7 interesting masterbatch plastic forming methods you may not know

masterbatch manufacturing

The diverse in masterbatch field is being expanded every day. A great amount of new techniques that can use masterbatch as a material has been developed, either by creating new techniques or modifying the available ones, in the way that satisfying the demands of customers and markets while helping plastic producers save cost and gain more profits.

If you are interested in this field, you may have heard about some basic well-known technologies such as injection molding, blow molding, extrusion molding and thermoforming. But have you known these following ones? Let’s take an in-depth look into 7 interesting shaping methods using master batch as one of the important materials in this article below.

How to apply masterbatch in Compression Molding method?

The mixture of plastic materials (include masterbatch) after melted by heat is poured into the mold. Molds used in this technique consists two halves that can be opened and closed vertically. The main difference of this method compared to others is that the pressure vertically instead of horizontally. By applying heat and pressure at the same time, the final products that use master batch will be shaped exactly like the mold. After being shaped, the final products will be cooled down by air. This plastic forming method is mainly used to produce plastic containers since costs for required machinery and equipment tends to be very moderate.

compression molding masterbatch method

Additionally, compression molding is also suitable and valuable in applying to compounds with superior strength such as thermosets, fiberglass and reinforced resins to manufacture detailed parts and small objects in the automotive industry.  

Functions of calendar molding using masterbatch as an important material

Calendar molding is a special masterbatch technique in which the final products, which are usually plastic sheets or films, made by passing masterbatch compound through several pairs of heating rolls.  These rolls in calendar molding are manufactured from high speed steel with roundish edges and straight cylindrical shafts, which contribute a flat, glossy and smooth surface for the final products.

calendar molding masterbatch

Advanced knowledge about masterbatch plastic forming method with Rotational Molding

Rotational molding, or in short is rotomolding, is the technique in which utilize rotational movement to coat an even layer of melted plastic to the interactive surface of the mold. By rotate the molds in multiple axes around the central hub, this allows manufacturers to form desired shapes for their products, especially for large, hollow and seamless objects such as utility carts, car parts, marine bouys, pet houses, kayaks, etc. The special point of this masterbatch technique is that it does not use the regular master batch. Instead, powdered plastic is the suitable material for this method. Since it is only appropriated to produce large objects, its ideal annual productivity is only in low to medium quantity, approximately from 25 to 10,000 products / year. 

Applying masterbatch in vacuum molding and thermoplastic shaping method

Besides the original version of thermoforming, there is another simplified masterbatch shaping method used to shape products called vacuum molding. In this method, a sheet of plastic is placed onto the mold and exposed to the heat above. Unlike the typical molds used in other methods which involves 2 halves, molds used in this molding technique only have a single opening surface. After vacuum suction is applied onto this surface, melted plastic sheet is forced against the mold, resulting in forming the wanted products.

Masterbatch using vacuum suction is suitable for thermoplastics, especially high impact polystyrene sheeting (HIPS) plastic in producing packaging or containers for any content requires being stored in hygienic containers which has the ability to retain heat and odor. Producing features for aerospace field is another application of this molding technique as it is conventional to manipulate vacuum forming for generating products form transparent materials such as acrylic masterbatches