Compounding and Masterbatch optimisation
Optimisation of the compounding process allows achieving the optimal balance between production efficiency and material quality, the main challenge faced by compounders and masterbatch companies.
AIMPLAS has over 25 years of experience in the advanced formulation of plastic materials. Our in-depth knowledge of the compounding process has enabled us to specialise in the evaluation and optimisation of compounding and masterbatch process, helping companies improve their production and quality.
Common Problems We Solve
- Insufficient Dispersion: Difficulties in properly incorporating pigments such as carbon black or titanium dioxide, as well as nanofillers (CNT, graphene, nanoclays, etc.). We assess working conditions and redesign screws to enhance dispersion.
- Inefficient Fibre performance: Issues with the correct fibres integration into the polymer matrix and its length, affecting material quality and mechanical properties.
- Production Limitations and Bottlenecks: Identifying restrictions that reduce production capacity, such as inefficient peripheral equipment, and optimising process parameters to increase output.
- High Energy Consumption: Optimising process conditions and feeding strategies to reduce specific energy consumption (SEI/SME) and improve efficiency.
- Recycling and Integration of New Materials: Adapting processes to recycled or bio-based materials, or regulatory-driven changes, which are typically more challenging to process (sensitivity) and handle (formats).
Audits to Optimise the Compounding Process
AIMPLAS experts can conduct on-site technological audits and advanced process simulations to evaluate and optimise compound production under both real and virtual conditions.
Our approach includes:
- Evaluation of Screw Design and Configuration: Selecting and adjusting mixing elements to improve dispersion and energy efficiency.
- Process Simulation for Data-Driven Decision Making: Using advanced simulation tools to predict:
- Residence time and shear distribution.
- Material flow, melt temperatures, and pressures.
- The impact of screw design modifications on dispersion and production capacity.
- Improvements in degassing and the removal of volatiles/odours.
- KPI-Based Evaluation: Using key performance indicators to measure improvements, such as:
- Specific Energy Consumption (SEC) [kWh/kg]: Assessing energy efficiency and adjusting quality.
- Production Increase [%]: Quantifying productivity gains.
- Dispersion Quality (MI, Colour Consistency, Microscopic Analysis): Ensuring compliance with quality standards.
- Scrap Reduction [%]: Evaluating the reduction of production rejects.
Thanks to our extensive expertise in co-rotating twin-screw extrusion, combined with advanced process simulation, we provide key technical insights to enhance efficiency, quality, and profitability in compound production.
