Professional Documents
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and Additives
Utilization of
Color & Additive
Concentrates
Bringing life to plastics
and plastics to life.
Research studies have long
proven that a product’s
color and appearance are
key factors in a consumer’s
purchasing decision.
Unquestionably, color has
become, and will continue
to be, a critical element in
the successful marketing
of a product.
Over the years, color and plastics have forged a vitally important partnership.
Technological advances in this area have given today’s processors an endless
range of color choices and forms. Functional additives can also be incorporated
into a plastic product, improving the appearance, quality, performance, and
value of the end product.
2 fUndaMentals of Color
Clariant
Color Sells
Color Sells Clariant works to create strategic
partnerships with our customers that results in value
added contributions to their brand identity.
Following are brief descriptions of types of additives dispersed in a polymer vehicle. In addition in the case of HiFormer®
colorants and common coloring methods: They offer processors numerous benefits, Liquid Masterbatches customers experience
including the following: the following:
1. Masterbatches Solids and Liquids · Competitive operating costs · low total cost of ownership
Of all the choices available to processors · Maximum equipment utilization · reduced color change time
today for coloring polymers, masterbatches · Optimal process flexibility · high flexibility
or color concentrates are overwhelmingly · Reduced inventory costs · improved efficiency
preferred. Masterbatches are highly · Decreased lead times · low let down ratio
concentrated pelletized colorants and/or · Superior lot-to-lot consistency
3
A cost-effective
method where low
levels of colorants
are required, liquid
color is good for
delivering heat-
sensitive additives
into polymers.
Optimum choice Liquid and solid masterbatch
for injection molding.
4 Fundamentals of color
Arriving at the Optimum Choice
· Polymer type
Polymer? Color? Process?
· Polymer rheology
· Process type Solid Liquid
· Screw configuration
Process/LDR? Pump types?
· Color density / opacity
· Effect pigments FILM Most LOW LDR very LOW Long runs Shorter runs
applications 0,05–0,5% LDR few colors many color
· Frequency of color changes >1% 0,01–0,1%
3. Dry Color Clariant offers multipurpose concentrates let-down ratio of 1%, they offer a processor
An in-house process using powdered, pre- through distributors and direct sales. the following advantages:
matched colorant mixtures, it is the least · Maximum color strength
expensive coloring method. Dry color is Not suitable for critical applications or end · Critical dispersion
messy to work with, and environmental products that are for food contact, toys and · Lower coloring costs
implications must be kept in mind. medical and pharmaceutical applications. · Improved lot-to-lot consistency
· Better reproducibility from lab trial to
4. Multipurpose Concentrates 5. Single Pigment Concentrates (SPCs) production
Based on a multipurpose carrier system, SPCs contain only one pigment or one
these color concentrates are suitable for additive or one pigment and additive Clariant Masterbatches produces SPCs
use with a wide range of polymers and combination, plus polymer in a pellet form. based in polyethylene, polypropylene,
are generally available in small quantities SPCs may also be blended to produce a polyamide, polystyrene, and polyester.
from stock. They can be cost-effective custom color. They are very highly loaded
where low levels of colorant are required. and fully dispersed. With an average
5
Masterbatches
The Basics
Color concentrates are produced If you could look at a brilliantly colored beauty of the color on the one hand and
largely, but not exclusively, with plastic object under high magnification, you economy on the other. The better dispersed
pigments, dyes, and SPCs. would see that the color is not continuous, a pigment is, the less will be needed to
Pigments are highly colored but made up of many tiny dots of color, each color a given job.
bodies available as very small dot representing a particle of pigment.
particles – infinitesimally divided Normally, the eye sees the aggregate color. Most colors are matched from more than
particles. In coloring thermo- The problem in utilizing pigments is that one pigment. For example, a medium green
plastics, pigments are dispersed the particles have a tendency to clump color can be created using white, green, and
in the plastic medium. Each together to create specks, or agglomerates. yellow pigments. Every particle of each indi-
tiny particle of pigment is totally vidual pigment must be perfectly dispersed.
separated from every other Unfortunately, although a speck can be If one pigment is developed more efficiently
particle of pigment. Each is made up of hundreds of individual particles, than another, the color will not be correct.
surrounded by plastic – it contributes no more to the final color than
encapsulated within plastic or in does one of the ultimate particles. If the Perfect dispersion is especially essential
the case of liquids plastisols. speck gets big enough to be seen with the for masterbatches due to the high colorant
naked eye, it could result in a rejected piece. loading of this coloring method. This is
To use pigments efficiently, to get maximum because – in use – the concentrate is going
“value,” perfect dispersion is a must. to be diluted many times, under varying
conditions. Pigment dispersion must be
The separation of particles in a plastic or perfect, so that despite the dilution the
liquid medium is called “dispersion.” The colors remain true, and the pigments do not
achievement of perfect dispersion is the agglomerate.
6 Fundamentals of color
What makes such a compound a masterbatch?
How does a masterbatch differ from an ordinary
colored compound?
The pigment level is vastly increased, possibly 20
to 200 times. This multiple is a color concentrate.
The requisite amount of natural material is mixed with the concentrate. This is
put through a screw-based machine, and the product is uniformly colored and
perfectly color matched.
This allows the fabricator to become its own compounder and to color products
without the responsibilities of running an in-house color lab.
Yet the principle remains the same. The masterbatch manufacturer disperses,
i.e., wets out and compounds, the desired component in vast excess. The molder
or extruder acquires a reservoir of the particular materials needed. The
possibilities are endless.
7
Masterbatches
Key Terms
RENOL® High performance masterbatch Colorworks® specialized services ENIGMAtm Special effect masterbathes.
for engineering resins. for product designers, engineers and
brand managers.
8 Fundamentals of color
HiFormer® Liquid colorants Omnicolor® Universal carrier MEVOPUR® Masterbatches for
performance and flexibility. masterbatch. medical devices and pharmaceutical
applications.
9
Fundamentals of Color
Utilizing
Masterbatches
When your extruder is performing Selecting a Color scraps of metal, glass, wood, and paper, as
efficiently, it delivers uniformly Your color supplier will require the well as bath beads, threads of cloth, liquid
heated, perfectly plasticized necessary information for providing a color contents (e.g., shampoo), and photographs!
material at exactly the correct or additive concentrate sample to you. Achievement of an optimal color match
viscosity and temperature. In Discussion should include the following: will occur when a technician is provided
injection molding, this means · intended polymer with an established industry color standard,
perfectly filled, stress-free parts. · desirable let-down ratio a molded chip or existing processor
In extrusion, this means holding · color tolerances concentrate.
to perfect shapes. · part thickness
· regulatory requirements including FDA, The color matcher will need to know if the
Normally, you will be making every USDA, EU, REACH, CONEG, BgVV, JORF, color target will have matching components
effort to set up your machines NSF, JIS, JOSPHA and others molded in another shop or in different
to achieve such conditions. It is · area of end application (indoors or polymers.
significant that such conditions outdoors) UV stability is needed
are also the optimum conditions · molding conditions such as processing You will receive molded plaques and, if
for diluting concentrates and temperature, hot runner in use requested, a sample of the concentrate for
distributing them uniformly into · product certification (UL, GWI or NSF) production trial. This sample will be
the polymer matrix · finally, most important a color target or produced to the highest practical let-down
standard ratio, unless you have decided to standardize
on one ratio.
Clariant color specialists have worked with
a wide variety of color targets, including
10 Fundamentals of color
Product safety In a global
market where products are designed,
produced and sold in many parts on
the world, the demand for consumer
safety, regulatory compliants and
brand protection is rapidly increasing.
Because the cost of the raw Color Trials blow molder, or injection molder). No
materials varies, concentrates Begin by weighing out the proper amount special technique is required to properly
are priced individually after the of concentrate and natural polymer and utilize concentrates, because the operating
color matching process. mixing them together so that the conditions that will give you the best
concentrate is uniformly distributed. Weigh extrusions or best molded parts will also
your components as accurately as possible, give you the best concentrate distribution.
or work out either a volumetric or
gravimetric method or in case of Liquid Considerable technical assistance is also
Masterbatches metering by pump. The available in this field. Your concentrate
important factor is that once you establish supplier should be able to suggest starting
a mixture, you must be able to reproduce processing conditions for each material, and
that mixture exactly, as many times as your set-up people can easily work out what
necessary. is best for your particular application.
The next step is to mix the components, The color concentrate manufacturer can
using a drum tumbler, a ribbon mixer, a often put together concentrates with
paddle mixer, a double cone blender, a twin especially low viscosities that will distribute
shell blender, etc. Volumetric or gravimetric more readily.
machines operate on a continuous basis.
They are clean, accurate, and economical. Clariant is experienced with all types of
Whichever method you use, it must mix color-handling options, from feeders and
the materials uniformly and, batch by batch, mixing nozzles to gravimetric blenders.
the mixtures must be identical. We can recommend the most efficient screw
design and provide complete processing
Once the mixture is complete, it is trans- reviews including machine audits.
ported to a fabricating device (extruder,
11
Problem Solving
Dispersion & Distribution
Dispersion refers to the operation of creating the concentrate (for Step One
reference see page 6 paragraph 4). The color concentrate producer The first and usually most helpful step is raising the heat in the feed
must thoroughly mix these pigments with the plastic base, and each zone. The changes needed are not substantial, and the heat should
particle of color must be completely encapsulated in plastic. be raised gradually in increments of 5 to 10°C. The objective is to
bring the temperature of the rear feed zone above that of the rest of
If dispersion is incomplete, a defect may arise in the finished part, the machine. Molders may object on the grounds that finished part
showing as a streak of one of the individual colorants (green, white tolerances will be affected, but that is rarely the case since the
or yellow). Defects of this nature are very difficult to correct in the overall heat balance of the machine and the plasticity of the material
processor’s plant, and the concentrate should be returned to the are not disturbed adversely. Because only the feed zone temperature
concentrate producer for correction. is raised, it frequently is possible to decrease the overall temperature
of the machine.
However, in all fairness, before this action is taken please
determine whether the specks or streaks are, in fact, inherent in Step Two
the concentrate and are not dirt specks or spots of oil. Sometimes Decrease the screw return speed along as much of the cooling
a housekeeping problem is involved. portion of the cycle as possible. Target screw speed should be
approximately 40 to 60 rpm.
Distribution refers to the operation of the processor (molder or
extruder) in which the concentrates and the matrix material are These two steps should solve the greatest portion of distribution
thoroughly mixed to form a uniform color. Any failure of the problems.
concentrate and the natural resin to melt evenly and mix completely
will show up as a series of light and dark areas – usually streaks in If the situation has reached the point where incomplete distribution
the finished part. This is the problem most frequently encountered. is just short of achievement, the use of a dispersion nozzle is apt to
add the final degree of mixing needed. Be sure to also consider the
The solution frequently lies in the maximum use of the screw, following:
and the basic principle is the achievement of early melting of the · The machine should have an initial inspection to make sure all areas
contents of the screw, thereby utilizing the maximum length of are working properly.
the screw for color mixing. · A heater may be defective.
· A thermocouple may be displaced, giving erroneous readings.
12 Fundamentals of color
Usually, a minimum dwell time in a machine is needed for the In some cases, the concentrate producer can supply the concentrate
plastic material and the concentrate to be plasticized and mixed. in a smaller pellet size, thus improving the ratio of concentrate
On occasion, the following problems may be encountered: pellets to plastic pellets or increase the let down ratio for exampel
· The volume of the cavity is too great. from 3% to 4%.
· The cycle itself is too short, and the time in the cylinder is
inadequate. In any event, close communication between the masterbatch
producer and the processor will help to eliminate potential
In extreme cases of this sort, it may be necessary to transfer the distribution problems or recognize them in the sampling stages so
mold to a larger machine with a greater plasticizing capacity, or that corrective action can be taken before production quantities are
to increase the cycle time. needed.
13
Fundamentals of Color
Additive Masterbatches
Antistats Antimicrobials
Most of these additives require only small addition levels to show a high efficacy.
As a result, they need to be well dispersed in suitable carrier materials.
The same also applies for highly loaded concentrates containing flame retardant
or multicomponent additive formulations. The commonality is that all additive
types provide performance-enhancing features or protect the polymer from
environmental impact.
14 Fundamentals of color
Antistatic Agents Improved Antioxidants Heat stabilaziation Light Stabilizers For polymer
handeling. for polymers protection.
15
Fundamentals of Color
Additive Masterbatches
Antiblock Reduced adhesion to Flame retardants Reducing Antimicrobials Protecting plastic
processing equipment. combustibility of plastics. articles from deterioration.
16 Fundamentals of color
Laser Marking High-speed permanent Chemical foaming agents Nucleating Agents Influencing
printing. Weight reduction in thermal plastics. polymer properties.
17
Fundamentals of Color
Additive Masterbatches
The manufacturer of additive Interactions In recent years, HALS (hindered amine light
concentrates has the experience Most extruded or molded parts are colored stabilizers) have become the most widely
and knowledge to produce tailor- and contain combinations of pigments and used type of UV stabilizers for polyolefins,
made single or multicomponent a multitude of additives. Primary phenolic extending the life about tenfold. As opposed
masterbatches and to offer antioxidants are added to most to UV absorbers, their functionality is inde-
solutions to molders/extruders thermoplastics to reduce long-term thermal pendent of the plastic thickness. However,
and end-users. degradation. Secondary antioxidants serve HALS are highly active radical scavengers
as synergists and enhance the processing and can cause a variety of interactions with
stability, thus preventing molecular pigments, sulfur stabilizers, and halogenated
degradation. Phosphites are particularly flame retardants. Migrating additives such
effective to maintain color integrity. as antistats and antislip or antiblock
combinations require special formulation
The following are examples of significant know-how – especially in highly loaded
combinations of pigments with UV stabi concentrates.
lizers, antioxidants, and other additives:
· Automotive parts Today’s end-use requirements include fast
· Textile fibers and monofilaments static decay times in low humidity conditions,
· Stadium seats printability, biodegradability, non-corrosive-
· Crates ness, food approvals, etc.
· Refuse/storage containers
· Housings Color concentrate producers must have a
· Awnings clear understanding of the processing
· Agricultural film conditions, the type and efficacy of these
· Industrial liners additives, and their interactions in order
· Packaging to provide a sound recommendation.
· Building applications
18 Fundamentals of color
19
Regional Headquarters
Clariant Clariant SE
85 Industrial Drive BU Masterbatches
Holden, MA 01520, USA Am Unisyspark 1
Phone: +888-621-1282 65843 Sulzbach i. Ts, Germany
Phone: +508-829-6321 Phone: +49-6196-757-6276
Fax: +508-829-7887 Fax: +49-6196-757-6113
Asia/Pacific
Global HeadquarterS
www.Masterbatches.clariant.com
This information corresponds to the present state of our knowledge and is intended as a general description
MB 1015 10.13 EN
of our products and their possible applications. Clariant makes no warranties, express or implied, as to the
information’s accuracy, adequacy, sufficiency or freedom from defect and assumes no liability in connection
with any use of this information. Any user of this product is responsible for determining the suitability
of Clariant’s products for its particular application. *Nothing included in this information waives any of
Clariant’s General Terms and Conditions of Sale, which control unless it agrees otherwise in writing. Any
existing intellectual/industrial property rights must be observed. Due to possible changes in our products
and applicable national and international regulations and laws, the status of our products could change.
Material Safety Data Sheets providing safety precautions, that should be observed when handling or
storing Clariant products, are available upon request and are provided in compliance with applicable law.
You should obtain and review the applicable Material Safety Data Sheet information before handling any
of these products. For additional information, please contact Clariant.
* For sales to customers located within the United States and Canada the following applies in addition
No express or implied warranty is made of the merchantability, suitability, fitness for a particular
purpose or otherwise of any product or service. 9/2013