Turnkey plant
Turnkey Masterbatch Plant: feeder to bagging
Buying four machines from four suppliers is how a plant ends up with a feeder that does not match the throat, a pelletizer that floods the dryer and a control system with three HMI languages. One turnkey masterbatch plant scope, one acceptance test.
- Single scope: dosing, extrusion, pelletizing, drying, conveying, bagging
- Layout drawing and utility schedule before shipment
- Acceptance test with your material, record shipped with the plant
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Where turnkey plants lose money
The extruder is the part everyone compares. In a turnkey masterbatch plant the losses usually sit in the interfaces: feed throat, conveying, dryer capacity, bagging rate.
The feed throat interface
A gravimetric feeder sized for 800 kg/h of CaCO₃ at 0.9 bulk density delivers far less at 0.45. The throat, the agitator and the feeder are one design problem, and they are usually bought as three — the classic turnkey masterbatch plant failure.
Conveying and storage
Pneumatic conveying of filled compound abrades elbows and creates fines. The layout decides how much; a drawing before shipment is cheaper than a rebuild after installation.
One control philosophy
Recipe, alarms and data logging in one system. Three HMIs from three suppliers means three sets of spare parts and no single record of a batch.
- Material flow and layout drawing
- Gravimetric dosing for polymer, filler and additives
- Vacuum devolatilization and melt filtration where needed
- Pelletizing, drying, screening and conveying
- Bagging or bulk loading at the line rate
- Commissioning, training and a recommended spare set
Typical turnkey masterbatch plant scopes
| Scope | Output (reference) | Core machine | Includes |
|---|---|---|---|
| Filler masterbatch plant | 350–750 kg/h | KTE-75B / KTE-95B | dosing, extrusion, water ring, dryer, bagging |
| Colour masterbatch plant | 150–400 kg/h | KTE-65B / KTE-75B | dosing, extrusion, strand pelletizing, bagging |
| Engineering plastics plant | 140–300 kg/h | KTE-65D | drying, side feeder, vacuum, strand pelletizing |
| Recycling plant | 300–1,000 kg/h | KTE-95 / two-stage | feeding, filtration, underwater pelletizing, dewatering |
Reference values, subject to material trial. Final parameters are set on your own material.
Questions buyers ask before the call
Do you do the installation?
We supply drawings, a commissioning engineer and training; installation supervision travel is quoted separately. Most customers use a local rigging team with our engineer on site for the first run.
What is the delivery time for a full plant?
30–45 working days for a standard single-line plant, 45–70 for a multi-line layout with custom conveying. Every machine of the turnkey masterbatch plant is test-run with material before shipment.
Can the plant be expanded later?
Yes, if the layout is planned for it. We size the conveying and the utility headers for the second line at the start, which is a small cost now and a large one later.
Send the plant brief — get a layout and a scope
Products, output per line, available floor area and power supply. That is enough for a layout drawing and a turnkey masterbatch plant scope with the interfaces named.