This article provides practical Q&A insights into common issues encountered during masterbatch processing, including dispersion quality, color consistency, moisture control, and equipment settings. It offers actionable solutions for improving production stability, optimizing extrusion parameters, and enhancing final product performance.

Plastic broom filaments are synthetic bristles made through a plastic extrusion process at around 200°C, where melted polymers are shaped into fine strands. The main types are PET and PP filaments. PET broom filaments feature excellent mechanical strength, heat resistance, and durability, making them suitable for high-performance applications. PP broom filaments, made from polypropylene or recycled PP pellets, are lightweight, cost-effective, and chemically resistant, though less rigid and weather-resistant. Most broom filaments are produced using plastic extrusion machines, which melt and form plastic materials into consistent filament shapes for household and industrial broom production.

Black spots in PVC granules are mainly caused by **unclean screws, raw material contamination, carbonization from overheating, or poor environmental conditions**. Solutions include regularly cleaning the screw and die head, controlling temperature and residence time, inspecting raw materials, maintaining a clean production environment, cleaning auxiliary equipment and filters, and checking the heating system. These measures help prevent black spots and improve the appearance and quality of PVC granules.

Whether fillers in TPE pelletizing require surface modification depends on their activity, surface area, and loading level. High-activity or high-surface-area fillers (like nano silica or fine calcium carbonate) and high-performance or high-filling applications must be pre-treated with coupling agents to improve compatibility and prevent agglomeration. For low-activity fillers, low filling ratios, or low-cost applications, pre-modification is usually unnecessary and can be compensated by compatibilizers and lubricants. Proper modification ensures better dispersion, stability, and product quality in TPE processing.

Talc masterbatch is a polymer additive that enhances the durability, heat resistance, scratch resistance, and dimensional stability of plastics such as polypropylene (PP) and polyethylene (PE). Produced via twin-screw extrusion, it ensures uniform dispersion of talc particles, simplifying processing and improving mechanical performance. Widely used in automotive, packaging, and household applications, talc masterbatch offers cost-effective reinforcement, supports sustainable practices, and enables plastics to meet high-performance and long-lasting requirements.

Thermoplastic elastomers (TPEs) are naturally colorless and can be colored using pigments or dyes through pre-coloring or in-process coloring methods. In-process coloring, often performed with twin-screw extruders, allows pigments to disperse evenly during melting without adding extra thermal stress. The most common approach is using color masterbatch, which combines pigments with compatible carrier resins such as PP, PE, PS, or EVA to ensure uniform color and good material performance. Proper carrier selection, dilution ratio, and process optimization help achieve consistent, high-quality colored TPE pellets for various molding and extrusion applications.

Breathable film masterbatch, produced mainly with polyethylene and additives through extrusion processes, is widely used in medical, packaging, and construction fields. With excellent breathability, stable quality, and bright colors, it plays a key role in manufacturing breathable films. Its production involves raw material mixing, melt blending, hot-melt extrusion, and cooling. As demand grows, factories are focusing on technological innovation, eco-friendly materials, and market expansion to enhance competitiveness.

This article introduces four main methods of physical blending for polymer modification: dry powder blending, melt blending, solution blending, and emulsion blending. Among them, melt blending using extrusion equipment, such as single-screw and twin-screw extruders, is the most widely applied in industry due to its efficiency and ability to achieve fine dispersion. Each method has its own advantages, limitations, and application scenarios in research, testing, and industrial production.

Seaweed–polymer extrusion is an innovative and sustainable method of processing seaweed directly into polymer materials such as pellets, films, filaments, and 3D-molded parts. Unlike conventional fossil-based polymer production, this process minimizes CO₂ emissions while utilizing all natural seaweed components. The resulting seaweed-based polymers, known as Carraphane, offer biodegradable and eco-friendly packaging solutions with potential applications in films, small parts, and recyclable products. Continuous research aims to enhance water resistance and expand their role in the circular economy.

This article explores the diverse applications of TPU in the automotive industry, highlighting its use in interior and exterior parts, structural components, and safety features. It discusses various TPU composites, including glass fiber reinforced TPU (R-TPU), and their advantages such as lightweight design, recyclability, and improved safety. The article also emphasizes the growing trend of replacing traditional metals and PVC with TPU in automotive manufacturing.