Coperion has comprehensive know-how in compounding systems for masterbatch

Quality is our benchmark in compounding systems for masterbatch

The processing of masterbatch makes great demands on the compounding process: The pigment and additive parts must be mixed into the base polymer absolutely homogeneously. Coperion compounding systems and extruders are particularly suitable for the processing of masterbatch because of their excellent mixing properties and gentle product handling. In addition, Coperion and Coperion K-Tron offer a wide range of material handling components such as feeders, valves and conveying systems for both the raw ingredients and the end product.

With our extensive process know-how we tailor all the process steps from raw materials feeding, conveying, melting, dispersing, homogenizing, devolatilizing, pressure build-up to filtering and pelletizing exactly to the requirements of your masterbatch recipes. This gives you exactly what you expect: a compounding system that is optimally tailored to your application.

The term masterbatch includes concentrates of pigments or additives in a polymer matrix. Masterbatch is mainly available in the form of standard pellets but also in the form of mini-pellets. A distinction is made between white, black and colored masterbatch depending on the pigment type. The premix, split-feed and color-matching processes are available for compounding masterbatch.

Typical areas of application for processing of masterbatch

  • Color masterbatch
  • Special effect pigment masterbatch
  • Carbon black masterbatch
  • PET masterbatch

Masterbatch processes

In the premix process all masterbatch raw material components are first mixed homogeneously in a mixer. Then, normally via a volumetric feeder, this mixture is fed into the twin screw extruder where it is processed.

Advantages of Coperion extruders

  • Excellent dispersion at high throughput rates
  • High pigment and additive loading levels are possible
  • Very simple machine operation
  • Long lifetime of screw and barrel parts due to specially developed screw elements
  • Fast and therefore economical color changes

Advantages of Coperion K-Tron feeders

  • Reliable feeding of raw materials for consistent results
  • Wide range of feeder types and sizes
  • Quick change designs for easy recipe changes

Recipe ingredients

Base polymers: PE, PP, PS, EVA, PET, PA, PC, SAN, PMMA, ABS,
TPE, POM, PEEK, etc.

The split-feed process is used especially for producing monopigment and additive masterbatch. In this process, the polymer is fed into the feed barrel of the extruder in form of pellets. The pigments are then fed gently into the extruder by a twin screw side feeder downstream of the melting zone. The components are metered separately by individual gravimetric feeders.

Advantages of Coperion extruders

  • Very high pigment and additive loading levels are possible
  • Extremely gentle wetting of the pigments thus avoiding agglomerations
  • Excellent dispersion of the pigments, e.g. for fiber applications
  • Fast and therefore economical color changes
  • High throughput rates for maximum productivity

Advantages of Coperion K-Tron feeders

  • Accurate feeding of raw materials for consistent results, even at low rates
  • Wide range of feeder types and sizes
  • Quick change designs for easy recipe changes

Recipe ingredients

Base polymers: PE, PP, PS, EVA, PET, PA, PC, SAN, PMMA, ABS,
TPE, POM, PEEK, etc.

The color-matching process is used for high-end applications such as dyeing of fibers. Different monobatch pellets are fed into the extruder pre-mixed or separately. The extruder plasticizes and homogenizes them so that a masterbatch in the desired color shade is produced. Masterbatch based on the common base polymers PE, PP but also PA is used in this process. Accurate gravimetric feeders ensure consistent quality of the end product.

Advantages of Coperion extruders

  •  Excellent dispersion of the pigments, e.g. for fiber applications
  • Fast and therefore economical color changes
  • High throughput rates for maximum productivity

 Advantages of Coperion K-Tron Feeders

  • Accurate feeding of raw materials for consistent results, even at low rates
  • Wide range of feeder types and sizes
  • Quick change designs for easy recipe changes

Whether premix or split-feed or color-matching process, high torque or high volume requirement – with our twin screw extruder series ZSK Mc¹⁸, ZSK Mv PLUS and STS Mc¹¹ we can offer the perfect machine set-up for your range of masterbatch formulations.

Marina Matta, Process Technology Masterbatch, Coperion GmbH, Stuttgart/Germany

Comprehensive product range

Compounding Machines and Extruders

Both the twin screw extruder series ZSK Mc18 and the ZSK Mv PLUS as well as the STS Mc11 are used for compounding of masterbatches. We design – depending on the masterbatch recipe – all processing steps exactly to your requirements. Special developed features such as the feed hopper with quick-release clamps, the masterbatch die head or the easy-to-clean side feeder ZS-B ensure fast, easy cleaning of the extruders and therefore economical recipe and color changes.

Feeding Equipment

Delivering the right materials in the correct amount is critical to the manufacturing of Masterbatch. Coperion K-Tron’s feeding equipment along with our engineering expertise can design a complete material handling solution. Our screw feeders feed the most critical ingredients such as pigments at a high level of accuracy, even at low rates, while the Bulk Solids Pump (BSP) feeders are ideal for consistent feeding of the main polymer.  In addition, the KQx and QC feeders incorporate a quick clean design for easy material changes.

Material Handling

Coperion and Coperion K-Tron have the right material handling solution for your Masterbatch process.  Vacuum sequencing systems for bulk material handling and automated feeder refill can improve the accuracy and efficiency of the process. Maximum system performance is achieved by taking into consideration factors such as plant layout, material delivery, material characteristics, batch size and the required conveying rates.

Plants and Systems

Coperion has comprehensive know-how and longtime expertise in the design of compounding plants for masterbatch production. From raw materials handling and feeding to the twin screw extruder and down to the packaging equipment, we skillfully adapt all system components to each other.

Global Service

Coperion offers comprehensive services for compounding machines, extruders, feeders, weighers etc. Coperion's spare parts store for example is one of the largest in the industry with more than 48,000 parts in the data base. These include both original Coperion spare parts and parts from other suppliers.

Video of a masterbatch compounding plant

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Twin screw extruder ZSK 32 Mc¹⁸ smart and Coperion strand pelletizer for the production of high-quality masterbatch

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