1. Coloring uniformity
The particle size distribution of Masterbatch largely determines the uniformity of coloring. When the particle size distribution of Masterbatch is narrow, that is, the particle size is relatively uniform, Masterbatch can be more evenly dispersed during the mixing process with the base material. Just like mixing colored beads of the same size evenly in transparent beads, the color ratio of each area can be kept consistent. In the production of plastic products, this uniform dispersion ensures that the color of the entire product is uniform, without color spots or color bands. On the contrary, if the particle size distribution is too wide, the movement and distribution of large and small particles during mixing are different. Large particles may be difficult to disperse in the base material, resulting in excessive local pigment concentration, while small particles may be over-dispersed, resulting in different shades of color, seriously affecting the appearance quality of the product.
2. Processing fluidity
The particle size distribution has a key impact on the processing fluidity of Masterbatch. Generally speaking, Masterbatch with smaller particles has better fluidity in the base material and can pass through the flow channels and molds of the processing equipment more smoothly. However, if the Masterbatch particles are all too small, agglomeration may occur due to interactions such as van der Waals forces between particles, hindering fluidity. When there are larger particles, these large particles may cause blockages in processing equipment with narrow flow channels, such as the fine gate of an injection molding machine or the die head of a blown film. For example, when producing precision plastic parts, large Masterbatch particles blocking the gate will cause incomplete part molding or surface defects, affecting production continuity and product qualification.
3. Mixing stability
The particle size distribution of Masterbatch affects the stability of its mixing with the matrix material. During storage and transportation, after Masterbatch with a reasonable particle size distribution is mixed with the matrix material, the stability of the mixture is higher due to the more balanced interaction between the particles. If the particle size distribution is unreasonable, particles of different sizes are prone to stratification or segregation when subjected to external forces, such as bumps and vibrations during transportation or stirring before processing. This unstable mixing state will cause the Masterbatch to not be evenly integrated into the base material in the subsequent processing, thus affecting the color stability of the product and possibly causing the final product to fade or discolor during use.
4. Cost and efficiency
From the perspective of cost and efficiency, the impact of particle size distribution cannot be ignored. Reasonable particle size distribution helps to improve the efficiency of Masterbatch, so that it can achieve the ideal coloring effect at a lower addition amount, thereby reducing costs. In the production process, Masterbatch with good particle size distribution can make the processing process smoother, reduce equipment blockage and downtime cleaning time caused by Masterbatch dispersion problems, and improve production efficiency. Poor particle size distribution may lead to an increase in scrap rate, increase production costs, and also reduce the overall operating efficiency of production equipment.
