This is a continuation on the articles on Volume Cost. We should concede that we have significantly more commonsense involvement with Filled PVC when contrasted with filled Polyolefins, so our article on Polyolefins depended on hypothetical contemplations. We had asked for input with respect to whether the conclusions drawn are really reflected by and by. We have composed this specific article based on these inputs. The conclusions we had attracted for fillers Polyolefin like filler masterbatch were:

Filler Masterbatch for Injection Moulding

The utilization of mineral filled infusion formed polyolefins would fundamentally be the place physicals like solidness, flexural modulus and HDT require change. Cost decrease isn’t conceivable as the volume cost increments with filled mixes, and almost all moldings are sold by volume. Higher thickness of fillers and high aggravating expenses are unfavorable to cost lessening by filler expansion.

Filler Masterbatch for Raffia Tape

Raffia tape industry bases on the Denier of the tape and denier is Linear Density. In this manner dissimilar to in moldings, if thickness goes up, so does denier. Subsequently diminishment of denier by changing tapegeometry opens up cost lessening roads.

Filler Masterbatch for Funnels and Films

These are additionally adequately sold by volume (Pipe length of indicated thickness, meters of determined guage and width). Filler expansion would not prompt lower costs.

Notwithstanding, I find that as of late, there has been a considerable measure of movement in filler expansion in different sorts of blown film. As this is in fluctuation with the hypothetical discoveries in my examinations, it justified a more intensive look. My cost workings which demonstrate the impact of thickness opposite expenses have two different elements which can change with time, Raw material costs and intensifying expenses. I have attempted to track the ongoing changes in these parameters and reevaluated my discoveries in the light of:

• Higher Polymer costs
• Lower Filler (GCC) costs
• Lower Compounding costs

Color concentrates for plastics play an important role in contributing the value of a plastic product by bringing the diversity of choice to end users. However, in some cases, these color concentrates for plastics are easily faded, especially under the pressure of harsh conditions. But what was the exact causes of fading phenomenon happened in colored plastic products?

The impact of light causes discoloration of color concentrates for plastics

The stability under direct sunlight (to be more specific, to the UV radiation) is vital properties of plastic products, especially the ones that function as outdoor furniture. Masterbatch manufacturers have been trying their best to continuously improve this characteristic with the purpose of which adding more value to the final products. For outdoor plastic-based products subjecting to strong light exposure for a long period of time (sometimes it’s nearly the whole usage lifespan of the products), the light resistance (also called as sunproofing ability) level is an irreplaceable index that needs to be seriously considered when examined the color concentrates for plastics.

How did experts examine the light resistance of color concentrates for plastics?

The light resistance is divided into 8 levels with VIII levels indicates the best performance. For products required weather resistance, experts suggest that this level should not be lower than level VI while for other products (indoor objects for example), this level should be maintained at level IV or V. In general, light resistance does not only come from the color concentrates for plastics but also impacted by the carrier resin. This can be explained as the ultraviolet light exposure makes the molecular structure of the resins to be changed, causing color fading. The light resistance and color retention can be improved by adding light stabilizer (such as ultraviolet light absorber) in the masterbatch.

Color concentrates for plastics and the heat stability

The heat stability/resistance is usually considered as the maximum temperature at which there is no change in the molecular structure of the masterbatch, thus there is no fading or discoloration happens under the manufacturing process. Different types of color concentrates for plastics examined different level of heat resistant. For inorganic colorants, which composition is metallic oxide and salt, it has better heat stability than organic pigments, which building molecules are easily decomposed into small fragments under certain temperature. Generally, heat resistance lasts for approximately 4 to 10 minutes. If the processing temperature is higher than 280^oC, serious consideration and selection should be conducted in order to find the most suitable color concentrates for plastics with excellent heat resistance.

The antioxidant activity and its relation to color concentrates for plastics

The oxidation of organic pigments had led to the macromolecule degradation in products containing color concentrates for plastics. As a result, colored resins gradually lost its original colors. For example, red color will be faded after mixing with color flakes, azo pigments and chrome color. In some other cases, as the pigments were oxidized, it experienced darker color (such as chromate in chrome yellow tends to darken since the pigment compound also contains lead – a heavy toxic metal). The oxidation process usually causes by high-temperature or by strong oxidant or just simply after a long time exposure to the air.

The acid and alkali resistance also affects color concentrates for plastics

The fading of color concentrates for plastics is also related to the chemical properties of colorants in which the chemical resistance plays an importance role in determine how long the plastic products can keep it colors. Chemical resistance includes acid resistance, alkali resistance and oxido-reduction resistance. For example, while the cadmium yellow is not resistant to acid meanwhile the molubdate red resists to diluted acid (solution with low concentrate of acid). However, this red pigment is quite sensitive to alkali solutions.

Natural properties of the resins and color concentrates for plastics itself

The molubdate read, the cadmium yellow and resins belonging to the phenolic group have strong reduction reaction when interacting with some color concentrates for plastics. Color retention also depends on the natural basis of all components existing in the masterbatch mixture such as the carrier resins, the pigment/dye, surface active agent, fillers compound, dispersing agent, anti-aging agents, etc.

General overview of additives purposes

Additive products are known for:

• Optimise material cost
• Enhance final product quality and minimize side effects
• Enhance fabrication efficiency and speed
• Decrease energy consumption and defects
• Enhance working environment with better hygiene and reduce health risks to end-users
• Reduce interaction with other additives

Optimizing cost is one of the most important concerns. By enabling customers doing so, let customers lower the dose level or design a new multiple function additive are both great options.

To approach the second goal, multipacks reduce customers’ inventory costs, simplify metering and facilitate the addition of the additives to the base polymer.

Besides, additives boost particles that adhere to melt quicker, meaning saving energy and reducing heat damage to the plastics.

Generally manufacturers are always striving to supply their products in convenient and hygienic format, e.g., liquids, pastes, pastilles, flakes or pellets.

In recent years there has been an emphasis on no-dust or low-dust blends.

Anti blocking Agents

The primary demand for anti blocks constantly to be thin-gauge thermoforming packaging film.

Packaging applications

A loss of clarity, haze and gloss happens when anti blocks are added.

The agricultural film does not require ultra-high clarity, but it needs to be clear enough to allow visual inspection of the plants. The same principle applies to the packaging of goods on retail display.

However, films for agriculture do not require extremely high clarity. Enough to see visual inspection of the plants is fine. It is also the requirement of retail packaging display.

MTB has therefore invested a lot of time and effort to achieve the optimized balance of yellowness, haze and coefficient of friction. The main idea is both antiblocking and slip additives minimize the negative effects of oxygen, water vapour and carbon dioxide on the life cycle of the film.

2 well-known trends have created a difficult conditions to achieve a good balance of properties:

(i) Extremely clear polyolefin film is in high demand for packaging.

(ii) The newer metallocene LLDPEs require a high antiblock dose level, and the adverse effects on haze and other properties increase with an increase in the antiblock dose level.

Furthermore, some main markets in Asian and Middle Eastern countries prefer using a water-quenched process for the conversion of PP tubular film.

Mostly, they require good optical properties.

The film tube has to be opened up by hand immediately after conversion, and this requires good antiblocking properties to prevent delays through sticking.

MTB has created (mã hàng) which gives great optical properties. MTB gives anti-blocking and thermal barrier properties to polyolefin agricultural and greenhouse film, permitting them to be profoundly transparent and not having very many surface errors.

Antiblock sometimes are added in food contact packaging film. Approved by regulatory authorities and minimize taint, color and optimize color stability are all must for the additives.

Companies who sell food contact packaging film have to own an antiblocking agent approved by high authority for food contact applications with polyethylene.

Medical applications

Apart from packaging applications, antiblocking agents are used in medical gloves.

YBM Minerals Inc. provides uncoated and coated calcium powder for high clarity polyethylene film.

There can be a degree of antagonism between the effects of antiblocking agents and those of slip agents used to control the coefficient of friction. It is therefore difficult to get low blocking and low friction at the same time.

MTB believes that a combination of behenamide and erucamide slip agents gives a considerable improvement in antiblocking performance, as well as having good antislip character, although a mineral additive is still needed to roughen the surface.

A well-chosen amide slip agent can reduce the amount of antiblock needed, which lessens the adverse effect on the film’s mechanical and optical properties.

The packaging is the biggest market for additives.

The output of plastic packaging depends strongly on the population, people’s average income, and expenditure.

We need plastic packaging mostly for the food and beverage industry. Therefore, the increase in the population and the average income will have a positive effect on the demands of plastic packaging as well as additives.

Packaging industry

Foreign market

Asia has the rapid growth in the consumption of plastic packaging.

The first reason is that Asia has the highest and most developing population rate. Researchers forecast that Asia is going to reach 4,3 billion people in 2022. Moreover, the population growth rate and GDP growth rate are “gold rate” and desirable.

Besides, Europe and North America consume plastic packaging a lot. While those 2 regions have a quite low population density, they have a good source of income and their consumption habits of plastic packaging were established a long time ago (since 1950).

Flexible packaging makes up 59% of the total consumption of plastic packaging.

Flexible packaging is made from PE and PP resins by blow molding. The consumption of flexible packaging and bottle packaging is forecasted to decrease a little bit due to the increase in people’s awareness of the environment.

Food packaging and bottle packaging made up for 93% in 2,400 billion of packaging products in 2018. The demand for food packaging will reach 1,788 billion products in 2022.

Asia is the main and most potential market for the plastic packaging industry.

As I said before, Asia has the gold growth rate of population and average income.

Another reason is that many developed countries are moving towards “green life”, minimizing the use of single-use plastic products.

Việt Nam

The development in the non-alcohol beverage market will drive the plastic packing industry in a new chapter.

The demand for plastic packaging products mainly depends on the growth of food production, the beverage industry, and household income and expenditure in general.

According to BMI, household spending will be about VND 3.3 million billion in 2019 VND and 4.7 million billion VND in 2022. Of which, spending on food and non-alcoholic beverages will still account for a large proportion, about 20% of total household expenditure.

The growth of food and non-alcoholic beverages is expected to grow by 11.8% and 12% per year, respectively, from 2019 to 2022. This is the main driving force for the growth of food processing and beverage industries.

Main Additives used

Materials/Resins

The 5 most popular additives used in the packaging industry are anti-blocking and slip agents, anti-fogging agents, the usual heat and light stabilizers, and pigments.

Oxygen scavengers are also getting popular in food packaging.

PE is the dominant packaging polymer, it is used in very high-volume shopping bags, rubbish sacks, and food packaging. HDPE is the most essential, especially in Europe.

PP is used more in the specialized role of industrial goods.

Polyethylene naphthenate is being promoted in the form of thin, flexible film with good barrier properties.

Specific additives for packaging industries

Social habits change, people’s expenditure habits change. The increasing popularity of hanging out with premade meals and microwaveable containers leads to a remarkable increase in using food packaging; therefore, increasing the use of additives.

The technology to premade and packaged food requires special additives.

Plastic bottles and containers have undergone considerable changes in recent years due to increased interest in barrier layers.

Consumers also like bottles to have a wide mouth. PVC has been defeated as a bottle material by PET.

Adding an impact modifier creates a favorable condition for PET to gain competitive advantages over polycarbonate in manufacturing larger bottle sizes.

Moreover, PE clarifying additives allows you to produce cheaper and cleaner packaging.

Anti-fogging agents are used in flexible PVC food wrapping. UV absorbers used in transparent bottles to protect the contents and the polymer.

People are considering to stop using single-use plastic in many packaging applications. Due to litter issues, the fast-food industry is criticized a lot. Several countries have banned single-trip shopping bags.

Non-woven and multi-trip packages are trendy.

Flame retardants are in a unique position among plastics additives in that they are both created by regulations and yet are threatened by other regulations. They are expensive and lower the physical properties of the plastics in which they are employed.

On the other hand, environmental and toxicity concerns now have regulators looking at the important halogenated and antimony-based synergist flame retardants that have been developed over the years. Any regulations which limit the use of such products will again change the industry and force producers to develop a new generation of products.

Flame retardant overview

Flame-retardant additives for plastics are essential safety materials. The transportation, building, appliance, and electronic industries use flame retardants in plastics to prevent human injury or death and to protect property from fire damage.

Fundamentally, flame retardants reduce the ease of ignition smoke generation and the rate of burn of plastics. Flame retardants can be organic or inorganic in composition and typically contain either bromine, chlorine, phosphorus, antimony, or aluminum materials.

The products can be further classified as being reactive or additive. Reactive flame retardants chemically bind with the host resin. Additive types are physically mixed with a resin and do not chemically bind with the polymer.

Flame retardants are used at loading levels from a few percents to more than 60% of the total weight of a treated resin. They typically degrade the inherent physical properties of the polymer, some types significantly more than others.

Resin formulators and compounders must select a flame retardant that is both physically and economically suitable for specific resin systems and the intended applications.

It is common to formulate resins with multiple flame-retardant types, typically a primary flame retardant plus a synergist such as antimony oxide, to enhance overall flame-retardant efficiency at the lowest cost. Several hundred different flame-retardant systems are used by the plastics industry because of these formulation practices.

Driving forces

In addition to cost and performance demands, the plastics market for flame retardants is driven by a number of competing forces ranging from fire standard legislation and toxicity regulations to price situations, performance, and other market factors.

These combined factors have resulted recently in significant shifts in demand for the major types of flame retardants.

Further, large numbers of new flame retardants have emerged, designed for both traditional and specialty niche markets.

Recent acquisitions, joint ventures, and alliances by flame- retardant producers have also created constant change in this market. The largest area of activity is in non-halogenated flame retardants because of environmental concerns associated with the halogen-based products.

Down the road, the need and the market exist for non-halogenated approaches to the flame retarding of plastics. All the major flame retardant companies, including those making halogenated types, are working in the area.

Viable, non-halogenated flame-retardant products do exist, but customers are reluctant to sacrifice the cost/performance advantage of brominated products. Organic phosphate, inorganic phosphorus, melamine salts, and inorganic metal hydrate approaches seem to be the major directions being followed to develop non-halogenated alternatives.

Colorants are one of the most optimal methods to upgrade and strengthen your products’ competitiveness. Since there are various types of colorants regarding forms and price, it’s now easier than ever for manufacturers to equip themselves with a suitable coloring method. However simple it might seem, effectively applying colorants in injection moulding requires a high level of attention rather than just adding one more component as they may negatively affect end-products in case of incorrect use.

1. Common problems when adding colorants in plastic injection moulding

The impact of colorants on injection molded plastic items is complex. Depending on several variations, they can affect end-products in different ways. Here are top common problems encountered by injection moulding manufacturers during the colorant incorporating process.

Physical properties deterioration

Very often, adding colorants into plastic injection moulded items can weaken mechanical properties of end-products. This is mainly caused by the incompatibility between the colorants and original resin since most polymers are unlikely to mix well with other polymers, which leads to the degradation of the original properties, like impact resistance.

Discoloration

Discoloration (also known as color streaking) in injection molding occurs when a molded part is in a different color than intended. This part defect can arise from several sources, such as overheating, contamination, or manufacturing error.

In case discoloration arising from injection molding machines, the simplest cause can be the contamination of equipment which hasn’t been properly cleaned, resulting in dust-contaminated resin.

Meanwhile, discoloration arising from the mold has to do with temperature regulation. If a mold is hot, it compacts the plastic molecules before they solidify. This causes the part to be denser, resulting in a darker color in some areas. Whereas, if there is excessive cooling in one area, the material can become lighter in color.

Sometimes, discoloration can be a result of the raw materials. Mixing different grades of the same material or different flow values of the same material is the main cause of this problem. Other sources may include:

• Contamination: If the resin is contaminated, whether from dust or dirt regrind – the plastic will undergo discoloration according to the type of contaminant.
• Moisture: Excessive moisture or organic compounds can not only cause discoloration, but also result in pockets of air and plastic’s mechanical degradation.
• Plastic additives: The interaction between polymer and colorant can also be affected by other additives which are added during the injection moulding process.

Different shades of colors under the same processing conditions

This is often caused by the injection molding machine. Different injection molding machines have different mechanical conditions due to different manufacturing, use time or maintenance conditions, especially the distinction in the degree of close contact between the heating element and the barrel, which makes the dispersion state of the color masterbatch in the barrel different.

Poor dispersion

The performance of the colorant is directly related to the color quality of the molded part. If the dispersibility, thermal stability and particle morphology of the colorant can’t meet the process requirements, it will be impossible to be well-dispersed on the product’s surface.

2. Considered factors to effectively apply colorants in plastic injection moulding

So the question is, how to prevent these problems and effectively apply colorants in your injection moulding products? Here are some key factors that manufacturers need to consider for better use of colorants.

Chemical compatibility

The first item to be considered is the compatibility between the chemistry of the polymer and the chemistry of the colorant. As mentioned above, most polymers tend to conflict with the others due to the difference in their chemistry. Hence, the use of incompatible colorants can break down the chemistry of the polymer and weaken its original properties, like impact-resistance.

Processing temperature

The next step to effectively apply colorants in the injection moulding is to ensure your colorants have a good thermal stability. As injection moulding is a high-thermal manufacturing process, it is a prerequisite for a colorant to be capable of tolerating the high temperature at which the polymer formulation is going to be processed. In fact, the high heat used in injection molding can also influence the degree to which the colorant affects the polymer. And most surprisingly, a certain colorant may affect one polymer differently than it does another based on temperature, despite being chemically compatible.

The amount of colorants added

In order to effectively apply colorants in injection moulding, a useful tip is to well control the amount of incorporated colorants. Normally, it is totally harmless to add 1-2% of a colorant to the resin, as long as the compatibility issues mentioned above don’t come into play. However, in some specific cases, there is a certain limit on how much colorants should be added without negatively affecting the original resin. Any amounts of the colorant above that level should be generally avoided to guarantee that there is no loss in the properties of the base polymer.

Types of additives 

Despite being used with a very tiny amount, additives have a great impact on the interaction between a polymer and a colorant. For example, a polycarbonate, which is normally unaffected by a colorant, may have a different reaction to it when a flame retardant is added. Hence, it is worth considering carefully in order to effectively apply colorants in your plastic products.

Coloring methods

There are several methods of coloring plastics, including color masterbatch, compounding, surface coating and dry blending. They each have their advantages and disadvantages and vary in cost, color consistency and other factors. The coloring method used can influence the mechanical properties of the plastic. For example, in the masterbatch method, pellets of natural color are blended with a “masterbatch” of pellets with a high pigment content. Since most polymers do not tend to mix well with other polymers, care must be taken to ensure material compatibility, or the blend can cause problems.

To achieve the best result, manufacturers need to choose the most appropriate coloring method, which fits your requirements both in terms of economy and efficiency.

About thermoforming 

Before getting to know the application of filler masterbatch in thermoforming, let’s take a brief look on its manufacturing. Generally, thermoforming process involves 4 stages:

• First, a sheet of thermoplastic is heated until it becomes pliable and moldable.
• The second stage is the vacuum forming process. In which, the plastic is stretched over a single male mold, and the air is vacuumed out from underneath the mold.
• Subsequently, the heated plastic is placed between male and female molds, which are then pressed against the plastic sheet using compressed air at a pressure that ranges from 20 to 100 psi.
• After that, steam or wind is pumped into the mould to cool the plastic part while keeping it in shape.
• Finally, the moulded plastic part is separated from the mold by spraying air

Due to its simple technology and high productivity, thermoforming is favorable over other types of molding. Some of these benefits include:

• Cost at quantity: Thermoforming is the most optimal choice when it comes to orders in bulk as it allows processing a large quantity at a relatively reasonable price.
• Efficiency: Thermoforming is able to create several finished parts from the same material.
• Lower cost design changes: Thermoforming allows for the detection of possible design and fit issues before it is too late.

Thanks to these outstanding benefits, thermoforming is preferred in many fields such as household items production, medical packaging, trays,…

Advantages of using filler masterbatch in thermoforming

As other plastic manufacturing methods, thermoforming is compatible with most standard resins such as ABS, HDPE, HIPS, PC, PET, PVC,… However, due to the increasing demands for a cost-effective material associated with rising concerns about the global fossil resins market uncertainties, filler masterbatch has come into use as an optimal material solution.

Filler masterbatch (also known as calcium carbonate filler) is composed of three main ingredients including CaCO3 powder, virgin resins and specific additives (normally dispersant and processing aid). The use of filler masterbatch in thermoforming offers end-products several advantages.

• Cost reduction: Containing CaCO3 powder, which is a reasonable substance, calcium carbonate filler partly replaces virgin resins as well as helping manufacturers lessen the dependence on fossil plastic, thus minimizing the negative impacts of the global market on the entrepreneurs.
• Properties enhancement: By adding filler masterbatch in thermoforming, end-products are equipped with better mechanical properties such as tear resistance, anti-friction and anti-slipping property, dimensional stability, rigidity, impact strength and printability. This results in greater performance and aesthetic appearance of end-products.

• Productivity improvement: CaCO3, the main component of filler masterbatch, is a good thermal conductive. Hence, the incorporation of filler masterbatch in thermoforming reduces processing temperature and shortens the products cycle, thus saving energy consumption as well as increasing productivity.
• Environmental friendliness: Last but not least, an outstanding advantage of calcium carbonate filler is its environmental harmlessness. Compared to fossil resin, which releases a great amount of carbon footprint during its manufacturing process, the production of filler masterbatch is far more environmentally friendly. Also, it is an ideal alternative to non-renewable materials, thus opening up sustainable development for thermoforming manufacturers.

Common applications of filler masterbatch in thermoforming

Refrigerator liners

Refrigerator liners are one of the most common applications of calcium carbonate filler. By introducing filler to the processing, the overall performance of end-products can be lifted significantly. According to a study conducted by Heritage Plastics, with a loading of 18%, calcium carbonate filler can improve several key properties including rigidity, impact strength, and dimensional stability. Thus, it can exactly meet all strict technical requirements of manufacturers.

Food trays, pots, and covers

The addition of filler masterbatch in thermoforming applications remarkably enhances productivity by allowing the plastic to heat up and cool down faster. Due to the great thermal ability of CaCO3, plastic can be quickly melted in the extruder as well as faster cooled on calendar rolls. This results in less shrinkage and warping, which provides end-products with exact shape as required.

Transit trays, plastic pallets

The cost effectiveness of filler masterbatch is specifically preferable in thermoforming applications like transit trays and plastic pallets, which have simple design and large quantities. By embedding filler masterbatch, manufacturers can partly replace virgin resins, thus decreasing the material cost.

Building applications

Building trade is one of the largest contributors to the thermoforming products consumption. Plastic thermoforming with HIPs (High Impact Polystyrene) is widely used in the building trade from roof vents to underfloor heating systems, ducting, fascia panels, bath and shower rooms. Accordingly, filler masterbatch is also a vital part of these applications, which not only reduces material cost, but also considerably boosts efficiency.

Besides, the use of filler masterbatch in thermoforming also includes other applications such as disposable cups and plates, household items, plant pots and seeding trays,… Depending on each product’s requirements, the components and loading rate of the filler masterbatch will be determined, thus making it exactly match with end-products.

Công ty TNHH Masterbatch Việt Nam xin kính chúc Quý Khách hàng, Quý nhà cung cấp và tập thể cán bộ, công nhân viên công ty một mùa trung thu nhiều niềm vui, bình an và hạnh phúc.