1. Project Background
The client is a leading manufacturer of PVC pipes and plastic products in Tanzania. In plastic processing, untreated Ground Calcium Carbonate (GCC) often has poor compatibility with polymer matrices. This incompatibility can lead to decreased mechanical properties and poor processing fluidity in the pipes.
To reduce raw material costs and improve product toughness, the client introduced the Epic Powder Three-Roller Coating Machine. Their objective was to perform surface activation on the calcium carbonate using stearic acid. This process transforms the powder from hydrophilic to lipophilic, ensuring better integration with plastic resins.
2. Technical Solution: Epic Powder Three-Roller Coating System for Calcium Carbonate Coating
The three-roller coating machine is one of the most effective solutions for the surface treatment of calcium carbonate, especially for plastic fillers.
Core Equipment Advantages:
- High Coating Coverage: The triangular coating zone formed by the three rollers provides powerful shear forces. This ensures that the stearic acid forms a uniform monomolecular layer on the particle surfaces. Activation rates typically exceed 98%.
- Continuous Production: Unlike traditional batch coating methods, this machine supports 24/7 continuous operation. This significantly boosts overall production efficiency.
- Precise Temperature Control: The system includes integrated heating and cooling. Stearic acid melts at the ideal temperature and mixes thoroughly with the powder. This prevents additive waste and local clumping.
3. Processing Parameters & Results
The production line successfully achieved stable operation with the following parameters:
4. Key Outcomes
- Superior Hydrophobicity: The treated powder floats completely on water. This proves that the surface has been successfully coated with lipophilic groups.
- Reduced Oil Absorption: The process effectively lowers the oil absorption value of the calcium carbonate. This reduces the amount of plasticizer needed during downstream plastic processing.
- Enhanced Dispersibility: During PVC pipe extrusion, the modified powder distributes evenly. This significantly improves the tensile strength and impact resistance of the final pipes.
- Stable Output: The system maintains a steady capacity of 300-500 kg/h. This perfectly matches the requirements of the client’s medium-scale production lines.