Process upgrade of PET masterbatch production

The client is a company dedicated to producing high-quality PET (polyethylene terephthalate) masterbatch. These color masterbatch are used in products such as plastic packaging, fibers, and preforms to provide consistent color and enhanced performance for the final product. With the increasing demand for high-quality and environmentally friendly products in the market, customers have decided to upgrade their PET masterbatch production process to increase production, optimize product quality, and reduce energy consumption.

Project objectives

• Enhance production capacity: By optimizing equipment and processes, increase the production of PET masterbatch to meet the growing demand in the market.
• Improve product quality: Ensure the color uniformity and dispersion of color masterbatch to enhance the appearance and performance of downstream products.
• Improve energy efficiency: By applying energy-saving technologies, reduce energy consumption in the production process and lower operating costs.

Challenge

• Pigment dispersibility: In the production of PET masterbatch, the uniformity of pigment dispersion is crucial, as uneven dispersion can lead to inconsistent color in the final product.
• Heat sensitive material processing: PET is sensitive to temperature changes and requires precise temperature control during production to prevent material degradation or affect color quality.
• High energy consumption issue: The production process of color masterbatch includes high-temperature melting and mixing, which usually consumes high energy and requires optimization to improve energy utilization efficiency.

Solution

Industries has chosen an efficient twin-screw extruder known for its excellent mixing and dispersing capabilities, which can meet the production needs of high-quality PET masterbatch.

Key characteristics of twin-screw extruder

• Efficient mixing system: Through a specially designed screw structure, the pigment is uniformly dispersed in the PET substrate, ensuring the color consistency of the masterbatch.
• Precise temperature control system: using multi-stage temperature control technology to precisely control the temperature of each processing stage, preventing material degradation and color instability.
• Energy saving design: equipped with an energy recovery system and optimized heater design, significantly reducing energy consumption.
• Process optimization

Pre mixing process: Introducing advanced pigment pre mixing technology to ensure preliminary uniform mixing of pigments and PET raw materials before entering the extruder, improving the color consistency of the final product.
Automated control system: An automated production control system has been installed to monitor and adjust key process parameters in real-time, such as temperature, pressure, and screw speed, to ensure consistent quality of each batch of products.
Cooling and granulation system upgrade: The cooling and granulation equipment has been upgraded to ensure uniform cooling speed of color masterbatch, avoiding particle deformation or quality fluctuations caused by uneven cooling.

result

• Improved production capacity: Through equipment and process optimization, the output of PET masterbatch has increased by 35%, successfully meeting the growing market demand.
• Product quality improvement: The color uniformity and dispersion of color masterbatch have been significantly improved, resulting in improved product quality for downstream customers and more positive market feedback.
• Energy cost reduction: The optimized production line has reduced energy consumption by 20%, saving customers approximately $100000 in energy costs annually.

Sustainable production: By improving production processes and equipment, customers not only enhance product quality and production efficiency, but also reduce carbon emissions, helping the company achieve its environmental goals.
The successful implementation of this project has further enhanced the customer's competitiveness in the PET masterbatch market, and has also made significant contributions to the company's sustainable development and cost control.