MICROFILLER XP®

Calcium Carbonate Compound Microfiller is a unique class of compounded plastics materials designed to improve the performance and productivity of many plastics application such as Film Extrusion , Injection Moulding, Blow Moulding , Recycling and Compounding and Sheet Thermoforming Processes. For a technical description, please ask for the Product Data Sheet MICROFILLER XP Ground natural calcium carbonate CaCO 3 , in both uncoated or coated forms, is the most important mineral for the plastics industry and is the base of the “MICROFILLER” compo-sition.
The “MICROFILLER” compound contains 75% of fine ground, surface treated CaCO 3 combined with various polyolefin carrier resins (carrier: LLDPE and PS). 
Typical usage levels of the “MICROFILLER” CaCO 3 compound should be till 40 % added to PE-PP or PS.

There are at least two reasons why you should add Microfiller to the polymers:

  1. To improve the processing behaviour and modify certain properties in the finished parts.
    (Typical examples of mineral modifiers are the use of the „MICROFILLER“ in PE films for babies diapers, where they are used to provide breathability, and in the film production where the „MICROFILLER“ improves the impact strength of both LLDPE and HDPE film and sheet, increasing the tear strength and the stiffness of the film as well and increasing the seal strength, printability etc.)
  2. eduction of material costs
    Where cost reduction is the most important consideration, the „MICROFILLER “ is known as a filler and a certain volume of polymer is replaced by the more economical material. Calcium carbonate is known by its low cost as well as is characterized by the high chemical purity, high degree of whiteness, low abrasiveness (improving the lifetime of machine parts), good dispersibility and approval for food used, making it suitable for use in plastics packaging.

MICROFILLER USAGE ADVANTAGES

1. Significant Savings on Raw Material Costs :

  • depending on percentage of the “ MICROFILLER ” used (recommended usage level range is till 40%)

2. Lower Extrusion Costs :

  • It reduces energy consumption AMPS

3. Productivity Improvement :

  • Higher extrusion output
  • Lower melt viscosity pressure
  • Increase line speed
  • Better bubble stability (Film Extrusion )
  • Faster cycle time (Blow-Injection Moulding)
  • Dimensional stability increase (Blow-Injection Moulding )
  • Warping reduced (Blow-Injection Moulding)
  • Keep clean screw and head.

4. Improve Physical and Mechanical Properties:

  • Dart drop increase (Film Extrusion)
  • Elmendorf tear resistence improved (Blow-Injection Moulding)
  • Increase stiffness

5. Improvement during Converting:

  • Better printability
  • Better heat sealing / thermoforming

6. Reduce Master Batch Consumption

7. Anti-blocking Properties (Film Extrusion).

PRODUCTIVITY IMPROVEMENT

CaCO 3 conducts heat approximately 20 times faster than polymers. So a major advantage of the “MICROFILLER” is its ability to increase the thermal conductivity of the part in the production processes.

Apart from its thermal conductivity properties, it reduces the cycle times, sometimes by as much as 30% and reduces the warpage .

Due to excellent heat conductivity the “MICROFILLER” also improves the quality of the polyethylene bubble by increasing its stability, because the faster cooling means the frost line comes down, so the bubble is more stable, and further advantage for LLDPE processors, whose output is often limited by bubble stability.

Using the “MICROFILLER” means 10% to 30% less resin in the extruder going through the phase change of melting, so you save energy and the melt ends up cooler. The better melt strength (a higher melt homogenity) and the excellent cooling gives the bubble a remarkable stability even at higher outputs and line speeds.

By introducing the “MICROFILLER“ the melt pressure decreased by 16.73% , i.e. from 550 down to 458 bar.

Due to this fall of the pressure, the increase of the specific screw output and the faster cooling of the bubble, the output of the blown film line can be increased.

As the general rule, the use of 1% CaCO 3 (“MICROFILLER“) will increase the output by at least 1%. Certainly depending upon the machine specification, the production programme and the polymer blend composition of the film, this output increase could reach up to 1.5% for each percent of CaCO 3 (“MICROFILLER“)

More rapid heating and cooling with CaCO 3 means bags seal at lower temperatures and behave differently in sealing machines. Operators are used to turning up the heat to correct sealing problems, but with the high CaCO 3 levels, they may have to turn the temperature down instead of up.

The higher line speeds, increased outputs, better adhesion, easier converting, improved printability, dimensional stability (less warping and reduced shrink), increased stiffness, higher impact, faster heating of sheet and part cooling after forming, all these benefits also can be observed during Injection Moulding and Sheet Thermoforming processes.

IMPROVE PHYSICAL AND MECHANICAL PROPERTIES

If you apply from 10% to 20% of the “MICROFILLER”, your “dart drop” increases in Film Extrusion processes . The dart impact strength is commonly used as a measure of the ability of film to resist local failure in a loaded bag or package and is of the great interest in some applications, specially for all types of bags.

The “MICROFILLER“ dispersed in the film improve also the tear resistance of the HD–LDPE films, which is confirmed by the Elmendorf Tear Resistance Test.

Thanks to “MICROFILLER” you can receive the products more resistant to the stress crack in the Blow-Injection Moulding processes. The final part are stiffer and the warpage should be reduced as well as the thickness .

It is generally agreed that the presence of the „MICROFILLER“ in polyolefines improves printability, what can be verified during bag production. The Calcium Carbonate, which in the great percentage is contained in the „MICROFILLER“, creates micro-roughness of the surface, allowing better adhesion of the ink to the substrate .

Summarising the addition of the “ MICROFILLER ” to polyolefines introduces a new set of variables which affect polymer processing and physical as well as mechanical product properties.

SIGNIFICANT SAVING ON RAW MATERIAL COSTS

One of the reason of the “MICROFILLER” utilizing is the reduction of the material costs. Calcium Carbonate (CaCO 3 ) is known by its low price, so whithout any problems can replace more expensive material such as polymer, playing the basic role of the filler in the “MICROFILLER” composition.

The “MICROFILLER” provides significant raw materials savings compared to other filled compounds. 

It is well known that CaCO 3 contained in the great percentage in the „MICROFILLER“, help to disperse fine particle pigments such as TiO 2 or Carbon Black, increasing its efficacy. When CaCO 3 particles are added into the film they will contribute to the light diffraction and so increase the opacity. These two effects allow the reduction of the TiO 2 content by 20 to 30%, depending on the final opacity required.

But first of all the use of the „MICROFILLER“ in waste bags, can bring comparative advantages by reducing pigment content in colour master batches. The “MICROFILLER” is the natural whitener, so it extends and brightens pigments even if some of them, may require higher levels when used with CaCO 3 , for example red will turn pink, if the more red pigment or a darker red is not added to mask CaCO 3 .

Moreover adding higher levels of the “MICROFILLER” to film can reduce the amount of slip and antiblock additives and colourant needed, cutting costs even more.

Film producers, and specially bags manufacturers, where dart drop and tear strength are of the major importance, thanks to the “MICROFILLER“ could decide to produce thinner films with equal mechanical properties or the same thickness with much improved mechanical properties. So the improved products can be manufactured and have successfully replaced more costly ones. The “MICROFILLER“ could then help to upgrade standard resins, allowing them to compete with higher performance resins.

As a result of its characteristics the “MICROFILLER“ leads to raw material savings. Less energy is required. The ecological aspects are without any doubt in favour of the “MICROFILLER“. Moreover CaCO 3 (the “MICROFILLER“) is a sustainable raw material.

Use of the “MICROFILLER” in resin only systems can provide additional productivity and performance improvements.

The most important applications for the Microfiller in the polymer industry are:
A variety of polyolefin markets including diaper film, furniture, construction materials, automotive products, trash and garbage bags, pipe, large garbage cans, food containers, synthetic paper and bottles etc. Performance benefits such as significantly increased output (linear rate or cycles) and improvement of many physical properties are achievable.

PACKAGING

PE bag of 25 kg. Please keep in the dry place.

Why should you add our compound to the polymers?
Because you can just save 50,000 EUR a month.

CASE 1
Your production is 500t of HDPE film monthly .
You need a raw material, i.e. HDPE film to your production, which cost is close to 1.25 EUR/1kg (in other words 1,250 EUR per 1 t). Looking for your cost reduction you find up about MICROFILLER giving to you significant savings on raw material costs, so your decision to buy the Calcium Carbonate Com-pound seems to be absolutely reasonable.

PRODUCT INFORMATION “MICROFILLER XP” COMPOUND

» CHEMICAL ANALYSIS OF THE CALCIUM CARBONATE

1 CaCO3 content (%)
> 98.5
2 SiO2 (%)
< 0.10
3 MgO (%)
< 0.02
4 Al2O3 (%)
< 0.02
5 Fe2O3 (%)
< 0.05
6 Moisture (%) < 0.10

» PHYSICAL PROPERTIES OF THE MINERAL COMPONENT

2 Fineness Mean particle size (D50%) 2 μm
3 Smoothing level at 0.125mm 100
4 Absorbent in Linseed Oil (ml/100g) 34
5 Absorbent in DOP (ml/100g) 48
6 Specific gravity in water (g/cm3) 2.65
7 Bulk Density (g/cm3) 0.70
8 Whiteness (%) 96
9 Brightness (%) 95

» SPECIFIC PRODUCT DATA

1 Colour form Natural pellet
2 Density (g/ml) 1.80
3 MoiSture (%) 0.1
4 Size (mm) 3.0
5 Melt Index (g/10 min) 10-12
6 Melting Point ( O C) 120 – 130

» COMPONENTS

» CaCO3 (powder) 75%
» LLDPE (polimer/additive) 25%

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