There isn’t a definitive consensus on what type of resin should serve as the carrier for masterbatches. Some companies opt for what they call an “application-specific carrier,†meaning the carrier is made from the same material as the final product. This approach works exceptionally well for masterbatches with a low pigment concentration, preventing issues like delamination and maintaining the integrity of the material’s properties. However, it becomes more challenging when dealing with high-pigment-content masterbatches. When the pigment concentration is too high, achieving even distribution becomes incredibly difficult. Using a low-molecular-weight wax to facilitate faster infiltration can hinder the dispersion of pigments within the carrier because the necessary shear forces cannot be effectively applied.
Other manufacturers take a different route by employing an “approximate carrier†method. Here, a material partially compatible with the target material is used as the carrier. This approach demands significant flexibility from the carrier. Nevertheless, for certain products featuring dot-like adhesive inlets, localized flow shearing during the molding process can lead to issues such as gas formation, discoloration, or even phase separation. Consequently, selecting the appropriate carrier base for a masterbatch doesn’t appear to follow a one-size-fits-all principle—it must be tailored based on molding conditions, material composition, and the end-use of the product.
When working with some of the masterbatch factories we’ve collaborated with, they typically choose a carrier that matches the specific resin being used. This prevents compatibility issues. Reputable color masterbatch producers often incorporate silicone oil into their formulations, likely to enhance both dispersibility and fluidity. While silicone oil is effective, its high cost poses challenges, especially when higher concentrations are required. One downside is that its low molecular weight can impact printability and coating quality if it precipitates out. On the other hand, using white mineral oil or stearic acid can also present problems, particularly in high-temperature environments where decomposition and unpleasant odors may occur.
In summary, the primary focus when formulating color masterbatches is achieving excellent dispersibility and fluidity. These factors are critical to ensuring consistent performance across various applications. Yet, each formulation must be carefully adjusted to account for the unique requirements of the materials involved and the end product’s intended use. Balancing these elements while managing costs remains a key challenge in the industry today.
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