BLENDING · FILLERS · REINFORCEMENT

Masterbatch and Polymer Compounding Lines

Configurable twin-screw lines for colour, flame-retardant, functional, filler and fibre-reinforced compounds.

Processing challenge

Compounding requires controlled feeding, dispersion and temperature management while maintaining stable throughput and pellet quality. High filler or fibre loadings increase torque, wear and feeding demands.

Recommended equipment approach

SJSH or DY co-rotating twin-screw extruders with main and side feeding, atmospheric or vacuum venting and a pelletizing system selected for the formulation.

Typical materials

PP, PE, PS, ABS, PA, PC and polyester systems
Calcium carbonate, talc and other mineral fillers
Glass or carbon fibre
Colour and functional additives

Pelletizing and downstream

Water-cooled strand, air-cooled strand or chain, hot-face and water-ring methods are available in the catalogue.

Information required for quotation

Base resin and grade
Additive, filler or fibre percentages
Required output and pellet specification
Bulk density and feeding method
Water sensitivity and colour-change frequency

Line layouts and output

Masterbatch and compounding work is normally built on one of three pelletizing routes. The choice follows the additive, the pellet you need and whether the compound can touch water.

Strand pelletizing — filled, blended and fibre-reinforced compounds

Flow diagram of a compounding and strand pelletizing line for fillers, polymer blending and fibre reinforcement — 1 high-speed mixer, 2 solids conveyor, 3 main feeder, 4 SJSH twin-screw extruder, 5 water trough, 6 air knife, 7 pelletizer, 8 product container.

The standard route for glass- and carbon-fibre reinforcement, PC+ABS and similar alloys, high-concentration colour masterbatch, flame-retardant and functional masterbatch, and cable insulation and sheathing compounds.

Air-cooled hot-face pelletizing — heat-sensitive and lightly filled masterbatch

Flow diagram of a twin-screw air-cooled hot-face cutting pelletizing system — 1 metering feeder, 2 twin-screw extruder, 3 air-cooled hot-face pelletizer, 4 cyclones, 5 vibrating sieve.

Used for reinforcing modification of PE and EVA with calcium carbonate, talc, titanium dioxide and carbon black; starch-based degradable masterbatch; and flame-retardant masterbatch with antimony trioxide, magnesium hydroxide or aluminium hydroxide.

Water-ring hot-face pelletizing — filled systems at higher output

Flow diagram of a water-ring hot-face pelletizing line for filled systems and polymer blends — 1 high-speed mixer, 2 main feeder, 3 side feeder, 4 SJSH twin-screw extruder, 5 water-ring granulator, 6 centrifugal dewatering, 7 vibrating sieve, 8 product container.

Suited to colour concentrates, flame-retardant masterbatch, TPR and TPU elastomers, EVA and hot-melt adhesives, and PPR or crosslinked-pipe compounds.

Reference output by masterbatch type

Type	20	35	50	65A	75A	95	132
Colour masterbatch	2–10	30–50	80–150	150–250	250–350	500–750	500–1100
Black masterbatch (carbon black)	2–8	30–40	50–100	150–220	220–320	400–700	600–1100
Flame-retardant masterbatch	2–10	30–60	100–180	200–300	350–450	800–1100	1000–1800
Degradable (starch) masterbatch	2–10	30–50	90–150	150–200	200–350	600–800	600–1200
Mineral-filled compound	2–10	30–60	100–200	200–400	300–550	700–1000	1100–1800
Glass- or carbon-fibre reinforced	1–8	30–80	100–180	180–300	250–450	550–900	900–1800
Polymer blending and alloying	2–10	25–60	80–180	160–250	300–400	600–1000	800–1800

Output in kg/h by SJSH screw size in mm. Catalog reference values — indicative and formulation-dependent.