COLOUR AND ADDITIVES MASTER BATCHES
[EIRI/EDPR/1616] J.C.: 417INR, 417US$
INTRODUCTION
As the name Suggests the predispersed colors or color concentrates contain a high ropertion (20-50% or even more) of pigment by weight uniformly dispersed in a suitable carrier resin. The carrier resin may be a liquid or solid. In the former case the product is a liquid dispersion while in the latter case the product is known as solid predispered colour. Liquid dispersions may be available as low viscosity materials for plastisols, or high viscosity pastes for thermoplastics. Solid concentrates in the form of powders they are suitable for use in powder resins. These concentrates are usually marketed for specific or a group of related plastics. Some so called universal dispersions are also available in the market.
The carrier resin is selected upon the type of polymer to be processed. Concentrates, when added to the base polymer (let down resin) in specified proportion, give the desired quantity of the colour in the finished product for the desired application the simplest example is that of carbon black masterbatch for polyethene. A concentrate containing 25% carbon black in a suitable grade of polyethene is formulated. This when added in 10% proportion (10 parts of concentrate + 90 parts of natural PE)gives 2.5% carbon black in the finished product eg. polytheylene film. The carrier may generally be a mixture of one or more polymers with one or more surfactants. The carrier is usually other than the plastic to be coloured. Low melting polyamides have excellent pigment dispersion characteristics and hence are suitable for the job as a carrier. Ethylene vinyl acetate and LDPE are often used as dispersion media in predispersed colouts which are to be used for define resins due to their better dispersion properties, capacity for high pigment loadings and compatibility with a variety of other resins. For solution vinyl coatings a co-polymer resin is frequently used which provided high shear.
Polymer granulates with a high percentage of additives, higher than in the end use, are called masterbatch. In later production steps, such as injection moulding, film or fibre production, those granulates are mixed with the raw polymer for colouring or the targeted modification of certain properties.
Advantages: In comparison to pastes, powders or fluid additives, using masterbatch increases the process stability. The reason lies in the exactly defined pigment quantity in each granulate. Additionally: Since there is no handling of large powder masses and therefore the environment and the work station are not being polluted, masterbatch is regarded to be a very good processing material.
COST ESTIMATION
Plant Capacity 4.00 Ton/Day
Land & Building (1500 Sq.Mtr) Rs. 2.12 Cr
Plant & Machinery Rs.55.00 Lacs
W.C. for 3 Months Rs.2.76 Cr
Total Capital Investment Rs. 5.53 Cr
Rate of Return 37%
Break Even Point 40%
CONTENTS
INTRODUCTION
USES AND APPLICATIONS
PROPERTIES
COMPATIBILITY OF COLOUR CONCENTRATES
TESTING OF PIGMENT DISPERSIONS
SELECTION OF COLOURANTS
FACTORS WHICH AFFECT SELECTION OF COLOURANT
B.I.S. SPECIFICATIONS
RAW MATERIALS
COLOURANTS FOR POLYETHYLENE:-
INORGANIC PIGMENTS:-
INORGANIC PIGMENTS SUITABLE FOR POLYETHYLENE ARE GIVEN IN THE FOLLOWING LIST:
ORGANIC COLORANTS
COLOURANTS FOR VINYL PLASTICS
FLEXIBLE PVC
INORGANIC COLORANTS
ORGANIC PIGMENTS
RIGID PVC
SOME IMPORTANT ORGANIC PIGMENTS SUITABLE FOR RIGID PVC ARE GIVEN BELOW:
COLOURANTS FOR ABS
SELECTION OF COLORANTS
INORGANIC PIGMENTS
ORGANIC COLORANTS
COLOURANTS FOR NYLON
COMPOUNDING & PROCESSING CONSIDERATIONS
INORGANIC PIGMENTS
ORGANIC COLORANTS
COLORANTS FOR POLYPROPYLENE
COLORANTS
IMPORTANT ORGANIC PIGMENTS SUITABLE FOR POLYPROPYLENE ARE GIVEN BELOW:
COLOUR COMPOUNDING PROCESSING & EQUIPMENT
DISPERSION OF PIGMENTS & COMPOUNDING EQUIPMENTS
(I) COLOR DRY BLEND
(II) PIGMENT PLSDYIVIDER PASTE
(III) COMPOUNDED COLORS
(IV) PIGMENT CONCENTRATES
METHODS OF PIGMENT DISPERSION
THERE ARE THREE BASIC DISPERSION PROCESSES FOR PIGMENT PLASTIC SYSTEMS:
DRY BLEND DISPERSION
MELT SHEAR DISPERSION
LIQUID DISPERSION
COMPOUNDING EQUIPMENTS
DRY BLENDING
CONTINUOUS MIXERS
MILLING MACHINES & INTERNAL INTENSIVE MIXERS
ROLL-MILLS
EXTRUDERS
SINGLE SCREW EXTRUDERS
COMPOUND-EXTRUDER
TWIN-SCREW EXTRUDER
INJECTION MOLDING MACHINE
ON THE MACHINE COMPOUNDING
MARKET POSITION OF MASTERBATCHES
HOW BIG IS THE MASTERBATCH MARKET IN INDIA ?
EXPORTS GREW BY 35% FOR THE YEAR.
MASTERBATCH MAKERS EXPANDING IN INDIA
GROWTH AND PROSPECT OF PLASTIC INDUSTRY IN INDIA
INDUSTRIAL POLICY
STRUCTURE OF PLASTIC INDUSTRY
GROWTH PROSPECTS – 2014-2015
EMPLOYMENT GENERATION POTENTIAL
PROFILE OF PLASTIC RECYCLING INDUSTRY IN INDIA
STATUS OF POLYMER (PLASTIC) INDUSTRY
POLYMERS (PLASTIC) DEMAND GROWTH IN INDIA
PRESENT MANUFACTURERS/SUPPLIERS OF COLOUR MASTER BATCHES
ANTISTATIC MASTERBATCHES
USES & DOSAGE:
FEATURES;
PACKING & STORAGE;
BENEFITS OF MASTERBATCHES
THE BENEFITS CAN BE SUMMARIZED AS FOLLOWS:
TYPES OF MASTERBATCHES
GENERAL FORMULATION OF MASTERBATCHES
FORMULATIONS
PLASTIC FILLER GRANULES (PP):-
FORMULATION - 1
FORMULATION - 2
1) FORMULATION
COLOURED MASTERBATCH FOR LDPE
1) FORMULATION
COLOUR MASTERBATCH FOR PVC
1) FORMULATION
COLOUR MASTERBATCH FOR PVC
1) FORMULATION
COLOUR MASTER BATCH FOR POLYPROPYLENE
1) FORMULATION
MASTER BATCH FOR ABS
1) FORMULATION
EVA BASED MASTERBATCH
BLACK MASTERBATCH FOR EPDM
PVC GRADE MASTERBATCHES FOR RIGID APPLICATION
PVC GRADE MASTERBATCHES FOR FLEXIBLE APPLICATION
COLOUR MASTERBATCHES FOR LLDPE
FORMULA-1
FORMULA-2
HDPE BASED MASTERBATCHES
FORMULATION OF ADDITIVE MASTERBATCHES (UV MASTERBATCH)
FORMULA-1
FORMULATION OF COLOUR MASTERBATCH FOR PVC USED IN WIRE & CABLE INDUSTRIES
FORMULATION OF COLOUR MASTERBATCH FOR PVC WIRE & CABLE (EVA GRADE)
PROCESS OF MANUFACTURE
EXTRUDING & GRANULATION
MIXING AND COMPUNDING METHOD OF MASTERBATCHES
CARRIER MATERIAL
LET DOWN RATIO
DISPERSION
PROCESSING
METHODS OF PRODUCING MASTERBATCHES
DISPERSIVE & DISTRIBUTIVE MIXING
SINGLE-STAGE PROCESS
TWO-STAGE PROCESS
PLASTIC TRANSPARENT GRANULES
FOR SHOE LIGHTING SYSTEMS
RAW MATERIALS:-
PLASTICIZER:-
SOLVENTS:-
AROMATICS:-
HIGHER ALCOHOLS:-
CHLORINATED HYDROCARBONS:-
LUBRICANTS:-
COMPOUNDING FORMULATION:-
ANTISTATIC AGENTS:-
GENERAL GUIDELINES FOR INJECTION MOULDING OF SAN
THE GENERAL GUIDELINES ARE :
PROCESS OF COMPOUNDING:-
STEPS:-
MANUFACTURING DIAGRAM
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
TALC
DIOCTYL PHTHALATE
ANTIOXIDANT
POLYPROPYLENE
CALCIUM CARBONATE
ZINC OXIDE
SUPPLIERES OF PLANT AND MACHINERY
EXTRUDER
PLASTIC MIXER
PELLETIZER
SCRAP GRINDER
AIR BLOWERS
WEIGHING MACHINES
FILLING MACHINE
LABORATORY TESTING EQUIPMENTS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)