LEISTRITZ Extrusion Technology MASTERBATCH

PRODUCTION
At Your Service. Globally.

Extruders and extrusion lines

Headquarters Subsidiaries
Leistritz Extrusion Technology Leistritz France Extrusion
Markgrafenstr. 36-39 Ceyzeriat, France
90459 Nuremberg
Germany Leistritz Advanced Technologies Corp.
T +49 911 4306-775 Somerville/NJ, USA
E extruder@leistritz.com
Leistritz Machinery (Taicang) Co., Ltd.
Shanghai, China

Leistritz Machinery (Taicang) Co., Ltd.

Jiangsu, China

Leistritz SEA Pte. Ltd.

LEX-7 en 09/22 0,3’ fl

Singapore

extruders.leistritz.com
 Overview 03

Raw polymer > 10%

MASTERBATCH.
Small, but with a major impact

Plastic pellets with a high share of pigments and/or additives

that is much greater than in the final application are called One generally distinguishes between three
masterbatches. In later process steps such as injection mold- MB GROUPS:
ing, film or fiber production, these are added to the raw poly- „ Color Masterbatch is used to color plastic
mer to color this or to specifically change other properties. products
Additives Fillers Pigments
„ Additive Masterbatch ensures certain chemical „ thermal stabilizers „ filler „ organic pigments
Compared to pastes, powders or liquid additives, the use of and physical properties of the final products (e.g. „ light stabilizers „ reinforcing agent „ inorganic pigments
a masterbatch improves the process reliability on account of UV-stabilization, flame-retardant, anti-static) „ flame retardants „ effect pigments
the precisely defined share of pigments in individual pellets. „ Filler Masterbatch contains a high share of „ anti-static agents „ mono preparations
A further advantage is that the masterbatch is very easy fillers such as CaCO₃ „ anti-blocking agents
to process because it does away with the handling of large „ nucleating agents
amounts of powder. It’s use is also beneficial from the point
of view of environmental impacts and workplace pollution.

Important: the correct dispersion 1 Mixing (Homogenization of the mixture)

Compounding
The goal when manufacturing masterbatches is the optimum
Dosing (constant addition over time in the continuous
dispersion and distribution of the additives in the polymer extrusion process)
matrix. This is carried out after wetting by the mechanical
energy introduced by the screws. If this takes place too early 2 Wetting (bonding of the pigment particles to the matrix
without compacting this)
in the process, the un-moistened pigments can be com-
pressed back into agglomerates by the force exerted on them 3 Dispersion (dispersion of the agglomerates in a plasti-
(cold agglomeration). Two processes can be used to produce a cized state, introduction of the dispersion energy)
masterbatch: premix* and split-feed**.
4 Distribution

5 Stabilization (prevents re-agglomeration

MASTERBATCH RAW POLYMER

1 2 3 4 5

Dispersing agent Primary article

INJECTION MOLDING FILM EXTRUSION FIBER EXTRUSION PROFILE EXTRUSION TUBE EXTRUSION

*see P. 8/9 ** see P. 10/11

 Applications 05

COLOR MASTERBATCH.
Knowledge of the right color

The main benefit for manufacturers by using co-rotating twin Color masterbatches can be divided up into Color masterbatches largely consist of individual color pigments that are combined to produce a specific target color.
screw extruders is the very good quality of dispersion. This is Other components may include effect pigments, dispersing agents and additives. Their production places great demands on the
roughly the following types:
the basis for a high quality masterbatch. The two co-rotating dispersion process because raw materials with different properties have to be optimally incorporated in only one process step.
screws that engage with each other produce a self-cleaning � Mono batches or “Single Pigment Concentrates” (SPC): What is crucial here is a knowledge of the properties of the pigments used (coloristics) and great expertise with respect to the
effect. This allows fast cleaning and consequently a more Masterbatches from a certain pigment and a supporting extruder’s process parameters.
rapid change of product. Another advantage of co-rotating base; wax and/or dispersing agents are often added
twin screw extruders is the modular design of the screws and � Customized masterbatches: bespoke formulations, mix-
barrels, which, depending on the process, enables a fast set- tures of various powder pigments Organic pigments Inorganic pigments Mono preparations
up and conversion of the processing unit. � Custom Coloring: mixture of different SPC granules to
produce precisely the color the customer wants Effect pigments

very different: from very

Particle size 0.01 – 0.1 μm 1 – 20 μm 2 – 180 μm
small to large

Particle shapei isometric isometric Platelets depending on pigment

no data
+ ++ sensitive to shearing depending on pigment
Migration resistance more dispersion little shearing, easy – lowest possible fully dispersed, hardly any
Processibility energy needed, diffi- to disperse, some- shearing forces, shearing needed, fuse and
cult to disperse times abrasive highest possible distribute
mixing effect

Recommended Premix and split- Premix and split-

Split-feed*
process feed* possible feed* possible

The loading concentration* for inorganic fillers ranges from 40 - 8 % by weight, and for organic pigments from 30 - 60 % by weight.
*The maximum load depends amongst other things on the application and base material.

The ZSE MAXX

twin screw extruder from Leistritz is at the heart of hundreds of systems
worldwide. The products manufactured quality demands.

Example of a masterbatch system

 Applications 07

ADDITIVE MASTERBATCH. FILLER MASTERBATCH.

Optimization of properties Low-cost polymer substitute

Additive masterbatches can be used in a wide variety of free volume of the ZSE MAXX twin screw extruder (OD/ Highly-filled masterbatches contain more than 50 % by There are two main reasons why CaCO₃ is used in plastic:
applications. They can be used to modify the physical and ID = 1.66) means that there is enough space in the process weight of fillers that are dispersed in a polymer matrix. it acts as a functional filler or mineral modifier (e.g. to
chemical properties of plastics, e.g. the UV- or flame-re- chamber to ensure a good dispersion and high throughput. Different process set-ups are possible depending on produce breathable films) or it is used to reduce the costs
sistance, thermal stability or impact strength. The pol- the type and amount of filler. The most common fillers of the compound.
ymer is hereby enriched with large amounts of liquid or The additive feed often poses a challenge in processing: include calcium carbonate or talcum. Filler masterbatches
powder additives. if additives with a low melting point are added, they could are primarily used to optimize and increase the stiffness, What is important when using CaCO₃ is its very good
already melt in the side stuffer. This would lead to a block- reduce shrinkage and improve the surface appearance of incorporation in the polymer matrix. Coated CaCO₃ types
Powder additives with a low bulk density such as silicate age in the side stuffer. The formulation consistency can the final product. are the most suitable because the surface coating adjusts
are usually added by means of one or two side stuffers for then no longer be guaranteed. In such cases, the use of a the surface tension of the mineral to that of the polymer,
incorporation. The lower-cut screws in the Leistritz LSB XX side stuffer with cooled barrels and screws (Leistritz LSB XX Application example: greatly facilitating its incorporation and dispersion.
side stuffer also help the feed of the material. The high side stuffer*) is recommended. CaCO₃ (70 – 85%) in polyolefin
*see accessory units P. 13

Important parameters for the residence time

On account of different viscosities and in some cases
difficult mixtures, the residence time has to be in-
creased for
certain formulations. This is achieved by

„ extending the processing unit

„ the use of reverse screw elements

Example of a filler masterbatch system

 Production 09

PREMIX PROCESS.
Metered addition of a premix

The process set-up shown here is suitable to produce The quality of the masterbatch is determined largely by
both a masterbatch of mono pigments (SPC = Single Pig- the preceding mixing process. This is why this process step
ment Concentrate) as well as customized masterbatches of is extremely important: if the premix is not good, e.g. if
The be all and end all for a high quality result
powder mixtures. All components are mixed in advance if agglomerates have formed, this fault cannot be remedied Advantages of the premix process
in the premix process is optimum premixing.
the premix process is used. in the extrusion process.
� lower investment costs than for split-feed
(use of gravimetric systems, no side stuffers)
through the use of volumetric dosing
� high pigment and additive loading possible
� easier cleaning (only one dosing unit)

Example of a possible cylinder set-up for the premix process

In this, the most widespread production process, the The extruder can be adapted to various requirements by
extruder is fed with a premix of the polymer, pigment altering the number of cylinders depending on the de-
and dispersing agent through the main feed opening and sired quality of the masterbatch. A masterbatch quality
the feed cylinder. Since volumetric metering is possible, for injection molded parts can be produced with a short
this means not only a high operational reliability but also dispersion zone depending on the quality of the mixing.
uncomplicated handling. Venting is carried out a few The highest quality demands, for example film or fiber
cylinders further along so that the air introduced with the products, on the other hand call for a long dispersion zone.
premix can escape. The screw geometry in the fusion zone The dispersion zone is followed by vacuum degassing and
should be chosen in such a way that not only is the com- the discharge zone. A conventional pelletizer is used in the
plete mixture fused, but also the pigment is sufficiently majority of cases.
wetted. This is then followed by the actual dispersion zone.
 Production 11

SPLIT-FEED PROCESS.
Material feed through several dosing units

As an alternative to premix, both mono as a well as cus- pigments (e.g. effect pigments) or pigments with a great
tomized masterbatches can be produced by the splitfeed tendency to compact (e.g. certain phathalo pigments)
process. The material flows are hereby separated. too. The energy needed to melt the polymer is introduced
directly into the polymer - without the pigment - in the
Through a separation into two or more material flows, split-feed process. The pigment therefore experiences a
the split-feed process allows processing of shearsensitive lower physical stress.

Split-feed process with effect pigments

Some effect pigments have a layer structure consisting of platelets with a high surface relative to the height of the particle.
Since the surface layer of these pigments can be easily damaged and they can thus lose their pearl luster, flop or shimmering
colors, they have to be incorporated into the molten polymer matrix very gently. The appropriate process is thus split-feed.
The melt mobilizes the platelets when they are added and largely prevents their destruction by the kneading and conveying
elements of the screw. The viscosity of the melt dissipates the agglomerates and makes for an optimum development of the
effect. Important: mixing here is distributive, not dispersive.

Example of a possible barrel set-up for the split-feed process

With this version of masterbatch production, the polymer, Advantages of the split-feed process
and possibly smaller amounts of additives, are intro-
� easy handling of the formulation via the extruder or
duced into the process through the main feed opening
feeder control system
and then plasticized. It is important that the polymer is
� no complicated premix steps facilitates the production
100 % molten before feeding the pigment through one or
of larger mono batches
two side stuffers. Only then can the subsequent wetting
� allows the gentle incorporation of shear-sensitive
zone work. All components in the formulation are fed into
pigments
the process by gravimetric feeders. Unlike in the premix
process, wetting can be somewhat softer in the split-feed
process since the polymer is already molten at this stage.
The masterbach melt is stabilized and discharged after
Split-feed, ZSE MAXX Premix, ZSE MAXX
distributive and dispersive mixing. Effect pigment based on mica in a polymer matrix; larger particles with split-feed better quality
 Production 13

CUSTOM COLORING. AUXILIARY EQUIPMENT.

The right color mix For fast and optimized processes

This term describes the color adjustment by means of The pre-dispersed pigments already in the mono batch
a mixture of various standard colors, so-called mono need more distributive than dispersive mixing. They can be
batches. With the help of gravimetric, multi-component colored more gently in a wide variety of different shades. Leistritz LSB XX side stuffer Screw extraction device Leistritz die heads
feeding (usually between five and eight components), Here again, a twin screw extruder has proven to be better
The side stuffer is usually used to The machine often has to be Various die heads are available, some
a color of the customer’s choice is produced from pre- than a single screw extruder.
add powders. As in the extruder, reassembled for the next process with an integrated screen. The focus
defined standard colors. The extrusion line set-up is similar
co-rotating twin screws that quickly, particularly when was on the following aspects for all
to that for the premix process. This process is also very
engage with each other are used producing color masterbatches versions: easy handling and cleaning
suitable to satisfy even higher quality requirements, e.g. to
to safely feed the material into the with frequent, small batch sizes as well as fast access to the screws.
produce color masterbatches to colorize PET fibers.
process. The LSB XX from Leistritz and a number of product changes.
convinces through: Leistritz thus offers a special tool Leistritz strand die head with
to extract the screws. screen insert (LSA)
� a high OD/ID ratio of the twin � specially developed Masterbatch
screw (easy feed of materials � allows safe extraction of die head: short flow channel
with a low bulk density) the screws � ideal for small batch sizes)
� segmented screws can be � easy handling � fast cleaning and change of color
used (individual adjustment thanks to removable screen
depending on the process) plate
� the possibility of cooling the � only two bolts
screws from the inside
� adaptation of the LSB XX to the
ZSE MAXX extruder via tie rod
(easy handling from behind)

ZSE 40 MAXX with custom coloring metering station

Since the extruder here is primarily responsible for mixing, a short process part is sufficient.
The twin screw has the following advantages over a single screw extruder:

� better mixing effect, particularly with different viscosities

� self-cleaning, and thus advantages when changing colors
� higher product quality
� wider throughput range
� significant reduction of start-up material

„ Leistritz LSB XX side stuffer „ Screw extraction device „ Leistritz die heads
 System examples 15

THE IDEAL
MASTERBATCH EXTRUDER. ZSE MAXX SERIE.
ZSE 35 iMAXX - for widely varying batch sizes Twin screw extruders

1 ZSE MAXX process part Type 18 27 35 40 50 60

with OD/ID = 1.66
2
Screw diameter OD (mm) 18,5 28,3 35,1 41,4 51,0 61,6
1
2 cover over complete drive unit
OD/IDi 1,66 1,66 1,66 1,66 1,66 1,66
4

3 cooling device integrated in Spec. torque density (Nm/cm³)

5 11,0 12,5 15,0 15,0 15,0 15,0
base frame up to max..

3
4 optimum user friendliness
Through the combination of a high, free screw volume (OD/ID = 1.66) and a high torque (up to 15 Nm/cm³) the ZSE MAXX twin
screw extruders have very high throughputs for masterbatch production.
5 maximum ease of cleaning

SCREW CLEANING
Since co-rotating screws wipe each other out, they have a very good self-cleaning effect compared to single screws. The photos
show the difference in the feeding, melting and dispersion zone. Both extruders were only “purged” with a cleaning polymer.

ZSE 18 MAXX ZSE 27 MAXX ZSE 27 iMAXX

Dispersion zone Melting Feeding ZSE 50 MAXX ZSE 40 MAXX ZSE 60 MAXX