masterbatch processing masterbatch processing masterbatch processing masterbatch processing
Applications
Black Masterbatch Compounding

Superior dispersion enhances quality and processability.

With a high surface-area-to-volume ratio, compounding black masterbatch or carbon black masterbatch requires attention to structure, fineness, porosity and surface area. Carbon black particles accumulate as a result of physical attraction, so the mixing technology needs to adequately distribute those particles to produce a consistently high-quality final product. A masterbatch is formed and then added in the formation process at a reduced amount to provide coloration, enhanced mechanical properties, UV stabilization and conductive properties.

Material characteristics

Carbon black is a material produced by the incomplete combustion of heavy petroleum products such as fluid catalytic cracking (FCC), tar, coal tar or ethylene cracking tar. Carbon black is a form of paracrystalline carbon that has a high surface-area-to-volume ratio. Subtypes include acetylene black, channel black, furnace black, lamp black and thermal black.

Carbon black masterbatch is a concentration of carbon black in a carrier or binder, usually at levels from 20% to 50% depending on the application and the particle size of the type of black used. Common polymer-carriers for the application include:

Polypropylene (PP)

Low-density and Linear low-density polyethylene (LDPE & LLDPE)

High-density polyethylene (HDPE)

Ethylene-vinyl acetate (EVA)

Polystyrene (PS)


Farrel Continuous Mixers are designed to address the many challenges of processing black masterbatch including:

  • A unique rotor geometry, specifically designed for masterbatch production, ensures optimum dispersion of the carbon black with the resin
  • Both Standard and XL rotor technologies are available for the best dispersion and processing of a variety of carbon black grades and formulations
  • Adjustable rotor speed during production as well as multiple temperature control zones and rotor cooling maintain ideal processing temperature
  • A variety of production sizes to meet large throughput requirements for economies of scale and productivity

Using black masterbatch for a variety of products

black agricultural film masterbatch processing

Common applications for black masterbatch/carbon black masterbatch include:

  • Pipes
  • Molding injection
  • General-purpose & packaging film
  • Conductives
  • Agricultural film
  • Fiber

FARREL POMINI Nominal Production Rates for Black Masterbatch Compounding

Application CP250 CP550 CP1000 CP2000 CP2500 CP4000 9UM
Line
Black Masterbatch kg/h
T p.a.
170 - 190
680 - 760
350 - 400
1,400 - 1,600
600 - 800
2,400 - 3,200
1,200 - 1,500
4,800 - 6,000
1,200 - 1,500
4,800 - 6,000
2,800 - 3,000
11,200 - 12,000
5,000 - 5,500
20,000 - 22,000

*Based on 4000 hrs per year.

Typical plant line for black masterbatch compounds

black masterbatch processing line drawing

Would you like to learn more about our process expertise with Black Masterbatch applications?

Contact us or call +1 203 736 5500 to speak with a Sales Engineer or schedule time in a Customer Demonstration Facility.

FARREL POMINI, your solutions provider.

LET OUR EFFICIENCY DRIVE YOUR SUCCESS.

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Farrel Corporation
One Farrel Boulevard
Ansonia, Connecticut 06401-1256
USA

Phone: +1 203 736 5500

Fax: +1 203 736 5580

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