In the last few decades, the cable industry has witnessed a number of changes.
The PVC industry is moving towards LSZH (Low Smoke Zero Halogen).
The export markets have started looking into regulations such as RoHS, REACH, and CPR.
The new energy, electric vehicles, solar energy, and data centers have brought the thermal and weathering and flame resistance levels up.
Thus, it is imperative that a good Cable Masterbatch should not only provide perfect color matching but also take care of material compatibility, process windows, and regulatory aspects.
Taking forward the legacy of over five decades of formulation experience from the United States and almost two decades of expertise in the field, we continue to offer custom products to cable producers here and abroad. They include Color Masterbatch, Flame Retardant Masterbatch, Rodent Repellent Masterbatch, UV Masterbatch, and many others.
Construction wire has to be installed for a considerable time period and used in residential, commercial and public projects. It requires color consistency and stability. We provide various carrier systems such as PE, PVC, and LSZH which assure exact coloring, good dispersion and stable heat resistance. This will help our customers to minimize extrusion variations.
Upon being exposed to sun, rain, and high temperatures for an extended period of time, common color masterbatch becomes unstable in its performance. According to our experience with testing weathering resistance, we utilize quality UV stabilization packages along with weather stable pigments. That way, we can achieve high levels of stability and performance of Cable Masterbatch in outdoors.
It will be possible to cater to individual requirements of various nations by providing appropriate formulations for their respective standards, maintaining color uniformity.
A high-speed extrusion line demands Masterbatch which has good dispersion characteristics along with stable flow properties. We provide optimal pigment dispersion and masterbatch formula. While retaining the color uniformity, we successfully minimize the migration problem, black specks, and Die Build-up for our customers.
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From our observation, big companies in the production of cables tend to be interested in knowing whether the 200th batch after one year will match — apart from the initial batch. We have therefore put in place a formulation management system.
Temperatures for the cable production process are usually higher than that of regular film. Optimizing pigments and carriers for different resin systems allows products to remain stable at high temperatures without discoloring or degrading.
Migration not only changes the appearance of the cable but also causes easy formation of dies. We employ low migration system configurations that assist our customers to increase the time of continuous operation and equipment utilization.
Bad dispersion in the color master batch is similar to flour that hasn’t been stirred well. Not only does it result in poor color, but it also readily creates particles and black dots. Our pre-dispersion method helps to make the pigments more homogeneous.
Our products have reached out to markets in Europe, Southeast Asia, the Middle East, and America. We understand the rules and standards in different nations, thus reducing risks of certification for our clients.
We like to be involved in the development process for the customer rather than just providing samples. These include: •Optimizing color match •Flame retardant system recommendation •Weathering solution optimization •Processing parameter suggestion Helping customers validate projects faster.
Many differences in masterbatch do not arise from differences in machinery. The reason is the slight variance in the properties of pigments, flame retardants, and resin raw materials.
Based on our experience, simply changing the supplier of pigments for the same color or even different batches will result in some variances. These variances may affect color shade, flow characteristics, and heat resistance.
Thus, we maintain a full database and management system of raw materials used in formulations.
Consequently, even when the customer orders the same product a year after the initial order, the color and processability will stay the same.
However, many producers check only the final product. However, the elements that determine quality stability happen while manufacturing.
Thus, we cover quality control through all stages.
Such stages are:
High lab test scores do not guarantee a stable production process at the customer end.
So for each and every development of Cable Masterbatch, we conduct simulations according to the client’s equipment, temperature ranges, resins, and ratios used – instead of just basing everything on lab results.
Some of the lab tests that our lab can conduct are:
For some of our key clients, we provide tracking of trial productions as well. This helps us improve the formulation according to client feedback.
This involved a domestic cable manufacturer who was looking to optimize their expenses on their flame retardant systems without compromising on UL testing criteria. We helped to re-optimize the formulation of flame retardant master batch. This brought about cost savings without affecting production.
We provided a Southeast Asian client that is developing communication cables for the outdoors with weather-resistant Color Masterbatch and a UV package. The products were able to pass the local environmental regulations and were used outdoors for a long time.
We believe clarity leads to better collaboration. Here’s what you need to know before getting started, including minimum order quantities and typical production timelines.
Small custom masterbatches quantity: 25KG
Fully original development: Fee
Samples for evaluation: available upon request (some free, some paid depending on project)
Can be flexibly used for small-batch production and regional releases.
Let’s talk.
Sampling: 3-7 working days
Mass Production: 1.5-4 weeks (depending on the complexity)
Shipping: 5–15 days by air / 30–45 days by sea
We ship globally and assist with export documentation.
We will gladly develop special solutions for LSZH, PE, PVC, XLPE, EVA and other compounds.
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