agent , PP clarifying agent , blowing agent , anti oxidant MB and flame retardant for PP compounds .

Special effect masterbatches Color Masterbatches Supplier in India are used to achieve the coloring effect of marble, metallic, glitter, wood, phosphorescence, granite, pearl scent effect, fluorescent effect, transparent MB   etc. Other colors that get changed under the influence of ultra violet light or temperature are also possible to get. These batches are used in making toys, CDs, cosmetic bottles and plastic chairs.

The cost of the masterbatches depends on the formulations. The special property formulations make a masterbatch expensive. Some masterbatches that are not packed with some specific properties may not be so expensive. General operating cost cost of product and formulations in a masterbatch affect the cost of the masterbatch.  Processor, machine, its size and capacity and screw type affect the performance of the masterbatche.

Advantages in use of masterbatches and their types

Masterbatches are used to add color or performance enhancing capabilities to the natural or base polymer. This process is done at the plant itself.   The technical benefits of this combination is reduced stock holding of material that is compounded , reduction in cleaning cost , optimum dispersion , increase in performance on the desired level by mixing process . The additional benefits are that the finished products are dust free with no health and safety risks.  The elimination of trial and error development work is ensured because the use of masterbatches ensures consistency in performance and color.  

Masterbatches are mixed with basic polymers in a number of ways.  The two most successful methods are, volumetric or graviametric., In both methods, the masterbatch is added directly to the polymer stream before processing .In volumetric dosing, the low capital is required but here the calibration is done every time the color or batch is changed. On the other hand, the graviametric gives accurate results but the establishing plant is expensive.   

The properties or qualities that are added to the basic polymer may range from UV protection to anti static and metal deactivator. Masterbatches are generally supplied in granules forms. They also come in miniature granules form known as micro granules. The masterbatches are also given in rough cut form, which is combination of small chucks and shreds.

The selection of masterbatches will depend on the end use. Toys and food packaging for example are made with materials, which are made with controlled ingredients. For engineering products, the reliable and high performance properties are added.

Color masterbatches are used in bags, tarpaulin, films, drums, woven sacks, combs and household products and HDPE duct pipes.

While masterbatches offer high opacity and whiteness and find uses in very thin film, blow molded plastic components. The other uses of white masterbatches are in laminated tarpaulin, HDPE tapes, PP and monofilament, multiple or single PE films.

Black masterbatches Colour Masterbatches Supplier in India are used in many applications protection from UV and conductivity is desired.  The other uses of black masterbatches are in automobile and engineering industry. HDPE pipes for agriculture, PE films, filament, laminated tarpaulin, rotomouled tanks, telecom duct pipe, and PP fiber.

Additive masterbatches are used to reduce molding speed by increasing the heat conduction quality of the plastic material.  The masterbatche also increase the rigidity and tightness of the property. It also helps in removing surface light from the plastic products.

  

Special effect masterbatches Black Masterbatches Manufacturer in India have special pigments or fillers to get the effect of different colors. These effects can be marble, metallic, glitter, phosphorescence, wood, fluorescence or granite. The other colors that can change with the influence of temperature or ultra violet light are also possible .These special effect masterbatches  are used in making of plastic chairs , toys , cosmetic bottles and CDs. 

Mixing and making process of masterbatches in India

Masterbatches is a product in which additives or pigments are dispersed in a carrier material. This carrier material is same as the main plastic, in which this carrier material will be let down in either granule or pill form. The carrier material can be low density polypropylene, polyethylene, EVA, low molecular weight, an alkyd resin, polymer specific material or polystyrene. The let down ratio of the carrier material can vary depending on the type of additives and pigments quantity required in the final product. The ratio can be below 1 % for some types of additives, UV and color tints to above 50 % in case of flame retardants. Generally for most color products the 1- 3 % is the normal range. To obtain a particular color or additive strength the ratio can be changed.  

 

The most important first step, when masterbatches are made, is  the additive ratio or color formulation. Then all the ingredients are mixed in such a way that they produce homogeneous product. These ingredients are also weighed or may be pre-mixed if necessary. The melting stage must have exact pre-determined temperature, so that the final mixing is homogeneous. The low or high temperatures can give lead to poor shearing and pigment dispersion. To control the rate at which this pre-mix is fed to the extruder, a screw fed system, matched with extruder’s output, must be used.

Using high melt index resin and compounding it with pigments and additives is the efficient way of dispersing.  This high melt resin is compatible with the end use product. The equipment used for mixing should provide high degree of shear with suitable mixing temperature. The mixing is best, when the level of viscosity of the polymer used is quite high. The highest point is the point beyond flux. If mixing is done beyond this threshold, the temperature will rise and viscosity will come down.  The pigment and additives must be properly dispersed .For large production, the internal mixer Banbury is used,

The final masterbatch must be in consistent form and there should be no oversize or presence of any extra matter in the granule form. Today most competent producers use color computers to give all the required information. Color Masterbatches Manufacturer in India  is using the database of more colors and shades to give precise matching with spectrophotometer. The products are made with strict safety and regulatory measures. From the health point of view also care is taken to ensure that the final use of products have no adverse on the users in food packaging products, cosmetics and toys.  More and more manufacturers are customizing the products and color selection. Black Masterbatches Manufacturer in India is using special carbon black to give the quality of UV protection, and resistance to shocks to the products. The final product can withstand heat also.

Hitech Colour Polyplast Pvt. Ltd. manufactures and supplies the finest quality of color masterbatch at competitive prices.

For the purpose of coloring raw polymer economically, the use of color masterbatch is recommended in plastic processing industry. Color masterbatch is manufactured and supplied by Hitech Colour Polyplast Pvt. Ltd.

Color masterbatch is used for coloring raw polymer in plastic processing industry. Hitech Colour Polyplast Pvt. Ltd. manufactures and supplies the finest quality of color masterbatch at competitive prices.

“Additive masterbatch and color masterbatch are manufactured by using the latest machinery and raw materials. White Masterbatches and Black Masterbatches are different types of color masterbatch manufactured and supplied by us, to meet the precise needs of plastic processing industry. Automatic processing & production facility, Sound infrastructure set up and qualified professionals, has helped us in processing the color & additive masterbatch in industry laid norms and regulations” Mr. Rakesh Kumar said.

Mr. Rakesh Kumar further said, “The color masterbatch is used for the purpose of coloring raw polymer in various colors in the most economical manner. Standardized packaging of the color masterbatch and additive masterbatch, ensure safe transportation at the clients’ end. Compositional accuracy, optimum purity and enhanced shelf life, makes the color & additive masterbatch highly appreciated among their customers”.

Prompt delivery and transparency in business dealings has helped Hitech Colour Polyplast Pvt. Ltd. has established as the reputed Masterbatches Manufacturer & Supplier.  Large color & additive masterbatch production capacity and well-equipped warehousing unit with excellent storage capacity, has helped Hitech Colour Polyplast Pvt. Ltd. to systematically manage the bulk assignments of color masterbatch and additive masterbatch. Infrastructural facility is upgraded at regular intervals of time, for the purpose of ensuring that all the processing of color masterbatch and additive masterbatch.

Hitech Colour Polyplast Pvt. Ltd., since its inception in the 2001, is known for processing and supplying a qualitative assortment of Masterbatch.  The masterbatch range consists of White Masterbatches, Additive Masterbatch, Additive Master Batches, Black Masterbatches, and Colored Masterbatches. For processing of color masterbatch and additive masterbatch in accordance with the plastic industry laid standards, the ultra-modern, sound and state-of-the-art  processing facility are used. Qualified and experienced engineers, technicians and support staff ensure that all the processing of color masterbatch and additive masterbatch in the most streamlined manner. The professionals are provided with regular training sessions through different workshops, for upgrading them with latest happening and development in this domain. Timely delivery, customized packaging and easy modes of payment, has helped Hitech Colour Polyplast Pvt. Ltd. to win the trust of its clients. Financial stability and company creditability has helped Hitech Colour Polyplast Pvt. Ltd. to establish as one of the foremost Colour Masterbatches Supplier in India. 

Making Process of Masterbatches and its Uses

Making of a masterbatches is a two way process. First is gathering of ingredients and then mixing them by heating them to produce homogenized pellets.  Generally, the addictives are made by pre mix method by using high or low speed mixers, which is then compounded on roller mills, single or twine screw extruders and kneaders. The distribution and breaking down of the addictives throughout the carrier are essential. The processing of masterbatches depends on several key elements like quality of raw material, mixing quality and compounding plant.

A masterbatch can be introduced to the processor base of a polymer in a number of ways. In the most successful method masterbatches are added to the polymer stream immediately directly before processing. This direct technique is used in both volumetric and gravimetric dosing. In volumetric technique, low capital investment is required but it involved calibrating every time the color or batch is changed, which depends on the bulk density of the material. In the gravimetric technique, plant is expensive but the dosing will be accurate.

Opaque requirement and color thickness affect the dosages. The right loading for the transparent colors can be tricky, because any imperfection is clearly visible. Sometimes, manufacturers go for weaker masterbatches, so that the demand on the dosages and homogenization is reduced.

Injection moulding, profile extrusion, film extrusion, fibres, blow moulding, sheet extrusion, calendered sheet processes use masterbatches. Masterbatche offers an easy way of adding color or performance enhancing addictives to natural polymers. This technique has several benefits apart from cost saving and they are,  reduction in cleaning cost , less stock holding of compounded material and optimum dispersion . Some manufacturers make masterbatches of highly durable polymer addictive. They are used in anti block, UV protection, antioxidant, anti fog, and for processing aid properties. Masterbatches are also made for mulch film, green house film, shade nets, silage and drip irrigation system.

Masterbatches manufacturers make black masterbatches, which are based on PS, PV, EVA and universal polymer. These products contain selected carbon blocks to give properties like high jetness and ultra violet ray protection. Because of its performance, cost effectiveness and coloring ability, carbon black is widely used pigment.  Masterbatches Manufacturer & Supplier are now delivering Special Effects Masterbatches for producing glittering or metallic effect in the final product. To achieve this effect the metallic flakes are added to a traditional solid coloring system. These are mainly used in injection moulded items and cosmetic tubes. Black Masterbatches Manufacturer in India use special addictives and processing aids are also used so that carbon black gets uniformly dispersed in carrier resin, to give optimum performance in the final applications.  Customization process is now increasingly used by all manufacturers to deliver the best solution possible to clients in various industries.  The demand for Pearlescent and Fluorescent Masterbatches is also growing these days for various plastic products.