Filler Masterbatch Compounding
Filler masterbatch is a concentrate of CaCO₃, talc or BaSO₄ in a PP or PE carrier. We design the line around your output, formula and end use: from 85% loading for injection moulding to film-grade dispersion without fish-eyes.
- CaCO₃
- Talc
- BaSO₄
- PP / PE carrier
- Typical filler loading
- 75–85%
- SAT110 + underwater pelletizing, PP + CaCO₃
- 2,500–4,000kg/h
- Barrel life vs. standard bi-metallic
- 2–3×
- SAT-T triple screw vs. twin screw of the same size
- +30–50%
Formula & processing challenges
Your machine configuration must adapt to the rheology of high-loading formulations. Each component brings its own problem.
Filler · CaCO₃ / talc
75–85%Extreme abrasion; low bulk density causes feeding bottlenecks.
Cr26MoV solid alloy liners as standard; CWS series twin screw side feeders for de-aeration.
Carrier · PP / PE
10–20%High-MFI carriers can cause surging or unstable pressure.
Screw geometry that keeps conveying stable even with low-viscosity melts.
Additives · wax
2–5%Excess lubricant can cause screw slippage and output loss.
Grooved feed bushes that maximise friction and bite.
A liner you wear down, not through
A standard bi-metallic barrel has a 1–2 mm alloy layer and is scrapped once it is worn through. In the melting and mixing zones we fit integral solid Cr26MoV liners, more than 10 mm thick at HRC 60+, and screw elements in W6Mo5Cr4V2 high-speed tool steel.
Under 80% CaCO₃, barrel life is typically 2–3 times that of a bi-metallic barrel, with fewer replacements and less hidden downtime.
Standard bi-metallic
Scrapped once the layer is worn through.
USEON solid Cr26MoV liner
Integral liner in the melting and mixing zones. 2–3× life under 80% CaCO₃.
Application-specific quality control
Different end uses set different extrusion priorities.
Film & packaging · blown film
- Critical metric
- Zero fish-eyes, high dispersion
- USEON edge
- 52:1 L/D and a high-vacuum vent in zone 10 for micron-level dispersion in thin film.
Raffia & woven sacks
- Critical metric
- High tensile strength, no breakage
- USEON edge
- Gentle shear profiles preserve polymer chain length and the strength of the yarn.
Injection moulding
- Critical metric
- Cost reduction, maximum loading
- USEON edge
- Side feeding pushes CaCO₃ loading to 85% and minimises raw material cost.
Optimized processing flow
Our standard procedure, drawn along the barrel. Resin goes in at the throat; the powder joins the melt from the side.
- 1
Premixing
Even with split feeding, premixing the additives prevents segregation.
Reduces dust at the feeder by 30%.
- 2
Force feeding & de-aeration
High-loading powders carry a lot of air. The side force feeder builds pressure while its back-venting channels let the air out.
This is what prevents “vent flooding”.
- 3
Compounding
Melting and dispersion in the SAT / SAT-T extruder. Multi-stage kneading blocks break down agglomerates.
- 4
Vacuum venting
A high-vacuum system removes moisture and volatiles for dense, glossy pellets.
Non-negotiable for blown film grades.
- 5
Pelletizing
Water ring pelletizing: the robust, economic standard for PE / PP fillers. Underwater pelletizing for lines above 2 t/h that need full automation.
Flexible feeding configurations
Two proven feeding systems, chosen by budget and automation level.
Economic premixing system
Best for: Start-ups or small batches with frequent formula changes.
- Weighing
- High-speed mixer 5–10 min
- Screw loader
- Volumetric feeder
- Main throat
- The mixer coats the filler before extrusion.
- Our screw profile prevents the premix from segregating in the hopper.
High-precision loss-in-weight system · split feeding
Best for: 24/7 continuous production with strict formula accuracy.
- Vacuum loaders
- Storage buffers
- LIW: resin → main throat
- LIW: powder → side feeder
- Fully automatic closed-loop control removes human error.
- CWS series side force feeders mechanically de-aerate the powder.
Machine selection guide
According to your application and output, there are three routes.
SAT twin screw
Proven reliability, ease of operation and excellent ROI.
Ideal forStandard 75–85% filler masterbatch for injection, blown film and pipes.
250–1,600 kg/h
SAT-T triple screw
Higher shear intensity and surface area: 30–50% more output than a twin screw of the same size, at the same energy.
Ideal forHigh-volume production that needs superior dispersion.
400–1,100 kg/h
Kneader + extruder
Intensive mixing in a kneader, pressure build-up in a single or twin screw extruder.
Ideal forFilling levels above 85% or additives that are hard to disperse.
600–1,700 kg/h
| Model | Diameter (mm) | Max. Speed (rpm) | Motor (kW) | L/D | Output (kg/h) |
|---|---|---|---|---|---|
| SAT52 | 51.4 | 800 | 110 | 48–52 | 250–350 |
| SAT65 | 62.4 | 800 | 160 | 48–52 | 450–600 |
| SAT75 | 71.4 | 800 | 250 | 48–52 | 700–900 |
| SAT95 | 93 | 600 | 600 | 48–52 | 1200–1600 |
| Model | Diameter (mm) | Max. Speed (rpm) | Motor (kW) | L/D | Output (kg/h) |
|---|---|---|---|---|---|
| SAT-T52 | 51.4 | 600 | 110 | 44–48 | 400–500 |
| SAT-T65 | 62.4 | 600 | 160 | 44–48 | 600–800 |
| SAT-T75 | 71.4 | 600 | 250 | 44–48 | 900–1100 |
| Model | Kneader Volume (Liter) | Screw Diameter (mm) | Screw Speed (rpm) | Motor (kW) | Output (kg/h) |
|---|---|---|---|---|---|
| K75-TDD150 | 75 | 150 | 75 | 110/75 | 600–700 |
| K110-TDD180 | 110 | 180 | 75 | 160/90 | 900–1100 |
| Model | Kneader Volume (Liter) | Screw Diameter (mm) | Screw Speed (rpm) | Motor (kW) | Output (kg/h) |
|---|---|---|---|---|---|
| K75-SAT75 | 75 | 71.4 | 600 | 110/132 | 800–900 |
| K110-SAT95 | 110 | 93 | 400 | 160/200 | 1500–1700 |
Output depends on filler type, mesh, loading and pelletizing. Co-rotating Twin Screw Extruder · SAT-T Parallel Triple Screw Extruder · Single Screw Extruder
Project · South America
75% CaCO₃ at 650–750 kg/h, pellets below 150 ppm
A polyolefin compounder needed a turnkey line for a new 75% CaCO₃ formulation, with dust control, stable feeding and dry pellets. FAT ran the whole line, from powder feeding to big-bag weighing.
- Extruder
- SAT75 · L/D 60
- Drive
- 250 kW · 600 rpm
- Pelletizing
- WRP800 water ring
- Moisture
- < 150 ppm
Two L/D 8 forced side feeders add the CaCO₃ in stages after the resin has melted.
A melt pump before the water ring die evens out surging.
Centrifugal dewatering, then a dehumidifying dryer and hot-air silo.
Output reached the 650–750 kg/h target; uniform pellets without agglomeration.
Filler masterbatch lines we have delivered
From a 250 kg/h SAT52 to a 4 t/h SAT110. Sorted by output.
| Line | Formula | Output | Pelletizing |
|---|---|---|---|
| SAT110 twin screwL/D 56 · melt pump | PP + CaCO₃ | 2,500–4,000 kg/h | Underwater |
| SAT-T75 triple screw | PE/PP + CaCO₃ up to 85% | 2,000–2,500 kg/h | Water ring |
| SAT-T75 triple screwFiller MB & bioplastic | Filler masterbatch | 500–1,500 kg/h | Air-cooling strand |
| SAT75 · Saudi ArabiaL/D 52 · X-type LIW powder feeder | PP homopolymer + 70% CaCO₃ | 900–1,000 kg/h | Water ring WRP1000 |
| PE + CaCO₃ line | PE + CaCO₃ | 500–900 kg/h | Water ring |
| SAT75–TDD180R · China | PE filler | 800 kg/h | — |
| SAT75 · South AmericaL/D 60 · featured above | PP/PE + 75% CaCO₃ | 650–750 kg/h | Water ring WRP800 |
| SAT-75 · IndiaLoss-in-weight split feeding | PP filler | 700 kg/h | — |
| SAT52 · 90 kW | HDPE (MFI 0.35) + up to 65% CaCO₃, 8000 mesh | 250 kg/h | Water-cooling strand |
| SAT-T75 triple screw · Middle EastL/D 52 · 250 kW · 600 rpm | PE/PP + 82% filler | — | Water ring |
Also delivered: two SAT65 lines for PP + CaCO₃, one with water ring and one with water-cooling strand pelletizing. SAT65 Twin Screw Extruder with Water Ring Pelletizer for PP+CaCO3 Filler Masterbatch · SAT65 Twin Screw Extruder with Water Cooling Strand Pelletizer for PP+CaCO3 Filler Masterbatch
FAQ
Wear, output, vent flooding, fish-eyes, talc and service.
You emphasize wear resistance. How long does it actually last compared to standard bi-metallic barrels?
Standard bi-metallic barrels typically have a thin alloy layer (1-2mm) that is scrapped once worn through. For abrasive filler masterbatch, USEON utilizes integral solid Cr26MoV alloy liners (Thickness >10mm, Hardness HRC 60+) in the melting and mixing zones. Under harsh 80% CaCO₃ conditions, our barrel lifespan is typically 2-3 times longer than standard bi-metallic options, significantly reducing your hidden downtime costs for replacements.
I'm struggling with output on my current twin screw. Does the Triple Screw (SAT-T) really help?
Absolutely. The Triple Screw extruder features three intermeshing zones arranged in a flat line, doubling the shear area of a twin screw. This implies it can achieve better plasticization at a shorter L/D ratio and lower temperature. Field data shows that when producing high-loading filler masterbatch, the SAT-T series delivers 30-50% higher yield than a twin screw of the same size, with lower Specific Energy, making it especially suitable for low-margin bulk filler production.
How do you handle "vent flooding" or feeding issues when running 85% ultra-high loading?
This is a typical "powder air entrapment" issue. Fine powders contain significant air that forms an air lock if fed directly into the main throat. Our solution is:
- Adopt a split feeding strategy, feeding the majority of the powder via a CWS twin screw side feeder;
- The side feeder features a special mechanical Back-venting design, allowing air to be expelled in reverse while the powder is forced in. This is the key to achieving 85% loading.
For blown film grade masterbatch, how do you ensure dispersion and minimize fish-eyes?
Fish-eyes usually stem from filler agglomeration or uneven carrier plasticization. Beyond ensuring sufficient torque hardware-wise, we focus more on screw configuration design. We recommend a high L/D ratio of 52:1 with more than 3 sets of staggered kneading blocks. Meanwhile, the high-vacuum degassing system in Zone 10 thoroughly removes trace moisture and volatiles, which is the core guarantee for preventing bubble breaks in blown film.
Can your machines handle Talc filler? Talc is very light and hard to feed.
Talc has an extremely low bulk density (0.3-0.5 g/cm³), which indeed challenges the feeding system. We equip our lines with dedicated force feeders or side feeders with degassing functions specifically for Talc. Our field cases prove that with these optimizations, even 3000-mesh ultrafine Talc can be produced stably at high loading levels.
Equipment shouldn't just be easy to use, but also easy to maintain. How is your after-sales service?
We understand the cost of downtime. USEON's equipment adopts a standardized modular design, with highly interchangeable spare parts (such as screw elements and heaters). We have service hubs in key global markets and offer remote PLC diagnostic services. We may identify the fault via remote data analysis before an engineer even arrives at the site, helping you resume production quickly.
Guides and equipment
Know How · Filler masterbatch
PP + 80–85% Ultra-High Filler Masterbatch: An Engineering Deep Dive into Stable High-Throughput Compounding
Powder, split feeding, why L/D 52 matters for PP, and degassing above 80% loading.
Read the guide Related
Know HowPolypropylene (PP) Compounding & Extrusion Guide – Manufacturing, Processing & Recycling
Fillers, reinforcement and recycling of PP.
Know HowPE Compounding, Extrusion & Pelletizing: Applications, Formulations and Extruder Solutions
Applications, formulations and extruder solutions for PE.
EquipmentSAT-T Parallel Triple Screw Extruder
Three screws in a line for high-filler output.
PelletizingWater Ring Pelletizing System
Die-face cutting for heavily filled PE / PP.
Get a quote
Tell us the filler, its mesh and loading, the carrier and the end product. We size the feeding, the extruder and the pelletizing together. Trials with your formulation can run on our lab line before you order.
- 01Formula, loading & end use
- 02Feeding, extruder & pelletizing
- 03Lab trial with your formulation, on request
Souder Chen
Head of Compounding Division
With USEON since 2008. Twin screw compounding, devolatilization and recycling lines.