Color masterbatch premix which pigments, , additives, and other components are dispersed in at high concentrations within a carrier resin. As an indispensable key raw material in the production of plastic products, color masterbatch plays a crucial role in imparting color to plastics, improving processing performance, and even enhancing special functionalities.
A masterbatch is a solid, granular a concentrated mixture of pigments fillers and/or additives and other components ,it is also named color concentrates for plastics. Masterbatches give users better color consistency when working with large orders ,they are mainly used for coloring plastics and added to the plastic to be colored prior to or during processing
The color masterbatch is an essential additive widely used in the plastics industry ,so that provide vibrant and consistent color to plastic products.
By adding a small amount of color masterbatch during plastic processing, the color of plastic products may be changed, which avoid other problem such as uneven dispersion of powdered pigments and the generation of dust.
Since the color masterbatch is so popular in plastic industry ,so how to produce high-quality masterbatch ? One of main equipment is dispersion kneader machine .
Firstly ,let us know what Is a Dispersion Kneader?
A dispersion kneader is a heavy-duty mixing machine specially designed to mix, knead, and disperse high-viscosity materials. It features a mixing chamber and a pair of rotors, and a hydraulic or mechanical tilting system for easy discharge.
This dispersion kneader machine is widely used in industries like color masterbatch ,rubber, silicone ,plastics, polymer, pigment, chemical etc.
A dispersion kneader matchine is a powerful mixing equipment essential in the production of color masterbatch, it provides sufficient dispersion, reduces processing time, and ensures consistent product quality.
Here ,let us explore how do the dispersion kneader work as follows:
1. Loading the Raw Color Masterbatch Materials
Before the process, the raw color mastebatch compound materials are fed into the kneader chamber from its hopper . The compound compound material may include Carrier resin (e.g., PE, PP) ,pigments or dyes ,additives (dispersants, stabilizers, lubricants) .
2. Mixing & Dispersion for Color Masterbatch
As the counter two rotors rotating, the color masterbatch compound material is kneaded and blended under high pressure and high temperature .
The kneader’s precise temperature control ensures no degradation of pigments or resin during this high-intensity process. After appro 20 minuters ,the closed dispersion kneader prevents contamination and ensures safe, dust-free operation ,it ensures homogeneous compound dispersion, easy colour change cleaning, and simple operation, thus ensure consistent material quality accordingly.
3. Kneading Time & Temperature
Depending on the pigment type and formulation, the kneading time for the color masterbatch is usually between 6 to 20 minutes, and at temperatures around between 120°C to 180°C.
4. Discharging the Batch
Once the compound mixture achieve the desired consistency and dispersion level, the kneader would tilts at max 130 degree to discharge the compound material from the front or back ,which depend on the design of dispersion kneader . The processed compound material would be homogeneous and high-quality color masterbatch, which are ready for pelletizing or further processing.
Why is a Dispersion Kneader Essential for Masterbatch?
* Excellent dispersion ability even with high pigment loading
* Short mixing time with consistent results
* High-temperature resistance for engineering plastics
* More energy saving compared to traditional intensive mixers
* Easy cleaning and batch changeover, ideal for color changing
For manufacturers who are looking for reliable, scalable, and efficient color masterbatch production, a dispersion kneader is definately one of the best solutions in the industry.
If you are in the plastic industry and want a quality dispersion kneader ,then you come to the right place and contact us now .