Application · Plastic Masterbatch
Masterbatch Production Line: Filler, Color & Functional in One Plant
A masterbatch plant is a feeding system, an extruder, a pelletizer and a material-handling skeleton. Buying them as four separate decisions is how plants end up with a bottleneck at the bagging station. A reference masterbatch production line page from Kerke.
Masterbatch Production Line — workshop photo 1, Kerke workshop, Nanjing
Masterbatch Production Line — workshop photo 2, Kerke workshop, Nanjing
Masterbatch Production Line — workshop photo 3, Kerke workshop, Nanjing
Masterbatch Production Line — workshop photo 4, Kerke workshop, Nanjing
Masterbatch Production Line — workshop photo 5, Kerke workshop, Nanjing
Masterbatch Production Line — workshop photo 6, Kerke workshop, NanjingQuick answer
A masterbatch turnkey line covers feeding, compounding, devolatilization, pelletizing, drying and packing for filler, colour, black, white and functional masterbatch, at 100–4,000 kg/h. Layout, electrical standard and voltage are built around the customer plant, not a catalogue.
Workshop photos and a running video — shot on our own lines, not stock images.
What sets the limit
Requirement gathering (material, output, pellet standard, plant size, voltage, budget) → 3D layout and screw configuration → machining and IQC → assembly with gearbox run-in, no-load and loaded test → FAT (on site or by video) → sea-worthy packing → installation and training.
| Parameter | Value / range |
|---|---|
| Scope | Feeding → compounding → pelletizing → drying → packing |
| Output | 100–4,000 kg/h |
| Pelletizing options | Water ring, strand, underwater, air-cooled hot face |
| Electrical | Voltage/frequency per destination country |
| Delivery | 30–45 working days standard; 45–70 for custom layouts |
| Model | KTE-50B to KTE-135D, KTE/SE series |
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 set by the polymer.
- 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 | Two-Stage Extruder KTE/SE | 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
| Configuration | Stage 1 (twin screw) | Stage 2 (single screw) | Output (kg/h) | Typical product |
|---|---|---|---|---|
| KTE-50B / SE-120 | 50.5 mm | 120 mm | 300–500 | Colour / filler masterbatch |
| KTE-65B / SE-150 | 62.4 mm | 150 mm | 500–800 | Filler masterbatch 85%, PVC |
| KTE-75B / SE-180 | 71 mm | 180 mm | 700–1,200 | High filler 88–90%, HFFR |
| KTE-95B / SE-200 | 93 mm | 200 mm | 1,000–2,000 | High filler, cable compound |
Three mistakes that cost the most
1. Buying machines separately and discovering the conveying, drying and packing equipment doe
Buying machines separately and discovering the conveying, drying and packing equipment does not fit the plant.
2. Ignoring the local voltage/frequency until commissioning week.
Ignoring the local voltage/frequency until commissioning week.
3. Sizing downstream by the catalogue top number
Sizing downstream by the catalogue top number — dryer, screener and packer must match the worst-case formulation, and one undersized dryer throttles the whole line.
FAQ
Can you design around my existing building?
Yes — send a CAD plan and column grid; we return a 3D layout before quotation.
What is included in a turnkey quote?
Main machine, feeders, pelletizer, dryer, conveying, control cabinet, spare parts list, English manual and electrical drawings. Installation and commissioning are quoted separately as man-days.
What output can you guarantee for this application?
The reference band is 100–4,000 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.
Masterbatch production line — the short version
Note on masterbatch production line: 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