What is filler masterbatch? How it is applied to your production?

Filler masterbatch is widely applied in many aspects in the plastic industry. So what exactly is filler masterbatch and how is it applied into plastic manufacture? Let’s discover in the article below!

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1. What is filler masterbatch?

Filler masterbatch (also known as calcium carbonate filler) is amongst the most common plastic fillers. It is the combination of CaCO3, primary plastic resin and other special additives in accordance with customer’s demand. The production of filler masterbatch includes 4 steps:

Step 1: CaCO3, additives and plastic resin are mixed together by high-speed mixer. 

Step 2: The mixture above is completely melted at high temperature.

Step 3: That mixture is then cooled and put into a screw extruder, pushed forward and pressed into the mold. 

Step 4: The output of the extruder is cut into similar small pieces. They are filler masterbatch applied into plastic manufacture.

Related: Top 3 suppliers for you to buy plastic filler calcium carbonate

2. Why choose filler masterbatch?

First of all, primary plastic is made up of high molecular polymers, which are constituted of monomers. To create primary plastic, humans combine natural components including cellulose, rubber,... or Ethin, Benzol, Ethene gas, and most importantly - kerosene together. 

Read more: What is plastic? Everything you need to know about plastic

Thus, using 100% primary plastic in plastic manufacture has the following disadvantages:

• Firstly, primary plastic is non eco-friendly. It takes hundreds of years for products made of primary plastic to be completely decomposed under natural conditions.

• Secondly, kerosene - the main component of primary plastic largely depends on foreign suppliers, which ends up with a relatively high price of finished products. Besides, due to the instability of kerosene supply, primary plastic is easily influenced by negative effects of foreign market.

• Thirdly, kerosene is a non-renewable resource, thus contributing to the unsustainable and unstable development of firms which takes kerosene as the main input material. 

With a view to providing customers with an appropriate solution to address the root of the production expense problem, filler masterbatch was born. 

Related: Top 3 industries that benefit most from filler masterbatch

3. How it benefits plastic products?

So, how exactly plastic firms benefit from filler masterbatch? 

• Product’s cost decrease: One of the main components of filler masterbatch is CaCO3, which is famous for its rich and high-quality reserve worldwide. This will definitely reduce production cost, stabilize the amount of input materials and significantly improve product’s competitiveness. 
• Physical properties enhancement: Rigidity and plasticity increase, shrinkage decrease.

• Flexible applications: Thanks to the suitable toughness and stable chemical properties, filler masterbatch can be easily cut into small pieces or crushed into powder. It can also be mixed with other plastic resin to create new products with more functionalities. 
• Forming enhancement: Filler masterbatch plays a vital role in adequate heat distribution in blow film or raffia, thus getting rid of bubbles on plastic surface situations. 

4. What are filler masterbatch's applications in the plastic industry?

Thanks to its outstanding advantages regarding functionality and price, filler masterbatch has been widely applied into many industries. 

4.1. Injection molding

Injection molding is a common technology based on two main phases: extruding melted plastic mixture and pressing it into the mold for forming. This method is used to create many plastic products including rice cooker lid, toilet lid, buckets, baskets, boxes, toothbrush, plastic toys,...

With filler masterbatch, the injection molding products have these following advantages:

• Manufacturing lead time decrease due to the good thermal conductivity of CaCO3. 
• Input material expenses reduce thanks to the reasonable price of CaCO3, which is significantly more economical than primary plastic. 
• Energy saving due to the decrease of manufacturing lead time. 
• Stability increase during the product forming process. 
• Carbon footprint decrease thanks to the replacement of primary plastic with CaCO3.
• Product’s physical properties increase (flexibility, rigidity,...)
• Product’s tear resistance increase regardless of its thickness. 
• Product’s printability increase. 

4.2. Extrusion

One of the most popular plastic manufacturing methods is extrusion. After being mixed together, input materials go into the extruder through the hopper. This combination is then melted under extremely high temperature and extruded by a mould clamping cylinder in the form of fibers. The cross section of these depends on the form of the mould clamping cylinder (commonly square or round). 

Filler masterbatch has been applied in extrusion

The plastic fibers are then cooled by water or fan on the assembly line and cut into small pieces for packaging.  

Extrusion is a common method to produce plastic products such as PVC pipes, straws, gutters,... thanks to its simple technology.  

The application of filler masterbatch into extrusion helps: 

• Reduce production cost thanks to the reasonable price of CaCO3 compared to primary plastic, thus decreasing product’s price and driving competitiveness. 
• Enhance rigidity and Cải thiện độ cứng và khả năng chịu lực cho thành phẩm.

4.3. Blown film

Blown film is a common plastic manufacturing technology, especially in producing packaging (thin-film packaging, biodegradable packaging, paper packaging, packaging roll film, waste packaging,...). To create packaging film, materials mixture enters the extruder through the hopper. After being melted, it goes through an annular slit die and is formed as a thin tube. The tube is then cooled by the air ring and continues moving upwards until it passes through nip rolls, where it is flattened. This lay-flat tube is then taken back down via more rollers. The edges of the lay-flat are slit off to produce two flat film sheets and wound up onto reels.

Filler masterbatch is used in blown film to improve the rigidity, control heat, enhance the turbidity and most importantly, cut production expense.

Relating: Filler masterbatch and 4 most well-known applications

5. EuroPlas filler masterbatch 

Thanks to its advantages, filler masterbatch has been widely applied in many fields with a view to optimizing production cost and to enhancing product’s competitiveness as well. 

Contact us to discuss your requirements of desiccant masterbatch. Our experienced sales team can help you identify the options that best suit your needs.

After 13 years of establishment, EuroPlas filler masterbatch has become the top-of-mind filler masterbatch manufacturer all over the world. We take pride in providing products for thousands of clients ranging from Asia, Middle East and North Africa to Europe.

Our most popular products including:

• PP filler masterbatch: the combination of PP resin, high-quality CaCO3 and additives. 
• PE filler masterbatch: is produced with PE resin, high-quality CaCO3 and additives. 
• PS filler masterbatch: the mixture of PS resin, CaCO3 and other additives. 
• BiOMates: includes bio plastic, CaCO3 and other additives. 

Plastic presents every aspect of life, from electric appliances to children’s toys. Plastic resin and filler masterbatch are the two most often used materials when making products from this material. The benefits and drawbacks of each are different. Plastic resin is highly pure, ensuring the quality of the finished product. Filler masterbatch, also known as plastic filler, is a versatile additive that can reduce the cost or improve the properties of plastic.

How are plastic resin and filler masterbatch different from one another? In this article, you’ll find all the details you need to know about the two varieties.

1. What Is The Difference Between Plastic Resin And Filler Masterbatch?

Plastic resins are derived from fossil fuels such as oil and natural gas. The basic production process includes the following steps:

Step 1: Separate the components of petroleum or natural gas.
Step 2: Polymerize the components to form long molecular chains.
Step 3: Mold the plastic resins to the desired size and form.

Polyethylene (PE), Polypropylene (PP), Polystyrene (PS), Polyvinyl chloride (PVC), and Polytetrafluoroethylene (PTFE) are examples of common plastic resin types.

Read more: What is Plastic Resin? How is Plastic Resin Made?

Filler masterbatch is produced from these natural materials, like clay, limestone, paper pulp, and many others. The following steps are part of the production process:

Step 1: Prepare ingredients.
Step 2: Crush or grind ingredients into powder.
Step 3: Mold particles to the desired size and shape.

Some typical filler masterbatches: inorganic fillers (clay, CaCO3 filler masterbatch, mica), organic fillers (wood pulp, paper pulp, cellulose fiber)

In contrast to fillers, which can vary in color, turbidity, and gloss depending on the production components, plastic resins are clear or white and contain no contaminants. Plastic resin products are often better quality, last longer, and look better than products made from other materials, but they cost more and are harder to recycle. Filler masterbatch products are less expensive and easier to recycle, but at the same time, they are also of inferior quality, less long-lasting, and less aesthetically attractive.

Learn more about filler masterbatch: What is CaCO3 filler? Benefits of CaCO3 filler in plastic production

2. Methods to distinguish plastic resin and filler masterbatch?

The easiest way to tell two ingredients apart is to observe them.

• Direct observation testing: Plastic resins are typically bright white and have a smooth, uniform texture. Filler masterbatch, on the other hand, often has smaller particle size than the original plastic and a colorful look, due to its content of different colored fillers.
• General-purpose machine testing:

Characteristics Plastic Resin Filler Masterbatch Differential scanning calorimetry High Low Shore D hardness High Low Tensile Strength High Low

• Chemical analysis testing: Chemical analysis methods can reveal the composition of plastic pellets. Virgin plastic pellets contain only plastic, while filler masterbatch contains plastic and other fillers.

2.1. Applications

Depending on the needs and purposes of use, manufacturers can choose the appropriate type of virgin plastic resins or plastic fillers.

Products made from virgin plastic resins are suitable for the following needs:

• Prioritize quality and do not contain toxic substances: household appliances, children’s toys, electronics, medical devices, and food packaging.
• Direct contact with food: food containers, eating utensils, food packaging.

Products made from plastic fillers are suitable for the following needs:

• Need low prices: garbage bags, supermarket bags, and agricultural mulch.
• Improve product properties: plastic pipes, construction materials, and automotive parts.-
• Environmentally friendly: bioplastic bottles, biobags, and compostable packaging..

2.2. Sustainable plastic production and consumption: Plastic resin vs. filler masterbatches

Virgin plastic resins are produced from non-renewable resources and emit greenhouse gases. They are difficult to recycle and persist in the environment for a long time. Plastic fillers, made from various materials, can cause pollution during extraction and transport. When disposed of, products made with plastic fillers contribute to plastic waste. However, there are positive trends: recycled plastic is being used as an alternative to virgin plastic, conserving natural resources. Additionally, plastic fillers are increasingly used to enhance plastic properties, and new types with better qualities are being developed, potentially reducing the need for virgin plastic in the future.

3. EuP Egypt – The best filler masterbatch solution for businesses

EuP Egpyt is a leading global filler masterbatch manufacturer with 17 years of experience working with international businesses. EuP Egypt’s filler masterbatch utilizes calcium carbonate (CaCO3) combined with plastic resin and various additives as per customer requirements.
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EuP Egpyt’s filler masterbatch offers:

• Reduced production costs: By replacing a portion of plastic resin with calcium carbonate powder, the production cost of finished products is optimized.
• Enhanced product properties: including sturdiness, impact resistance, scratch resistance, heat resistance, etc.
• Increased stability in the processing process: Filler masterbatch increases solidity, minimizes deformation and cracking.
• Improved printing ability and surface quality: Filler masterbatch increases surface smoothness and minimizes shrinkage.​

EuP Egypt’s filler masterbatch is widely used in many plastic industries including:

• Packaging: Plastic bags, plastic films, plastic bottles, plastic boxes, etc.
• Electrical equipment: Plastic pipes, plastic cases, etc.
• Construction: Plastic bricks, plastic floors, etc.
• Automation: Plastic cases, plastic components, etc.​

Popular EuP Egypt’s filler masterbatch products:

• PP filler masterbatch: used in the production of woven bags, plastic conteners and plastic boxes,…
• PE filler masterbatch: used in the production of shopping bags. plastic bottles and plastic cases,…

For more information please contact us right here!

4. Conclusion

Distinguishing plastic resin and filler masterbatch is crucial for businesses to ensure product quality and optimize production costs. By understanding the key differences between these two materials, businesses can choose the right type of plastic for their specific needs and applications.