Filler Masterbatch
Masterbatch is a solid additive that is encapsulated in a carrier resin through a heat process, then cooled and cut into granular shapes. On the other hand, filler is a mixture of polymer and calcium carbonate that is widely used in plastic-based product manufacturing. The addition of calcium carbonate in plastics can improve processing, performance, sustainability, and the finish impact of the final product. The use of calcium carbonate as a filler is 100% FDA approved, making it versatile in applications, including critical ones like food and medical packaging.
Calcium carbonate filler contains a high percentage of calcium carbonate powder mixed with the primary resin and appropriate additives. This mixture is heated until it becomes a liquid, and then it is cooled until it solidifies. The solidified mixture is then passed through an extruder and cut into small solid granules or pellets called masterbatch. Masterbatch is used as a filler in the manufacturing of products like Blown HDPE Film, Raffia tapes, Tarpaulins, High-density and Low-density PP/PE fabric, LDPE, LLDPE, and HDPE films, and plastic furniture.
Furthermore, using calcium carbonate filler in generating non-woven fabric is an outstanding application. The products made from calcium carbonate non-woven fabric are used in various fields such as medical and personal care, hygiene, and geotextiles used in technical industries such as irrigation, transport, and environment. Calcium carbonate fillers are cost-effective, save production costs, and enhance multiple properties of the final products.
Advantages of adding calcium carbonate filler into non-woven materials are:
- Improving the product surfaces by
- Reducing luster, making the surface more matte and more opaque leading to enhanced covering ability of the fabric structure
- Giving natural white color with limited yellowness
- Creating a comfort and cotton-like feel and prevent carbon footprint when touching
- Creating more micro areas for air filtration and oil absorption
- Increasing thermal conductivity and physical strength
- Reducing processing temperature, hence the manufacturers can achieve higher productivity as well as save energy and producing costs in general.
- Easily cooperated with multiple base resins (thanks to good dispersion ability) and processed by various methods
Calcium carbonate filler mixed with PP masterbatch is an excellent solution for producing a wide range of household appliances, including furniture, containers, boxes, bottles, and buckets, using the injection molding method. This combination of PP resin and calcium carbonate provides superior thermal conductivity and impact resistance, as well as better flexural stiffness with lower shrinkage. Calcium carbonate filler can also be added directly into virgin plastics like LDPE, LLDPE, or HDPE, and function as both a filler and an additive masterbatch for manufacturing plastic films and sheets. These mixtures provide higher blocking and slipping resistance, as well as improved folding and creasing quality. The final product has a matte appearance suitable for printing, and the tensile strength is improved, offering complete protection even when stretched. It is also safe to contact with food since it does not contain any toxic components. At Bhavya Polyfilms, we only source the best quality filler masterbatches from suppliers with the highest quality calcium carbonate ores in Vietnam. Our filler masterbatches are carefully selected to ensure optimal performance and cost-effectiveness for our customers.
PE Calcium Carbonate Filler is a combination of high-quality polyethylene (PE) resin, pure Calcium Carbonate (CaCO3) powder and other appropriate additives. The proportion of these components varies among different end-products to achieve the optimal using effectiveness.
Benefits
Cost effectiveness
Thanks to the powerful component – CaCO3, which partly replaces plastic resins, PE Filler is far more reasonable than pure PE resin, thus helping customers reduce production cost.
End-products properties enhancement
PE Filler Calcium Carbonate also improves end-products’ thermal resistance, anti-shrinkage ability and other mechanical properties, which upholds your products’ competitiveness.
PE Filler Calcium Carbonate is compatible with various plastic resins such as HDPE, LDPE, LLDPE. Thanks to its advantages, this material is widely used in many applications as belows:
| Manufacturing methods | Applications |
|---|---|
| Blown film | PE based films & bags (Roll bags, T-shirt bags, garbage bags, shopping bags, agricultural films, breathable films,…) |
| Injection moulding | Housewares, tanks, toys |
| Extrusion | PE/HDPE pipe, bar,… |
| Blow moulding | HDPE bottles, containers, cans,… |
