High-concentration polypropylene color masterbatch: Is a lower addition ratio always better? Dispersion is more important

When purchasing polypropylene color masterbatches, many customers will prioritize the "addition ratio" - believing that the higher the color masterbatch concentration and the lower the addition ratio, the lower the cost. But in actual use, you will find that: some high-concentration color masterbatches, although added in small amounts, cause frequent clogging of the spinneret and breakage; while some masterbatches with an appropriate concentration but good dispersion can keep the production line running stably. What's the problem? It is likely that you only focused on the addition ratio and ignored the dispersion. Below, we will help you clarify the selection thinking from two perspectives. 

1. A low addition ratio does not necessarily mean a low overall cost.

The addition ratio of color masterbatch does indeed affect the coloring cost, but it is not the only cost factor. 

Poor dispersion of the pigment: If the color masterbatch has poor dispersion properties, the pigments are prone to form agglomerated particles in the spinning melt. These particles can clog the filter screens, accelerate the increase in component pressure, increase the breakage rate, and even cause the spinning components to be prematurely scrapped. The additional downtime for cleaning, consumption of waste fibers, and replacement of components may far exceed the cost savings achieved by "adding a little less". 

The balance between pigment concentration and processability: A high concentration of pigment granules means a higher pigment content per unit weight, which may indeed reduce the addition ratio. However, if the pigment concentration is too high, the fluidity of the pigment granules may deteriorate, and the control of the uniformity of dispersion in the spinning melt will become more difficult. If dispersion is sacrificed for the sake of "adding less", it will be a loss rather than a gain. 

II. Dispersion: An Indicator Worth Paying More Attention To Than the Addition Ratio

Since dispersion is so crucial, how should we ensure it during the procurement process? 

The supplier is requested to provide dispersion data: During the procurement process, you can ask the supplier if they have tested the dispersion of the color masterbatch. For example, this can be evaluated through tablet observation, filtration pressure value (DF value), or spinning tests. Longkou Huacai Plastic Industry Co., Ltd. specializes in the production of polypropylene color masterbatch, nylon color masterbatch, polyester color masterbatch, and non-woven fabric color masterbatch, etc. They can provide on-site color matching according to user requirements. The products have passed the SGS standard system certification and are exported to countries such as Europe and the United States. 

Pay attention to the particle size of the pigments and the matching degree of the carrier: The finer the original particle size of the pigments in the color masterbatch and the more uniform their distribution in the carrier, the better the dispersion usually is. At the same time, the higher the compatibility between the carrier resin and your polypropylene substrate, the easier it is to achieve uniform dispersion during the melt mixing process. When purchasing, you can inform the supplier of your spinning process type (such as FDY, POY, BCF) to match the appropriate carrier and dispersion system. 

Sample machine testing: Before making bulk purchases, it is recommended to request color granule samples to be tested on your own production line in a small batch. Observe the breakage rate of the filament, changes in filtration pressure, and the color uniformity of the finished fibers. If the test is smooth and there are no color spots on the fabric surface, it indicates that the dispersion meets the requirements. Then, based on the actual coloring effect, determine the final addition ratio. 

Summary and Selection Suggestions

When purchasing polypropylene color masterbatch, the following steps are recommended for confirmation: 

Prioritize assessment of dispersion: By using the dispersion data provided by the supplier or conducting your own in-machine spinning tests, confirm that the masterbatch can be uniformly dispersed under your processing conditions. 

While meeting the dispersion requirements, further optimize the addition ratio: First ensure "usable", then optimize "how much to save". 

Match the process with an appropriate concentration: For fine denier yarn or high-speed spinning, a more dispersible and moderately concentrated masterbatch can be selected; for coarse denier yarn or conventional spinning, the requirement for dispersibility is relatively relaxed. 

Longkou Huacai Plastic Industry Co., Ltd. specializes in the production of polypropylene color masterbatches, nylon color masterbatches, polyester color masterbatches, non-woven fabric color masterbatches, plastic color masterbatches, functional masterbatches, etc. We can provide on-site color matching according to customer requirements. Our products have passed the SGS standard system certification. Please feel free to send samples for testing. 

Official website: http://www.lkhcsy.com