There are normally 4 ways in which a plastic processor can pigment his products: 1. Dry Colouring – In this process the pigments and polyolefin resin are mixed in a tumble blender for a fairly long time (10-20 mins.). The mixture is then directly extruded or moulded into the finished product by the usual processing methods. 2. Extrusion Colouring – This is an extension of the dry colouring process where the tumble mixed pigment/resin blend is extruded and pelletised. The pelletised and coloured material is then processed further into the final product by extrusion or moulding. 3. Pre-Coloured Compound – Use of pre-coloured compound, which is generally offered by the resin producers or colour compounders, is produced in an internal mixer, continuous compounder or twin screw compounding extruder. 4. Colour MASTERBATCH – Colouring through pigment concentrates (MASTERBATCH), which are available in powder or pellet form and contain a high loading of uniformly dispersed pigments in a compatible medium, is one of the most convenient method of pigmenting polyolefins. MASTERBATCHES have been found to provide good pigment dispersion, product flexibility, economy and retention of all the desirable polymer properties. The colouring cost by MASTERBATCHES will be slightly higher than Dry colouring method. The colour MASTERBATCHES are increasingly used for pigmentation of polyolefins and dominate most of the extrusion applications.
MASTERBATCH is a concentrated mixture of pigments and/or additives encapsulated during a heat process into a carrier resin which is then cooled and cut into a granular shape. The carrier resin of the MASTERBATCH is compatible with the main plastic in which it will be blended during the process, whereby the final plastic product obtains color or properties from the MASTERBATCH. MASTERBATCH allows the processor to colour polymer economically during the plastic product manufacturing process. MASTERBATCHES help to enhance the market appeal or the end-use performance of plastic products, packaging or fibers.
MASTERBATCH is preparations of organic and inorganic pigments and pigment combination, uniformly dispersed in a polyolefinic resin with a low molecular weight binder. The pigments used in our MASTERBATCHES are carefully selected to meet the Heat and Light Stability requirements of processing products. The characteristics of carrier resin/binder system are such that they improve the pigment wet-out and distribution and result in smoother processing. Depending upon the type of MASTERBATCH and the nature of pigment used, their concentration varies from 10% to 75% by weight of the composition. The pigments used in our MASTERBATCHES are carefully selected to meet the Heat and Light Stability requirements of processing plastic products.
Our MASTERBATCHES eliminate a number of problems faced by the processors in incorporating pigments into their products while providing various advantages: - MASTERBATCHES are specifically formulated for the quality conscious Plastic processors and wide usage in almost all plastics processing applications. - Our MASTERBATCHES are compatible with most of the grades of Polyethylenes and Polypropylene. We also offer MASTERBATCHES which are compatible with other polymers. - Our high strength, superior quality colour MASTERBATCHES provide improved mechanical properties, surface finish and gloss due to thorough pigment dispersion. - Ease of handling, weighing and proportionating because of the pelletised form of the MASTERBATCHES. - Flexibility in colour changes due to their wider compatibility and cleanliness. - Our MASTERBATCHES increase the production rates due to reduced filter pack clogging. - Ease of dilution and distribution because of the low viscosity of our MASTERBATCHES. - Lower space and inventory requirements of the MASTERBATCHES because of their highly concentrated form. - Our MASTERBATCHES have excellent lot-to-lot consistency. - We have wide range of colours to choose from and provide technical support on their use.
Our MASTERBATCHES are intended for direct colouring of all plastic products manufactured on a screw type plastic processing machines. Our MASTERBATCHES are successfully used in the following applications: - Blown Films - Blow & Injection Mouldings - Box Strappings - Canes 7 Straws - Cast & Oriented Films - Extrusion Coating - Fibres & Filaments - Pipes & Tubings - Reprocessed Materials - Raffia Tapes - Sheets & Profiles - Wire & Cable Coatings.
The selection of a MASTERBATCH will depend on the following questions, whether: - The product to be made in opaque, translucent or transparent. - The colour required is light, medium or dark. - Any special requirements are to be met. - The mixing efficiency of the processing machine - Thichness of the extruded/moulded product.
SPECIALITY polymers are produced by chemical grafting of reactive momomers like Maleic anhydride or Glycidyl Methacrylate and other similar materials on polyolefin. SPECIALITY POLYMERS possess superior properties than the simple polyolefin in terms of polarity, adhesion to different substrates, compatibility with reinforcements and fillers. They perform a variety of functions in different polymer systems. Speciality polymers are used as coupling agents, compatibilizers, wetting/dispersing agents, impact modifiers, scrap upgraders and chain extenders for polymer compounds. High end engineering applications demand excellent end use properties which are met only by using filled or reinforced polymer compounds. Usually, the mixing of fillers or reinforcers in polymers (typically polyolefins) is a tacky problem, caused due to the difference in polarities of the polymer matrix and the constituent fillers. Unfacilitated mixing of these two results in very poor or no adhesion, or in other words, products with very poor properties. In order to promote adhesion or bonding, SPECIALITY POLYMERS are added. The SPECIALITY POLYMERS are often made of the same polymers that constitute the target matrix, making them easy to handle and very efficient. When the adhesion promotion is required between two immiscible polymers, the same SPECIALITY POLYMER may also be incorporated as Compatibilizers. In general terms, chemical compatibilizers and coupling agents are the same materials and are popularly traded as Functionalized Polymers .
SPECIALITY POLYMERS enhance properties of polymer compounds. They are used in the following products: - White goods, - Automotive - Wire and Cables - Wood Plastics Composites - Plastics Film Industries
Our SPECIALITY POLYMERS are chemically modified polyolefines designed specifically to enlarge use of plastics materials in high performance applications. - They are polymeric in nature with flow, melting and processing characteristics similar to the respective parent polyolefins. - They have higher chemical reactivity & polarity – this makes them blendable with polar polymers like Nylons, imparting special properties to the nylon. - Acting as dispersing agents for colourants and mineral fillers and reinforcements. - Coupling agents for fillers like calcium carbonate, talc, glass fibres etc., improving mechanical properties of Nylon, PP, PC, PBT/PET compounds. - Increase in flow of filled PP compounds in injection moulding to facilitate mould filling and warpage free components. - Our SPECIALITY POLYMERS provide excellent low temperature impact strength in Nylons.
Rotogravure (roto or gravure for short) is a type of intaglio printing process, which involves engraving the image onto an image carrier. In gravure printing, the image is engraved onto a cylinder because, like offset printing and flexography, it uses a rotary printing press.
In direct gravure printing, the ink is applied directly to the cylinder and from the cylinder it is transferred to the substrate. One printing unit consists of the following components: - an engraved cylinder (also known as "gravure cylinder") whose circumference can differ according to the layout of the product being made. - an ink fountain - a doctor blade assembly - an impression roller - a dryer For indirect gravure processes, the engraved cylinder transfers ink in the desired areas to a transfer roller, and the transfer roller transfers it to the substrate.
The rotogravure printing process is the most popular printing process used in flexible-packaging manufacturing, because of its ability to print on thin film such as polyester, OPP, nylon, and PE, which come in a wide range of thicknesses, commonly 10 to 30 micrometers. Other appreciated features include: - printing cylinders that can last through large-volume runs without the image degrading - good quality image reproduction - low per-unit costs running high volume production Shortcomings of the gravure printing process include: - high start-up costs: hundreds of thousands of copies needed to make it profitable .
High Strength and Low Visocity inks - Extremely low solvent retention - Extremely stable - Excellent bond strength - High color depth and gloss - Excellent COF, rub resistance - Brilliant brightness - Excellent printability - Skin friendly.