How to Accelerate Masterbatch Formulation and Cut Waste with X-Rite Solutions

Color matching precision is critical for plastic masterbatch producers, especially amid growing market demands. With increased pressure for fast turnaround times and intricate color requirements and additives like flame retardants and UV absorbers, maintaining competitiveness requires an agile and accurate formulation process.

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Yet, this path presents challenges. Unclear color specifications often lead to multiple revisions to meet customer standards, delaying approvals and potentially allowing rivals to seize opportunities. Errors in formulations can result in significant material and time expenses with huge financial impacts. Moreover, repeated formulation trials can lead to unnecessary waste of expensive colorants and resins, disrupting production schedules when colors are not accepted.

X-Rite's Formulation Tools

To tackle these challenges and effectively meet customer needs, masterbatch producers need a robust formulation solution. X-Rite offers essential tools, including a precise benchtop spectrophotometer, the Ci7860, to establish master standards. Our formulation software, Color iMatch, provides quick and precise color matches, while our quality assurance software, NetProfiler, monitors and optimizes device performance throughout the workflow to minimize errors and downtime.

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The practical outcomes of implementing an X-Rite formulation solution is significant. For instance, in a typical lab scenario where five colors are formulated daily, with each color requiring initial formulation and subsequent adjustments, savings can amount to approximately 2,200 hours of labor and $110,000 in materials annually. Of course, these savings are estimates and may vary based on specific processes and materials.

Step-by-Step Breakdown for Masterbatch Formulation

Here is how the process works:

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1. Customer Request: First, the customer provides a color sample or requests a bid for a plastic color match.
2. Color Measurement: Using the Ci7860, the masterbatcher measures the target color and transfers the spectral data to Color iMatch.
3. Formulation: Color iMatch then utilizes available pigments and resins to identify optimal formula candidates, offering the option to incorporate leftover materials to minimize waste. The Search and Correct algorithm retrieves relevant recipes from the database and suggests adjustments to optimize formulations.
4. Sample Creation and Validation: The masterbatcher produces a sample plaque according to the formulated recipe and verify color accuracy using the Ci7860. This ensures the sample meets stringent color tolerance standards before it is sent to the customer for approval.
5. Final Formulation: Upon approval, the final formulation is prepared for transmission to the extruder, facilitating seamless integration into the production process.

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These solutions empower masterbatchers to streamline color formulation, improve accuracy in color matching, and maintain consistency across production cycles to boost operational efficiency and customer satisfaction.

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Join leading masterbatch producers who trust X-Rite to optimize workflows, minimize costs, and exceed customer expectations. Transform your formulation process today with X-Rite — click here to contact us.