Investigation of the Effect of Stearate Additive on Process and Optical Properties in High-Filled PE-Based Masterbatch Production via Extrusion Process

Abstract

In this study, high-filled polyethylene (PE)-based masterbatch formulations containing inorganic calcium carbonate (CaCO₃) at concentrations ranging from 72 to 81 wt.% were manufactured using an industrial-scale twin-screw extruder. To mitigate the rheological challenges associated with high filler loadings, specifically increased melt viscosity and particle agglomeration, a hybrid interfacial modifier system comprising calcium and zinc stearate was incorporated into the compounding process. This additive system was maintained at a fixed concentration of 1.2 wt.% to systematically evaluate its influence on both extrusion process stability and the optical characteristics of the final composite material.