What is the difference between compound and masterbatch?
Polymer Compounds and Masterbatches
Both polymer compounds and masterbatches are materials used in the production process of plastic products, but their applications and compositions are different. Let's examine the differences between the two:
1- Definition
Polymer Compounds:
A compound is a complete and engineered combination of a base polymer and additives that are uniformly mixed. These materials are commonly used in the plastics industry to produce finished products. Additives in compounds include the following:
Fillers: Materials such as calcium carbonate (CaCO₃) or talc that optimize mechanical properties or cost.
Reinforcements: Such as glass or carbon fibers to increase strength.
Stabilizers: To protect against environmental factors such as heat, light, or oxidation.
Pigments: To create the desired color.
Lubricants: To improve processability.
Compounds are used directly, without the need to add other materials, in manufacturing processes such as plastic injection, extrusion or blow molding.
Masterbatch:
A masterbatch is a concentrated mixture of one or more additives (such as pigments, stabilizers or antioxidants) dispersed in a carrier resin. This substance is added as an additive agent in small quantities to base polymers to give specific properties to the final product.
Types of masterbatch:
Color masterbatch: To create specific colors in plastic products.
Additive masterbatch: To improve properties such as UV resistance, heat resistance or antibacterial properties.
Filler masterbatch: To reduce costs and improve mechanical properties using materials such as calcium carbonate.
2- Application
Compound
Production of finished products without the need to mix other materials.
Suitable for applications that require special properties such as high strength, flexibility or heat-resistant properties.
Examples:
Automotive parts (such as bumpers and dashboards)
Pipes and profiles
Cables and wires
Medical equipment
Masterbatch
Additive to modify the properties of the base material.
It is added to the raw polymer to create special properties such as color, UV resistance or anti-static properties.
Examples:
Creating various colors in plastic bottles and containers.
Adding antibacterial properties to food packaging.
Increasing resistance to light degradation in agricultural products (such as greenhouse nylon).
3- Usage ratio
The compound completely replaces the raw polymer in the production process.
Masterbatch is usually added to the base polymer in small percentages (1 to 5% by weight).
4- Production process
Compound
Compounds are fully mixed and ready to use in the production process. Twin-screw extruders are used as the main equipment for compound production. In these devices:
Raw materials enter the extruder.
They are mixed and homogenized under a certain pressure and temperature.
The final product is produced in the form of granules or pellets, which are ready to be used in the production of final products.
Masterbatch
Masterbatches are usually produced in single-screw or twin-screw extruders. In this process:
The carrier resin is mixed with the desired additives.
The homogenization process is performed.
The product is produced in the form of small granules.
5- Type of final product
Compound: The final product is ready-made and does not require the addition of other materials.
Masterbatch: Must be mixed with raw materials to achieve the final properties.
Conclusion
Compound is used to produce finished products with precise and consistent properties and is the best choice for mass production with specific properties.
Masterbatch is added to raw materials as an additive to create color or specific properties and is suitable for production lines that require frequent changes.
Ultimately, the choice between polymer compound and masterbatches depends on the type of final product, production process and production economics.
For more information, you can have our address and contact number through the contact us page.
Related content:
What are polymer raw materials?/www.wci-polimer.com
What are polymer compound and granules?/www.wci-polimer.com
Plastic raw materials/www.wci-polimer.com
