Application · Plastic Masterbatch
CaCO3 Filler Masterbatch Line: 85–90% Filling Recipe & Equipment
Calcium carbonate is the cheapest thing you can put in a bag and the hardest to keep in suspension. The line is built around activation, feeder discipline and a wear package — not around motor size. A reference caco3 filler masterbatch page from Kerke.
CaCO3 Filler Masterbatch Line — workshop photo 1, Kerke workshop, Nanjing
CaCO3 Filler Masterbatch Line — workshop photo 2, Kerke workshop, Nanjing
CaCO3 Filler Masterbatch Line — workshop photo 3, Kerke workshop, Nanjing
CaCO3 Filler Masterbatch Line — workshop photo 4, Kerke workshop, Nanjing
CaCO3 Filler Masterbatch Line — workshop photo 5, Kerke workshop, Nanjing
CaCO3 Filler Masterbatch Line — workshop photo 6, Kerke workshop, NanjingQuick answer
CaCO3 filler masterbatch is produced at 85–90% loading on a two-stage KTE/SE line, with stearic-acid-coated ground calcium carbonate, a PE wax dispersant and L/D 48–52. Typical output 300–1,500 kg/h for film and injection grades.
Workshop photos and a running video — shot on our own lines, not stock images.
What sets the limit
Coated CaCO3 is fed by a twin-screw gravimetric feeder to avoid bridging. The first stage melts and disperses; the second stage builds pressure for the die at low shear, which keeps the filler from degrading the polymer and stabilises output.
| Parameter | Value / range |
|---|---|
| CaCO3 grade | Coated GCC, 1,250–2,500 mesh |
| Loading | 85–90% |
| L/D | 48–52 |
| Temperature | 160–195 °C, die 180 °C |
| Output (reference) | 300–1,500 kg/h |
| Model | KTE/SE-75/180, KTE/SE-95/200 |
Output figures are measured on the reference material stated above. Filler grade, bulk density and moisture move output by ±15% — that is why every quotation we issue is tied to a trial report.
Process flow, step by step
- FeedingLoss-in-weight dosing of polymer and filler; side feeder or liquid injection where the formulation needs it.
- Melting and dispersingScrew geometry with 45°/90° kneading blocks; barrel profile 160–195 °C, die 180 °C.
- DevolatilizationVacuum vent at −0.06 to −0.09 MPa removes moisture and volatiles before the die.
- Pressure build-upThrottle or discharge section stabilises die pressure; a melt pump where gauge control matters.
- Pelletizing and packingdie-face or strand pelletizing, see the pelletizing page; then centrifugal dryer, vibrating screen and bagging.
Equipment configuration
| Stage | Equipment | Why this choice |
|---|---|---|
| Main machine | Co-Rotating Twin Screw Extruder | Architecture follows the filling level and the mixing duty, not the required tonnage. |
| Screw geometry | Building-block elements, W6Mo5Cr4V2, bimetallic liner | Wear package for abrasive filler; mixing blocks only where dispersion demands them. |
| Feeding | Loss-in-weight feeder, side feeder where needed | Recipe accuracy: ±0.5% short term on the weighed component. |
| Pelletizing | Pelletizing system | Chosen by polymer and filler ceiling — water contact is the deciding column. |
| Downstream | Centrifugal dryer, vibrating screen, bagging | Fines below 2% and moisture below the specification of your downstream process. |
Output by model
| Model | Dia. (mm) | Speed (rpm) | Motor (kW) | Torque (N·m) | Output (kg/h) |
|---|---|---|---|---|---|
| KTE-50B | 50.5 | 500–600 | 55–75 | 2×525 | 80–200 |
| KTE-50D | 50.5 | 300–800 | 75–90 | 2×860 | 100–300 |
| KTE-52B | 51.4 | 500–600 | 55–75 | 2×720 | 80–200 |
| KTE-52D | 51.4 | 500–600 | 75–110 | 2×1050 | 100–400 |
| KTE-65B | 62.4 | 500–600 | 90–110 | 2×860 | 200–450 |
| KTE-65D | 62.4 | 300–800 | 132–160 | 2×1530 | 350–600 |
| KTE-75B | 71 | 500–600 | 132–160 | 2×1530 | 300–800 |
| KTE-75D | 71 | 300–800 | 200–315 | 2×2100 | 500–1000 |
| KTE-85B | 85 | 500–600 | 220–315 | 2×2100 | 550–1000 |
| KTE-95B | 93 | 500–600 | 250–315 | 2×3000 | 800–1500 |
| KTE-95D | 93 | 500–800 | 315–500 | 2×4800 | 1000–2000 |
| KTE-135B | 135 | 500–600 | 315–500 | 2×4800 | 1500–3000 |
| KTE-135D | 135 | 500–800 | 500–1000 | 2×7800 | 1500–4000 |
Three mistakes that cost the most
1. Uncoated CaCO3 absorbs the coupling agent and the pellets dust in the bag.
Uncoated CaCO3 absorbs the coupling agent and the pellets dust in the bag.
2. Feeder bridging
Feeder bridging — always specify a twin-screw feeder with an agitator for 1,250 mesh and finer.
3. No wear monitoring
No wear monitoring — at 85% filler the first sign of liner wear is a 5% output drop at fixed settings; weigh a 60-second sample monthly and plan liner inspection at 4,000–6,000 h.
FAQ
Which mesh size should I use?
1,250–2,500 mesh coated GCC for film; coarser 800–1,250 mesh for injection and pipe where cost matters more than surface finish.
Do I need a two-stage line?
Above 85% loading yes. Between 80–85% a high-torque twin screw (D-type gearbox) can hold output, but the two-stage is more forgiving on filler variability.
What output can you guarantee for this application?
The reference band is 300–1,500 kg/h, measured on the stated material. We quote a guaranteed figure only after a trial on your own material, because filler grade, bulk density and moisture move output by ±15%.
Can we run our material before ordering?
Yes — send 25–50 kg. We return pellets, a running video and a report with temperatures, screw speed, feeder settings and output per hour. The trial is free; you cover the freight.
What is the delivery time?
30–45 working days for standard configurations, 45–70 for custom screw geometry and ODM work. Voltage and frequency are built for the destination country.
Where these numbers come from
Parameters are taken from the Kerke product parameter table and the product master data sheet, and cross-checked against commissioning records for lines in the same application. Formulations and temperature windows are typical industry values, not a recommendation for your specific compound — every figure marked reference must be confirmed on a material trial before it becomes a contractual number.
Reviewed by the Kerke process team, Nanjing. Page updated 6 November 2026.
Send 25–50 kg and we run it on our lab extruder: pellets, running video and a capacity report back in 3–7 days.
CaCO3 filler masterbatch — the short version
Note on caco3 filler masterbatch: the numbers above are reference ranges from Kerke's own trial runs, not catalogue promises. Screw geometry, wear package and pelletizing method are set on the trial bench first, so the output you compare is the output you get. If your grade is not in the tables, send it — the closest configuration is usually a change of screw set, not a different machine.
Related on this site: Machine range: KTE-50B to 135D · Pelletizing methods compared · quotation and free trial · Wikipedia: Masterbatch