What is Polyethylene (PE) Filler Masterbatch
Polyethylene (PE) filler masterbatch is a concentrated compound of PE resin, calcium carbonate (CaCO₃) or other minerals, and additives, used to enhance the properties and reduce the cost of polyethylene products. By blending it with virgin PE during manufacturing, it partially replaces the more expensive resin, lowering material costs without significantly compromising quality. It also improves the final product's mechanical properties, such as rigidity, strength, and impact resistance.
PE Filler Masterbatches are widely used in applications ranging from film and sheet production to pipes, containers, and packaging materials. They are compatible with various grades of polyethylene, including LDPE, HDPE, and LLDPE.
Key Features
- Cost Efficiency: Reduces raw material consumption by partially replacing PE with functional fillers.
- Enhanced Mechanical Properties: Improves stiffness, dimensional stability, and wear resistance.
- Processing Optimization: Facilitates uniform flow and reduces cycle time in extrusion and molding processes.
- High Compatibility: Suitable for multiple PE grades without affecting processability.
- Customizable Formulations: Can be tailored with specific fillers for target properties such as UV resistance, opacity, or thermal stability.
Common Fillers Used
- Calcium Carbonate (CaCO₃): Improves rigidity and reduces cost.
- Talc: Enhances dimensional stability and thermal resistance.
- Clay & Kaolin: Provides better stiffness and surface finish.
- Silica & Other Mineral Fillers: For special mechanical or barrier requirements.
Applications
- Plastic Films and Packaging: Increases opacity and tensile strength, suitable for bags, shrink films, and liners.
- Pipes and Tubing: Enhances stiffness and dimensional stability for HDPE/LDPE pipes.
- Injection Molded Products: Optimizes rigidity and reduces warping in containers, crates, and automotive components.
- Sheets and Profiles: Improves flatness and surface finish for construction and consumer products.
- Household Products: Reinforces household items like bins, crates, and furniture parts.
Advantages
- Reduced Production Costs: Partial substitution of expensive PE with cost-effective fillers.
- Improved Product Performance: Enhances stiffness, impact resistance, and durability.
- Environmental Benefits: Enables lower polymer usage, reducing carbon footprint.
- Customizable Aesthetics: Fillers can modify opacity, texture, and color retention.
- Ease of Use: Supplied in a ready-to-use concentrated form for effortless blending with base resin.
Technical Specifications (Example)
| Parameter | Typical Value |
|---|---|
| Base Resin | HDPE / LDPE / LLDPE |
| Filler Content | 10% – 70% (by weight) |
| Melt Flow Index (MFI, g/10 min) | 0.3 – 5 |
| Density (g/cm³) | 1.0 – 2.0 |
| Color | White, Off-White, Custom |
| Particle Size | 5 – 20 μm |
| Moisture Content | ≤ 0.2% |
Note: Specifications can be customized to meet customer requirements.
FAQ
Q1: What is PE Filler Masterbatch used for?
A1: It is used to reduce production costs, improve mechanical properties, and enhance processing efficiency in polyethylene products.
Q2: Can I use it with all types of PE?
A2: Yes, it is compatible with HDPE, LDPE, and LLDPE.
Q3: How much filler can be added?
A3: Typically 10% to 70% by weight, depending on desired properties and processing requirements.
Q4: Will it affect the color of my product?
A4: Fillers may slightly affect the color. Custom masterbatches can be formulated to achieve specific shades or opacity.
Q5: Is it suitable for food-contact applications?
A5: Food-contact compliance depends on the filler and resin used. Food-grade formulations are available upon request.