PP+Caco3 Filler Masterbatch Manufacturing Process
Product Description
Related plastic extruder for various polymer compound
PP+Caco3 Filler Masterbatch Making Twin Screw Extruder
Machine Model: TSE-75D (TSH-75B)
Material: PP + Caco3
Cutting Method: Water ring
Configuration: side feeder, pelletizer, dewaterer, silo, shaker
Capacity: 600-800kg/h
D-type gearbox, CW-65 side feeder, improved water ring pelletizer, new centrifugal dewaterer...
This is an advanced configuration.
、
The production can be up to 800kg/h.
Pre mix the raw material with high speed mixer will help to improve the production effeciency.
Water ring pelletizing line is very popular among foreign customers.
Machine Model:
| Model | Diameter (mm) | L/D | Rotary (r/min) | Power (kw) | Torque (N.m) | T/N3 | Capacity (kg/h) |
| TSE-20 | 22 | 32-44 | 600 | 5.5 | 43 | 7.5 | 0.5-10 |
| TSE-30 | 31 | 32-48 | 600 | 15 | 119 | 6.7 | 5-40 |
| TSE-40 | 41 | 32-52 | 600 | 30 | 239 | 5.8 | 90-150 |
| TSE-50 | 50.5 | 32-52 | 500 | 55 | 430 | 5.4 | 135-270 |
| TSE-65 | 62.4 | 32-64 | 600 | 90 | 716 | 5.1 | 200-300 |
| TSE-75 | 71 | 32-64 | 600 | 132 | 1050 | 4.8 | 350-550 |
| TSH-75 | 71 | 32-64 | 600 | 200-250 | 1365 | 7.6 | 600-9000 |
| TSE-95 | 93 | 32-64 | 600 | 315 | 2506 | 5.3 | 800-1200 |
PP + CaCO3 Filler Masterbatch Production: Frequently Asked Questions
Q1: Why is a co-rotating twin-screw extruder essential for PP + CaCO3 filler masterbatch production?
A: Producing high-quality filler masterbatch requires incorporating a massive volume of inorganic calcium carbonate (CaCO3) powder into a polypropylene (PP) matrix. A co-rotating twin-screw extruder provides the intensive dispersive and distributive mixing necessary to break down CaCO3 agglomerates at a micron level. This ensures every single particle is completely encapsulated by the PP carrier resin, preventing clumping and ensuring excellent performance during downstream injection molding or film blowing.
Q2: CaCO3 powder is highly abrasive. How does your machinery handle long-term wear and tear?
A: Equipment durability is our top priority for filler masterbatch production. To combat the highly abrasive nature of calcium carbonate, our twin-screw extruders are equipped with:
High-Wear Resistant Alloys: Screw elements made from specialized tool steel or premium bimetallic materials.
Bimetallic Barrel Liners: Highly durable liners that protect the internal barrel from premature abrasive wear.
Advanced Surface Treatments: Specialized nitriding and polishing to extend the lifespan of core components, drastically reducing maintenance downtime and long-term operation costs.
Q3: Can your compounding lines handle ultra-high filler loadings, such as 70% to 80% CaCO3?
A: Yes, absolutely. Our lines are engineered specifically for high-load compounding. To achieve high filler percentages without stalling the motor or overheating the polymer, our machines utilize a high-torque density gearbox paired with an optimized screw configuration. This advanced setup easily manages high melt viscosity and maintains stable internal pressure, allowing you to produce highly concentrated filler pellets continuously and smoothly.
Q4: What is the recommended feeding strategy for PP + CaCO3 masterbatch manufacturing?
A: For high-filler applications, we strongly recommend a split-feeding strategy utilizing high-precision loss-in-weight gravimetric feeders:
Main Hopper: Feed the PP carrier resin, processing aids, and coupling agents to ensure a complete, stable melt zone early in the process.
Side Feeder: Introduce the CaCO3 powder downstream into the already molten polymer. This protects the early melting zone from premature abrasive wear and significantly improves overall dispersion efficiency.
Q5: Which pelletizing system is best suited for PP filler masterbatch production?
A: Depending on your required production capacity and automation preferences, two systems are highly effective:
Water Ring Pelletizing (Highly Recommended): The molten plastic is cut directly at the die face and instantly thrown into a circulating ring of cooling water. It is ideal for high-capacity PP filler production, offering clean automation, a small footprint, and highly uniform pellets.
Strand Pelletizing: A traditional, cost-effective method where extruded plastic strands are cooled in a water trough and then chopped. It is highly versatile and easy to operate for multi-purpose compounding lines.
Q6: How does optimizing the screw design improve the quality of the final filler pellets?
A: The screw configuration is custom-tailored to balance processing throughput and mixing intensity. By precisely arranging specific kneading blocks and conveying elements, the machine applies the exact amount of shear required to blend the raw materials without overheating and degrading the PP resin. This results in uniform pellet dimensions, zero moisture trapping, and excellent re-melting properties for the final plastic manufacturer.
The Masterbatch Pelletization Line efficiently mixes, disperses, and pelletizes pigments and additives into polymer carriers, ensuring high-quality masterbatch with consistent color and stable processing performance.
The Compounding and Pelletizing Line efficiently mixes polymers with additives and converts them into uniform pellets, ensuring stable processing, consistent quality, and high production efficiency.
The Production Line for Manufacturing Filler efficiently mixes, compounds, and pelletizes additives with polymer carriers, ensuring consistent quality, stable performance, and high-output filler masterbatch production.
The Twin Screw Extruder for Compounding provides efficient melting, mixing, and dispersion of polymers and additives, ensuring stable processing and high-quality compound production.