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Masterbatch is a solid additive that is encapsulated in a carrier resin through a heat process, then cooled and cut into granular shapes. It is a mixture of polymer and calcium carbonate that is widely used in plastic-based product manufacturing. It has a good percentage of calcium carbonate powder (82%) combined with the resin (18%) and appropriate additives. 

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. Filler Masterbatches are cost-effective, save production costs, and enhance multiple properties of the final products.

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.

Adding calcium carbonate filler helps improve product surfaces by:

  •  Reducing luster, making the surface more matte and opaquer 

  •  Giving natural white color with limited yellowness

  •  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

Applications

  • Extrusion: to improve stiffness, strength, and impact resistance

  • Injection molding: to improve flow properties, reduce shrinkage and warpage

  • Blow molding: to improve rigidity and strength of plastic bottles and containers

  • Film production: to improve opacity, whiteness, and smoothness of plastic films

  • Pipe and profile production: to improve stiffness, impact resistance, and surface finish

  • Cable production: to improve tensile strength and flame retardancy

  • Rotational molding: to improve dimensional stability, stiffness, and impact resistance

  • Thermoforming: to improve surface finish, opacity, and whiteness

  • Automotive industry: to improve mechanical properties and reduce weight of automotive parts

  • Packaging industry: to improve stiffness, strength, and barrier properties of plastic packaging materials

  • Electrical and electronics industry: to improve strength, dimensional stability, and flame retardancy of plastic electrical and electronic components.

Loading Percentages:

In general, the loading percentage of filler masterbatches typically falls within a range of 10% to 40%. Here's a breakdown of loading percentages in filler masterbatches:

  • Plastic Extrusion (e.g., pipes, profiles, sheets):

    1. Low Loading (10%-20%): In some cases, a low loading of filler masterbatch can be used to reduce material costs without significantly compromising the mechanical properties of the plastic products.

    2. Medium Loading (20%-30%): Many plastic extrusion applications use filler masterbatches in this range to balance cost savings with maintaining essential properties.

    3. High Loading (30%-40% and above): Some non-critical applications, such as utility pipes, may use high loading percentages to achieve substantial cost reductions.

  • Blow Moulding (e.g., bottles, containers):

    1. Low to Medium Loading (10%-30%): Blow-molded products often use filler masterbatches to improve stiffness, reduce weight, and lower production costs while maintaining product quality.

  • Injection Moulding (e.g., automotive parts, consumer goods):

    1. Low to Medium Loading (10%-30%): Injection-molded parts can benefit from filler masterbatches in this range to enhance dimensional stability and reduce manufacturing costs.

  • Film and Packaging (e.g., bags, packaging films):

    1. Low Loading (10%-20%): Filler masterbatches are used to reduce film thickness, improve barrier properties, and decrease material costs.

    2. Medium Loading (20%-30%): Some films may use higher loading percentages to achieve specific properties like opacity and rigidity.

  • Wire and Cable Insulation:

    1. Medium Loading (20%-30%): Filler masterbatches are added to cable insulation compounds to improve electrical properties and reduce production costs.

  • Rubber Compounding (e.g., tires, conveyor belts):

    1. Medium Loading (20%-30%): Rubber formulations often incorporate filler masterbatches to improve wear resistance, reduce rolling resistance, and enhance cost-effectiveness.

  • Construction Materials (e.g., PVC pipes, roofing membranes):

    1. Medium to High Loading (20%-40% and above): Building materials may use higher loading percentages of filler masterbatches to meet specific structural and cost requirements.

  • Automotive Parts (e.g., interior components, under-the-hood parts):

    1. Medium Loading (20%-30%): Automotive applications often utilize filler masterbatches to reduce weight and improve dimensional stability.

  • Thermoplastic Compounds (e.g., masterbatches for colouring, UV protection):

Loading percentages can vary widely depending on the desired colour or additive effects. It can range from low to medium loading, depending on the application.






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