Author Archives: Nuplex

There are numerous sorts of materials that might be utilized as a part of the injection molding process. Most polymers/plastics might be utilized, including all thermoplastics, some thermosets, and a few elastomers.

Picking the correct material for your clients’ custom plastic injection molding venture is a critical choice. Before picking a material, you have different things to consider: Part work, application, toughness, adaptability and shading. Plastic embellishment materials look and act in an unexpected way, so your material decision influences your part’s execution, properties and attributes. Indeed, even the material’s shrink rate should be considered.

At the point when these materials are utilized as a part of the infusion shaping procedure, their crude frame is typically little pellets or a fine powder. Likewise, colorants might be included the procedure to control the shade of the last part. The choice of a material for making infusion formed parts isn’t exclusively in light of the coveted attributes of the last part. While every material has distinctive properties that will influence the quality and capacity of the last part, these properties additionally manage the parameters utilized as a part of handling these materials. Every material requires an alternate arrangement of handling parameters in the infusion shaping procedure, including the infusion temperature, infusion weight, form temperature, discharge temperature, and process duration. A correlation of some ordinarily utilized materials is demonstrated as follows (Follow the connection on the link to look through the material library):

Defection possibility of injection molding

A considerable lot of the above deformities are caused by a non-uniform cooling rate. A variety in the cooling rate can be caused by non-uniform divider thickness or non-uniform mold temperature.

Rules of design in injection molding

Most extreme divider thickness

Lessening the most extreme divider thickness of a section to abbreviate the process duration (infusion time and cooling time particularly) and diminish the part volume

Part with thick walls -incorrect way

Part with thin walls – correct

Uniform divider thickness will guarantee uniform cooling and lessen absconds

Corners

Round corners to lessen pressure focuses and break

Internal range ought to be at any rate the thickness of the dividers

Reclosure highlights have been accessible on adaptable packaging for quite a long time. The reclosure has, all things considered, turn into a standard element versus a choice. End client desires for a positive bundle encounter have prompted the formation of reclosures and innovation that can address the neglected needs that remain a worry of the customer. New advancements in reclosable innovation are displayed that expand the abilities of the reclosure to additionally connect with the end client.

Introduction of Zipper composing

Zipper compose reclosures have been accessible for a long time, finding their way from the kid’s zippered pencil case to buyer sustenance stockpiling sacks and after that on to adaptable food packaging. It has been true decades since the primary precedents of reclosable cheddar and sausage bundles showed up on the supermarket racks. Since their presentation into shape fill seal(FFS) packaging, zippers have been set into numerous styles of the adaptable bundle, over different machine groups. Today, one can discover reclosures on anyplace one looks in a market, regardless of whether it is on destroyed cheddar, pre-bundled cut store meats, pet food or even salty tidbits.

Alongside the multiplication of the assortment of sustenance composes and bundle styles containing a reclosure, the zipper has transformed into different styles, some of which are moderately utilitarian in outline, while others are more particular and adjusted to particular bundle composes or circumstances. Today, one can discover reclosures extending from a straightforward press to close “webless” zipper, a case of which can be found on tortilla bundles, the distance to a slider zipper for hardcore use, a case of which can be found on a 10kg canine sustenance pack. In the middle of the limits is the pervasive “press to close” style(PTC) zippers, that will commonly comprise of basic profiles and transporter webs(flanges), provided as a careful profile expulsion. Figure 1 features this scope of zipper styles yet is in no way, shape or form a comprehensive portrayal of the conceivable outcomes.

Since the years have gone since the presentation of zippers and they are all around settled in adaptable packaging and in the hearts and brains of the purchaser, the inquiry winds up one of “What have you improved the situation me of late?” With the general acknowledgment of the zipper, comes the higher desire for something new and extraordinary. Previously, the bundle fashioner/engineer would concoct a thought, create it, and discharge it to the general population, with the desire that “in the event that we construct it they will come.” As we have all turned out to be horrendously mindful amid the ongoing financial stoppage, “they” won’t really come any longer on the grounds that the creator supposes he has a smart thought. The new reasoning is to connect with the client first, to decide their agony focuses, and after that to follow up on those neglected needs. This “Outside-In” believing the distinct difference a conspicuous difference to the old “Back to front” techniques (i.e., fabricate it and they will come). Things being what they are, the place do we begin with this new improvement technique? A review of current patterns in adaptable packaging was utilized to figure out what the up and coming age of zippered bundles may resemble.

Pattern Analysis of Zipper

Romanik as of late distributed an article distinguishing eleven patterns that he felt were important and creating impacts on adaptable packaging. The rundown:

1. All the more simple open, simple reclose alternatives

2. Clear high-hindrance films

3. Infiltration into altogether new classifications

4. Thick fluids in adaptable pockets

5. Moderate change of grain from pack in-box

6. More layers in coextrusion

7. Formed adaptable packaging

8. More reportable pockets

9. Pockets containing a more extensive scope of fluid, gooey, powdered, granulated and particulate items

10. Manageability in packaging

11. Squander to-Energy

Fascinating to note here that the main thing recorded is more simple open, simple reclose choices on adaptable packaging. A further report performed by Zip-Pak on key patterns in worldwide packaging appears to certify Romanik’s main finding – the world has to change demographics and a maturing populace. One of the finishes of the investigation was that “packaging must oblige a maturing shopper base with more less demanding to open packaging designs.” It would appear to be a straightforward augmentation of this idea to infer that this equivalent packaging must likewise be simpler to reclose. Anthony affirms this thought in his talk of the significance of simple to-open packaging.

There are yet different zipper patterns that have been making strides

• The ascent of the store mark as an opponent to the national brand – the store brands are utilizing packaging improvements as an approach to vie for straight on with the CPGs for the shoppers’ dollar
• Globalization – developments can begin from anyplace on the planet, and turn up on the opposite side of the planet in a matter of seconds
• Consumers’ craving for bolder, more extravagant encounters by accomplishing a more extraordinary ordeal to any or the majority of the faculties

In view of the investigations refered to above, it gives the idea that the customer still might want extra consolation that their bundle will open and reclose basically and effectively. Add to that the craving to connect a greater amount of the faculties in this procedure, and we have the criteria to start planning the cutting edge reclosure. We will approach this as a three-advance process, looking first separately and after that by and large calm of opening; simplicity of reclosing; and commitment of the end client in a multisensory mold.

Overhauling Easy-to-Open Zipper

The initial phase in our new bundle will be to address simplicity of opening concern. While there are a few strategies for giving simplicity of opening, a few plans are favored over others. While basic holes will enable the client to detach the best from an adaptable bundle without requiring scissors to cut it open, the punctured bundle isn’t impenetrable and won’t legitimately ensure numerous items that require a hermetically fixed bundle until being opened by the customer. Along these lines, apertures are out. Laser scoring of the bundle film can be a choice, also the new age of film structures accessible that display straight line tear highlights. Utilization of these highlights in an adaptable bundle can end up hazardous, contingent upon how the bundle will be delivered. In the event that the bundle is delivered in a vertical shape fill seal plan, that would require the simple tear highlight to be put in the cross bearing of the film. This is definitely not a decent plan for straight line tear film, nor is it ideal for laser scored film. While a laser score can be put in the cross bearing, the procedure must be checked precisely to guarantee that unnecessary web pressure does not cause untimely tearing of the score.

Peelable seals are another instrument that the bundle originator has available to them to accomplish simplicity of opening. Everybody knows about the salty bite sack that can be grasped and pulled open at the best without any difficulty. This strategy for the opening may not fill in too on a heavier measure film structure, in addition to the expansion of a zipper just beneath the sack best will likewise make this technique for opening more troublesome. Without some more positive method for holding the package film over a shut zipper, this technique for the opening turns out to be greatly troublesome.

A last choice is consider using the zipper conclusion itself as the methods for accomplishing simplicity of opening. Surely, after the film at the highest point of a bundle is either opened or evacuated over the zipper, the zipper in actuality turns into the “fourth side” of the bundle. All in all, one would ask, for what reason can’t the zipper work in this form for the underlying opening of the bundle too? One manner by which the zipper can accomplish this is appeared in Figure 2. Here the zipper has fused into its development a peelable seal over the zipper profiles. This seal can be pre-enacted on the zipper before it being set into the bundle to guarantee a uniform hermetic seal. The peel quality of this seal can be balanced with the end goal to adjust the power expected to open the seal with the requirement for that seal to stay unopened until the point when such time as the end client wishes to open it.

Any of the plan choices recorded above can create the simple open element so wanted by the Consumer; notwithstanding, for greatest adaptability, a simple open peelable seal pre-connected to the zipper spines is the most flexible of the decisions. This sort of development has been shown to viably work as the fourth side of the bundle, keeping up hermeticity from purpose of fabricate through the underlying opening. The power required to pull this seal open can be custom-made to the bundle creator’s prerequisites, guaranteeing a lovely ordeal for the end client.

Influential of Chinese in the Bioplastics industry

Thyssenkrupp constructed the primary business plant in China dependent on their licensed PLA bioplastics process.

The plant is situated in Changchun, China and is worked by the Jilin COFCO Biomaterial Corporation, a backup of COFCO, China’s biggest nourishment and drink gathering. The new plant produces PLA that can be utilized for the creation of eco-accommodating packaging, strands, materials and building plastics. PLA is produced using inexhaustible assets, for example, sugar, starch or cellulose.

Sami Pelkonen, CEO of the Electrolysis and Polymers Technologies specialty unit of thyssenkrupp Industrial Solutions:

“The bioplastics market will keep on developing in the coming years, not minimum because of the expanding ecological attention to industry, governments and buyers. With our PLAneo® innovation we need to do our bit to make the plastics area more economical and asset inviting. With it we empower our clients to create fantastic bioplastics with an extensive variety of properties – at a value that is focused with regular plastics.”

PLAneo innovation changes over lactic corrosive into PLA in an especially productive and asset amicable way. Another preferred standpoint is its transferability to extensive scale plants with limits of up to 100,000 tons for every year.

Shutting REMARKS of Bioplastics Industry

Thyssenkrupp is somewhat similar to the Rolls Royce of plant building. It’s German quality.

So when the Chinese request that Thyssenkrupp manufacture an industrial facility, is it to figure out it?

Which word struck a chord: presumably or clearly?

Is it accurate to say that someone is at Thyssenkrupp not focusing, not getting the updates or not grabbing the telephone?

Add up to Corbion should turn into the following enormous thing on the PLA scene however will the Chinese take the show?

Japan was turning into the bioplastics pioneer in Asia, yet will the Chinese beat the Japanese?

Will bioplastics move toward becoming standard if the Chinese deliver bioplastic?

Chinese Create PCF from FDCA and May Disrupt PET and PEF

The bio-based polyester exhibited extraordinary potential and could be utilized as building plastic.

PCF (poly(1,4-cyclohexanedimethylene furandicarboxylate) was incorporated from FDCA and CHDM with various steric adaptation.

The liquefying temperature of PCF could be dependent upon 294 °C and its crystallization half-time could be just a few seconds.

The mechanical properties and warm steadiness of PCF were tantamount to or superior to those of PET or PBT.

PCF has incredible potential as a bio-based polyester designing plastic.

Why are polyolefins – based materials important enough to focus on as a distinct segment of the plastic industry?

Plastic would not be so basic in day by day life notwithstanding the advances behind one general group of polymers: polyolefins. Since World War II, day by day life in both industrialized and creating nations has turned out to be fundamentally changed by simply these painstakingly defined natural material. Only a day by day excursion to the market opens shoppers to the most far-reaching employments of these polymers in bundling: other, more sturdy applications regularly lie holed up off camera.

The born of polyolefins – PP, PE

PE polyethylene and PP polypropylene depend on misleadingly straightforward sub-atomic structures, made just from C and H, carbon and hydrogen. PE, the most fundamental of every business polymer, is made of rehashing units of – (CH2)-, PP offers to some degree more basic and property varieties with its rehashing units of – (CH(CH3)- CH2)-.

With PE and PP, items once produced using different materials wound up less expensive and frequently more strong. Inventive items, and moderate, while different items ended up lighter, more brilliant, or easier to understand. What’s more, nourishment and water could be bundled and transported in new, adaptable courses (with even the unobtrusive polyolefin water basin contributing a lot to a network that generally could bear the cost of a couple of other mechanical items).

The sheer aggregate volume and development of polyolefins created mirror their significance. PE and PP make up well over the portion of the in excess of 150 million metric huge amounts of thermoplastics requested around the world, with PE representing almost 66% of all polyolefins utilized. This utilization is generally equal to 15 kg of polyolefin item every year for every individual on earth. Also, this use will develop; overall PE generation alone is relied upon to ascend from around 80 million metric tons in 2013 to around 120 million out of 2023 (over a 4% yearly increment). Along these lines, given this interest for polyolefins and the scope of item types accessible with these flexible materials, it is likely that a great many people on the planet currently come into contact with an article produced using PE or PP in any event once every day. This is framing polyolefins into items: film and sheet expulsion procedures of different kinds, profile and pipe expulsion, infusion shaping, thermoforming, rotational trim, and blow forming, to name only the most widely recognized procedures.

Polyolefin’s most noteworthy utilize is in bundling materials, which devour about 69% of all PE and 43% of PP. What’s more, now, as a prevailing building plastic too, PP has progressed toward becoming prevalent in the car area, making up about 60% of the 170 kg of the polymeric materials utilized per vehicle. This incorporates PP utilized in thermoplastic olefins (TPOs), complex mixes ordinarily produced using PP, an impact modifying the elastic part and a solidifying mineral filler. Other high volume segments for polyolefins incorporate customer merchandise, development and infrastructure applications, (for example, pipe, wood-plastic composites, and TPO material layers), and rural film and other film and sheet).

The demand of polyolefins

The generation of and interest for polyolefins keep on developing with worldwide PE request anticipated that would average 4.8% every year and PP request at 4.5% for the period 2014-2024. Be that as it may, their development has indicated generally fluctuating yearly rates after some time. PE’s yearly development rate was over 6% in the late 1990s/ mid-2000s. This development at that point fell underneath 1% amid the worldwide “Incredible Recession” however now PE request is normal, in the United States, to ascend back to 2-3% development rate more than 2014 – 2019. This will originate from new patterns in a recouping worldwide economy, with most extreme PE generation working rates and new creation limit, in addition to new sustenance bundling and different applications. PP, powered by its specific flexibility and enhanced properties, keeps on becoming in front of the saps. PP kept up an annual growth tumbling off to under 3% during the 2000s. Up to 2.7% interest growth in North America is normal for 2014 – 2019. PP creation limit has been extended in the Middle East as of late, yet the pendulum might swing back to growing PE limit in the West. In North America, new PP generation limit is relied upon to achieve just about 10% of the yield of new PE creation limit (9 billion kilograms included through 2020), because of growing shale gas supplies, popularity around the world, and processes switching from PP to PE in applications where they find can cost funds from the switch.

In the interim, both PE and PP development will be supported by more proficient handling helps, stabilizers, and different added substances that are being brought into the plastic market.

The short answer is yes. It is, and it will remain a noteworthy term in the market of plastic application for decade later.

According to the newest report from Business Wire, the masterbatch market has reached $16 billion dollar in the year 2016, almost double the size of the silicone market (GVR, 2017). Plastic packaging industry’s producers are seeking this additive material in mass to reduce the cost of coloring raw polymer.

What is masterbatch?

Masterbatch is, in short, a solution to “dye” plastic goods. It combines a mixture of additives and pigment into a carrier resin. Usually, it is often presented in four group: white, black, colored and additive masterbatch. According to the BW report, nearly 30% of the global masterbatch revenue in 2016 is accounted by white masterbatch.

Why are they becoming so popular?

What drives the demand for masterbatch comes from the packaging industry, construction sector and automotive market. For decades, the plastic packaging industry plays as the source of demand for white masterbatch, since it is often chose as the base color to produce milk bottle, plastic bags, food packaging and pharmaceutical packaging. In 2017, Clariant, the world leader of plastic application announced the launch of new EP white masterbatch, specially targeted for the pharmaceutical packaging market.

However, what is changing now is a strong drive in the automotive market, especially from South East Asia and other emerging markets. This growth is due to the mass optimization of vehicle parts. Producers have been replacing metal pieces by plastic-made items in order to reduce production cost and enhance the long-lasting use of the components. Plastic parts are also easier to molded and exchanged when needed. In the end, it leads to cheaper costs for consumers and serves the purpose of increasing consumer base in developing country. In the automotive industry, though, the favors of producers do not fall into white color, but black masterbatch. Hence the rocket rise of black masterbatch in the recent years. With the expansion of middle-class in developing nation, this trend will continue to thrive in a decade later.

What trend to come in 2019?

Industry specialists have reported on the increasing trend in researching Nano-based Masterbatch. Though the topic may sound far-reaching and unfamiliar, the use of nano technology in producing masterbatch is not new. Pigments used in manufacturing masterbatch are not often considered to be nano-materials, but many meet the condition of nano-material classification. Using nanotechnology to control the ratio of color mix and particle size of the plastic particles has been under serious research by the British Plastic Federation.

Together with the rise in demand of producers for new material is the consumer’s increasing awareness towards plastic recycling. This can result in large investment flowing into the recycling sector and further change in national-level production regulation. Recently, British government announced their plan to shift all the cost of waste disposal to plastic packaging manufacturers, accounting them as the main culprit for environment suffering. Nevertheless, it leads to the question of whether plastic producers would increase their price as the result and eventually tipping the damage toward the customers themselves.

Filler masterbatch is an important product in the plastics industry that brings a multitude of valuable applications in human daily life. Mulch film is a popular application of filler masterbatch in agriculture which is very useful for farmers. However, this product caused a contradictory controversy since a large amount of plastic will be discharged into the environment while people use them. In that circumstance, bio-plastic mulch film made from the plastic filler called BIO masterbatches is expected to be the best environmental protection solution.

What are functions of mulch film made from filler masterbatch?

Mulch film is a high-tech product that is frequently used in the agriculture that brings various economic benefits to farmers. Nowadays, almost of mulch films on the market are made from filler masterbatch. They are thin plastic screens used to cover the soil around the plants (there are slots or holes perforated on the film surface leaving free places for plant to rise up) with the main effect of preventing weeds from growing, avoiding evaporation (Farmers do not need to irrigate crops regularly), reducing pesticide usage and keeping methyl bromide in the soil during planting. Moreover, some studies have shown that using colorful plastic mulch films in agriculture will bring different effects on the development of crops in the way of improving agricultural quality and increasing crop yields.

What kind of filler masterbatch is commonly used to make mulching films?

From the mid-50s of the last century, people began the ideal of using PE plastic to make mulching films applied in agricultural production. The first who developed the idea of ​​using plastic instead of glass to build greenhouses is Dr. Emery M. Emmert – who is also known as the “father of plastic greenhouses”. Gradually, as the plastics industry expanded, the more advanced materials such as HDPE and LDPE filler masterbatch became the main raw materials for the production of this type plastic film. Currently, there are about 6,500 km² of agricultural land around the world using mulching plastic film.

Mulch film made from BIO filler masterbatch – Innovation with various environmental benefits

Unlike mulch plastic films made from normal plastic, mulch films made from BIO filler masterbatch do not need to be removed from the farming area when the season ends. After the crop is harvested and farmers conduct a new crop, these bioplastic films can become a source of fertilizer for the next crops. Thanks to the self-biodegradable properties of the bioplastic based-resin, BIO masterbatches are highly recommended for being utilizing in agriculture in particular and in other industries in general since they help people protect the soil environment as well as the water environment (oceans) in the context that plastic waste are increasingly threatening human life.

The unique product BIO filler masterbatch produced by MTB will be the perfect source of materials which cannot be more suitable to make mulch films. These products are now available in the most demanding markets such as the EU and are well received by a wide range of consumers due to the fact that they satisfy nearly all government standards and farmers’ needs. Besides, with 100% biodegradable properties, materbatches under brand-name BIOMATES are also suitable for producing shopping bags, food wrap films and other industrial packaging.

Masterbatch, including additives and color concentrates for plastics, is mixed with base resin materials: it is a plastic mixture that needs to undergo injection molding to produce plastic products according to molds. Today, injection molding technology is commonly used in plastic and masterbatch industries, aiming to produce finished products in precise shapes as requested that will serve for manufacturing packaging, automotive parts, machine parts and components, etc.

Plastic injection molding process after mixing the additives masterbatch with primary plastics

In general, plastic injection molding, consisting of a mixture of additives masterbatch and base resin, is the process of spraying the molten plastic mixture into the mold and forming the product. Finished products will achieve perfect colors and excellent surface smoothness.

The first phase is mixing additives masterbatch with plastic to create raw materials for injection molding process

Filler masterbatch, additives, color concentrates for plastics and primary plastic are ingredients of the masterbatch mixtures, which are mixed with a certain ratio (different for different products) before being put into the injection molding process. Each product requires a special and unique formula of compositions.

Plastic resins are usually thermoplastic, thermosetting, elastomeric or hard plastics. Depending on the product requirements, manufacturers will consider to choose the proper type of plastic with appropriate criteria, based on the physical properties of hardness, elasticity, heat resistance, bending ability, etc. and price of raw materials.

Plastic additives are also calculated carefully before mixed with plastic masterbatch compound to add new features that plastic does not have, for example, waterproofing, UV protection, enhanced durability, plasticity, etc.

The process of plastic and masterbatch injection molding

Beside of plastic, other materials such as metal or glass can also be extruded. This technique is also called pressure casting. However the most common application of injection molding is still plastic manufacturing, especially the thermoplastic and thermosetting plastics.

The mixture of input masterbatch, including additives, colorants and base plastic (which can be scraps or primary resin) will be heated until molten and then poured into hopper the mold before undergoing injection molding process. The output part of the funnel is a torsion screw system (located along the cylinder surrounded by a heating system for heating plastic during the process) that is used to mix materials and push materials forward with huge pressure to liquefy the ingredients. The mixture of molten plastic is pushed into the mold through a syringe system.

Molds are made of metal and processed according to the customer’s requirements. Different molds will produce different products. Depending on the products, the corresponding molds will be mounted on pressing frame when manufactured and taken off when the process is done. After filling the mold, liquid plastic is hardened by the cooling system to easily separate from the mold. Half of the mold will slowly split a certain space big enough to take the product out and then close it back to continue the new cycle of plastic production, staring with melting the masterbatch.

During the injection molding process, if a problem occurs, the staff will handle it by checking the faulty parts, finding the defects of the surface and settling in the mold design or the injection process itself. In order to avoid malfunction, tests are usually carried out prior to mass production to anticipate problems and adjust the appropriate specifications for the spraying process.

The masterbatch mixture after injection molding will be surface treated and stored

The masterbatch mixture, including primary plastic, color concentrates for plastics, after undergoing injection molding and cutting off excessive parts, the final product will be checked again to make sure it satisfy the standards and uniform in quality. Workers will review the entire product in terms of shape, weight, color, surface, etc.

The finished product will be transferred to the surface treatment process or also called post-treatment step. Staffs will use mechanical and chemical effects to improve the exterior surface, reduce roughness or plastic stripes and increase glossiness of the product.

Finished products will be imported into the warehouse, packed and stored at the appropriate temperature.

From masterbatches, wood powder and plastic additives we can generate a new material called Wood Plastic Composite (WPC) – the perfect choice for the construction industry. The combination of masterbatches, wood pulp and additives to create WPC – Wood Plastic Composite is a big progress in the material industry.

The mixture of masterbatches, wood power and additives instituting WPC with advanced properties

With the ability to protect natural wood resources while maintain the same production procedure, plastic wood composite, with superior properties, can be applied widely in architectural works, replaces natural wood material and avoids common problems such as humidity, being eaten by termite, etc.

The process of combine masterbatches, wood power and additives into a unique material

Masterbatches (in various types HDPE, PVC, PP, ABS, PS, etc.) and wood (in many forms of sawdust, pulp, peanut shell, bamboo, rice husk, etc.) is the two most basic ingredients to generate Wood Plastic Composite. These ingredients are mixed at a proper ratio and added several plastic additives such as colorant for plastic, splicing agents, stabilizers, reinforcing agents, etc., either with cellulose or inorganic origins, helping to constitute more durable products with improved properties and new features. The compound will then be put through the production chain to create WPC compound pellets and put into extruders, pressed with high strength to create shaped plastic panels according to customer requirements.

Plastic wood composite made from masterbatches, wood pulp and additives has the superior advantages over other types of wood

As being a product of masterbatches, wood pulp and additives, plastic wood composite inherited many advantages over the original wood. As the name suggests, WPC has both properties of wood and plastic so it can be processed by traditional carpentry tools. Meanwhile they still have the properties of plastic such as moisture-proof, anti-rot, although it is not as tough as normal wood. In general, products made of plastic wood composite not only have surface feels like natural wood, they also gain these the following advantages thanks to the combination of wood materials and plastic additives:

• Easily to be shaped according to customer requirements
• Perfect moisture resistance and waterproofing, even if applied in outside areas with high humidity or exposed to water
• Good anti-chapping and anti-warping ability
• Friendly to the environment
• Be able to making use of non-reusable wood resources in the circumstances in which the wood demand increasingly became scarce
• Good color retention ability. Do not need to use paints or colorant for plastic because it can be mixed masterbatches within the production process to create a variety of colors (instead of the common brown wood when using natural wood)
• Anti-termite, anti-corrosion, hard to be decayed, so there is no need for regular maintenance and repair like natural wood
• Good heat insulation and flame resistance inherited, in general it is less flammable than regular wood
• The weight is lighter than natural wood so it is easy to be transported
• Most important, its price is much cheaper than natural wood

From masterbatches, wood powder and additives to the applications of wood plastic composite

Made of masterbatches, wood powder and additives, the demand of using plastic wood composite in construction and architectural works is constantly increasing. If you want to have a cozy, clean interior space without worrying about mold, termites in the kitchen cabinets, the plastic wood composite is the perfect choice because of being able to withstand perfectly watery conditions and able to resist the termites. Common applications nowadays of this material are outdoor plastic wood floors, fences, ceiling tiles, walls, etc.

There are 2 popular types of plastic wood: PVC plastic wood compound (which main component is PVC resin) suitable for interior design with an economical price and PE plastic wood compound (which main component is PE plastic) that is widely used in outdoor buildings, also known as exterior constructive material  because of the ability to withstand extreme weather conditions.

Plastic wood composite from PE masterbatches – new material for outdoor construction

Made by PE plastic masterbatches, wood pulp and additives (colorant for plastic), PE plastic wood composite can overcome weaknesses of other materials such as stone, brick or natural wood. PE plastic wood compound combined with anti-plastic additives resist to cracking, warping and color fading so it is suitable for outdoor decoration without fear of being damaged by weather. Moreover, PE plastic wood is reusable and highly durable, only requires low maintenance cost.

Constructors often utilize PE plastic wood composite in flooring, building columns, multipurpose bars, multi-purpose blisters and wall panels.

WPC made from PVC masterbatches – new material for interior design

Combining PVC masterbatches, wood powder and additives, PVC wood plastic composite is suitable for making indoor furniture and features thanks to the properties of lightweight, easy processing, good moisture resistance and termites resistance. PVC plastic mixed with wood pulp and plastic additives will be the ideal choice to make kitchen cabinets, interior furniture of yachts, bathrooms, windows, etc.  with high aesthetics and durability.

Sản xuất masterbatch là cốt lõi của ngành công nghiệp nhựa và masterbatch. Sản xuất Masterbatch bao gồm một số công nghệ có thể gây nhầm lẫn cho người mới. Tuy nhiên, nếu bạn muốn trở thành một thạc sĩ trong ngành nhựa, bạn cần phải hiểu đầy đủ các quy trình này. Dưới đây là các phương pháp phổ biến nhất được sử dụng rộng rãi trong sản xuất masterbatch.

Injection Molding – kỹ thuật sản xuất nhựa và masterbatch được sử dụng nhiều nhất

Trong tất cả các phương pháp sản xuất masterbatch, bước đầu tiên là tác động nhiệt lên nguyên liệu đầu vào, điều này làm mềm nhựa masterbatch và tạo cho chúng khả năng định hình. Ví dụ, trong quá trình ép phun, nguyên liệu thô (có thể là hỗn hợp chính, bột màu và phụ gia) được đun nóng cho đến khi tất cả chúng chuyển thành hỗn hợp lỏng. Sau đó, hỗn hợp này được đưa qua một ống tiêm nằm ngang và va chạm vào khuôn. Sau khi hạ nhiệt độ, các nhà sản xuất loại bỏ khuôn để lại các sản phẩm cuối cùng với cấu trúc mong muốn.

Mặc dù chi phí trước cao nhất trong lĩnh vực sản xuất masterbatch nhựa do các yêu cầu phức tạp trong thiết kế, thử nghiệm và gia công khuôn mẫu, nhưng khả năng tạo ra sản phẩm hàng loạt của nó chắc chắn đã chiến thắng cuộc chơi với số lượng hàng năm có thể lên đến hàng trăm nghìn sản phẩm cho mỗi máy mỗi năm. Lợi thế lớn này mang lại cho các sản phẩm cuối cùng một mức giá rất tương thích. Về các ứng dụng, số lượng các lĩnh vực bao gồm thiết bị được sản xuất theo phương pháp này là rất lớn, bao gồm các vật dụng hàng ngày (đồ chơi trẻ em, dụng cụ nhà bếp, nắp chai, hộp đựng, v.v.), các ứng dụng phẫu thuật (đòi hỏi hình dạng và kích thước cực kỳ chính xác) , phụ tùng ô tô, v.v.

Nhìn chung, ép nhựa rất phù hợp với các đối tượng có khối lượng lớn, chất lượng cao. Có thể nói, đây đúng là kỹ thuật đa nhiệm nhất trong lĩnh vực sản xuất masterbatch vì nó có thể tạo ra các sản phẩm với mục đích sử dụng rất linh hoạt, hầu như vô hạn. Về mặt tương đối, quá trình đúc khuôn này hoàn toàn có lợi cho việc sản xuất hàng loạt hoặc tạo mẫu sản phẩm.

Đúc đùn – 3 kỹ thuật sản xuất masterbatch nhựa hàng đầu

Đúc đùn khá giống với ép phun, ngoại trừ thực tế là nó không có khuôn kết nối với ống tiêm. Thay vì khuôn như những người khác, nó có một khuôn. Do đó, hình dạng của các sản phẩm nhựa được tạo ra từ kỹ thuật sản xuất masterbatch này sẽ phụ thuộc vào hình dạng của mặt cắt cố định mà masterbatch đi qua (thường là hình vuông hoặc hình tròn). Do đó, sự đa dạng của các sản phẩm thông thường của nó hạn hẹp hơn nhiều so với các phương pháp khác. Đúc đùn phù hợp nhất để sản xuất ống và ống hút PVC, ống và ống dẫn, sàn nhựa và máng xối. Tuy nhiên, do chi phí thấp trong việc tạo ra các hệ thống và thiết bị đúc, nó vẫn có thể đạt được năng suất hàng năm cao.

Thổi khuôn – một kỹ thuật sản xuất masterbatch sử dụng không khí để tạo thành các sản phẩm nhựa

Đúc thổi, còn được gọi là đúc hỗ trợ khí hoặc ép phun khí, là một trong những phương pháp sản xuất masterbatch phổ biến nhất. Phương pháp này sử dụng không khí hoặc khí áp suất cao để tạo thành nhựa nóng chảy thành hình dạng cố định. Quy trình đúc bắt đầu bằng việc đưa các miếng ghép đã nấu chảy vào khuôn. Tiếp theo, khí được va chạm vào vị trí bên trong (khoang khuôn) của khuôn. Kết quả là, các sản phẩm nhựa được tạo ra với hình dạng của khuôn nhưng bên trong rỗng. Vì vậy, kỹ thuật này thích hợp để sản xuất các đối tượng có thành mỏng, rỗng và có kích thước nhỏ với hình dạng xi lanh như chai, phuy nhựa, thùng nhiên liệu hoặc ống tiêm. Vì các ứng dụng của nó dao động trong một loạt các ngành công nghiệp riêng biệt với các sản phẩm linh hoạt, nên số lượng hàng năm của kỹ thuật sản xuất masterbatch này khá cao so với các kỹ thuật khác. Tuy nhiên, mặt trái của phương pháp này là giá thành của khuôn khá cao.

Phim thổi là ứng dụng phổ biến nhất trong sản xuất masterbatch (Phim thổi)

Một trong những phương pháp phổ biến nhất mà các sản phẩm của Europlas đang sử dụng là thổi màng (còn được gọi là thổi màng hoặc thổi đùn). Quy trình này được sử dụng để sản xuất các loại màng nhựa như màng PE, túi xốp, màng mỏng có độ bóng hoặc độ đàn hồi tốt.

Công nghệ thổi màng được thực hiện theo quy trình sau:

Thêm các vật liệu bao gồm nhựa, hạt chính và phụ gia vào phễu để được làm nóng và nóng chảy bằng nhiệt độ cao
Nhựa nóng chảy được đưa qua một ống nhựa mỏng
Áp dụng không khí tốc độ cao xung quanh ống phim nhựa
Màng nhựa sau khi nguội được đưa qua các trục cán hình trụ, sau đó được cắt đôi hoặc cuộn vào lõi để sản xuất màng nhựa cuộn.

Trở thành chuyên gia trong sản xuất masterbatch với nhiệt luyện

Định dạng nhiệt có lẽ là kỹ thuật tốn ít công sức nhất vì nó chỉ cần nhiệt độ cao để làm mềm các tấm nhựa cứng. Có lợi cho sản xuất thấp với năng suất sản xuất masterbatch khoảng 250 đến 3000 tính năng mỗi năm, các sản phẩm phổ biến nhất được tạo ra bằng phương pháp này đa dạng và linh hoạt từ các thiết bị gia dụng như cốc, khay, nắp, vỉ và vỏ sò dùng một lần cho đến các phụ kiện công nghiệp như ô tô các bộ phận, cửa xe, bảng điều khiển hoặc tấm lót tủ lạnh. Tuy nhiên, thời gian xử lý khuôn nhiệt khá lâu, khoảng 8 tuần với giá thành dao động từ 20.000 – 50.000 USD tùy theo kích cỡ.

Kiến thức nâng cao về sản xuất masterbatch với lớp phủ

Lớp phủ cung cấp một lớp phủ cách điện và bảo vệ cho các vật liệu như linh kiện điện, dạng dây, tay cầm của các dụng cụ hàng ngày và thiết bị thể thao, thiết bị y tế, v.v. Trong quá trình này, nhúng các vật thấp hơn vào một thùng nhựa nóng chảy nơi nhựa dính vào bề mặt của vật thể. Một lớp sơn lót có thể được phủ lên bề mặt của một số vật liệu trước khi nhúng để đảm bảo độ che phủ lý tưởng. Kỹ thuật sản xuất masterbatch này – Lớp phủ nhựa có thể mỏng tới 0,25 inch nhưng thường được làm dày hơn thế.

Thời gian dừng là khoảng thời gian một vật được ngâm trong nhựa và thường thì vật đó được ngâm trong thời gian càng lâu thì lớp nhựa phủ càng dày. Vật được tráng sau đó được lấy từ từ ra khỏi thùng để tránh bề mặt không đều. Nhiệt độ lò, tốc độ nhúng và thời gian ngâm là tất cả các yếu tố ảnh hưởng đến chất lượng cuối cùng của lớp phủ.

Lớp phủ được sử dụng cho các mục đích khác nhau. Lớp phủ nhựa bảo vệ bề mặt của đồ vật khỏi bị hư hại. Nó được chứng minh là một điện trở tốt đối với sự thay đổi của môi trường và hoạt động tốt trong thời gian dài.