Masterbatch (MB) and its advantages - LinkedIn

Masterbatch (MB) is a solid additive for plastic, it can be grouped into two category, color masterbatch and additive masterbatch. Color masterbatch is used to color plastics, which is a concentrated mixture of colorants (pigments or dyes), additive masterbatch is used to impart other properties to plastics, which is a concentrated mixture of additives. Both color masterbatch and additive masterbatch are produced through a heat process in which the colorants/additives are encapsulated into a carrier resin which is then cooled and cut into a granular shape.

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One advantage of masterbatch is it allows the processor to color raw polymer or change the properties economically during the plastic manufacturing process compared with a fully compounded material (which may be more expensive and less open to color variability of the product). Another advantage is, masterbatches as premixed compositions, the use alleviates the issues with the additive or colorant clumping or insufficient dispersion. The concentration of the colorant/additive in the masterbatch is much higher than in the end-use polymer, but the colorant/additive is already properly dispersed in the host resin. In a way their use is similar to uses of ferroalloys for adding alloying elements to steels. Finally, the use of masterbatches allows the factory to keep stock of fewer grades of the polymer, and to buy cheaper natural polymer in bulk.

The masterbatches are fairly highly concentrated (in comparison with the target composition), with high "let-down ratios"; e.g. one 25 kg bag can be used for a ton of natural polymer. The relatively dilute nature of masterbatches (in comparison with the raw additives) allows higher accuracy in dosing small amounts of expensive components. The compact nature of the grains of solid masterbatches eliminates problems with dust. The masterbatch usually contains 40-70% of the colorant/additive, but the range can be as wide as 15-80% in extreme cases.

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The carrier material of the masterbatch can be based on a wax (universal carrier) or on a specific polymer, identical or compatible with the natural polymer used (polymer-specific). E.g. EVA or LDPE can be used as carriers for polyolefins and nylon, polystyrene can be used for ABS, SAN, and sometimes polycarbonates. The usual ratio of masterbatch to the base resin is 1 to 5 percent. Several masterbatches (color and various additives) can be used together.

Masterbatches can be used in most processes, except rotational molding and Plastisol and other liquid resin systems.

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