Calcium carbonate is increasingly recognized as an essential part of the plastic industry. In this article, we’ll dive deep into calcium carbonate’s role in plastic applications and reveal why it’s a preferred choice for manufacturers.
1. What Are The Properties of Calcium Carbonate Relevant to Plastics?
Calcium carbonate is a widely used plastic filler based on many favorable properties. These can be categorized based on physical and chemical aspects:
1.1. Physical properties
- Appearance: Calcium carbonate is a white, odorless and tasteless powder. This contributes a brilliant finish to the unplasticized plastics without any need for additional whitener or dyes.
- Hardness: High hardness makes calcium carbonate rational to be used as an efficient filler to strengthen the plastic material.
- Solubility: Calcium carbonate is an insoluble substance and its low solubility will be advantageous in maintaining the stability of this product in plastics.
1.2. Chemical properties
- Reactivity: Calcium carbonate is considerably reactive during the neutralization of acids. This aspect will be helpful for a variety of chemical processes in plastics manufacturing.
- Decomposition: At temperatures greater than 800 °C, calcium carbonate undergoes decomposition, which may be relevant to the processing conditions and final properties of the plastic.
- Compatibility: In mixing with all types of plastics and additives, calcium carbonate has no effect on any change in chemical properties.
2. Why is Calcium Carbonate Used In Plastic Production?
Calcium carbonate finds extensive applications in plastic production due to several compelling reasons, such as:
2.1. Cost efficiency
Calcium carbonate has been generally regarded as an effective economical filler material that helps save the overall production cost of plastic products to a considerable extent. Partial substitution of the more expensive polymer resin with calcium carbonate leads to reducing the material cost for the manufacturer without affecting the quality of the product.
Read more: PP Raffia Filler: Optimize Production Cost with CaCO3 Filler Masterbatch
2.2. Enhanced mechanical properties
Calcium carbonate significantly improves the mechanical properties of plastics, mainly the resistance to tensile. At any level of tension, materials can support a greater load and be resistant to breakage. Further, calcium carbonate also adds stiffness by which plastics become rigid to perform supportive roles.
These benefits of calcium carbonate in plastics result in stronger and more reliable materials for a wide variety of uses.
2.3. Improved processability
Calcium carbonate is noted to improve the workability of plastics during processing of the polymers. It possesses good flow properties and increases plasticity, contributing to enhanced mold filling and ultimately higher overall rates of production.
With this improved flowability, the energy-carrying capacity is reduced and the manufacturing processes are faster and inexpensive. It aids in enabling production work to go on seamlessly, therefore, calcium carbonate is a valuable additive in the production of plastic products.
2.4. Versatility
Calcium carbonate has a good compatibility with many polymers including PVC, polypropylene, and polyethylene. This makes it applicable in most sectors, ranging from packaging to automotive parts, further extending its utility in the plastic industry.
3. Applications of Calcium Carbonate In Plastic Industry
Thanks to its benefits, calcium carbonate finds various plastic applications:
3.1. Ceiling panel and plastic doors
Calcium carbonate is essential in producing ceiling panels and plastic door frames, enhancing product reliability and performance. Its incorporation improves the dispersion of plastic chemicals, ensuring a uniform mixing process for better material quality. Additionally, calcium carbonate also optimizes gloss, providing a smooth and visually appealing finish.
These benefits of calcium carbonate make it a key additive in high-quality plastic construction materials.
3.2. Plastic pipes
Calcium carbonate plays an important role in plastic pipe manufacturing. In unpressurized polyolefin pipes, it improves the hardness and reduces the cost of manufacturing.
For pressure PVC pipes, a lower content of CaCO3 ensures they can withstand high pressure. This improves surface smoothness and impact resistance, which leads to better performance and cost efficiency.
3.3. Transmission lines
Calcium carbonate in polyolefin plastic cables offers a reduction in production costs and improvement of fire resistance with the addition of appropriate additives. This dual function makes CaCO3 a valuable component for reliable transmission lines.
3.4. Films
Calcium carbonate is widely used in thin and thick film production. It improves chemical resistance, increases production capacity, and reduces material costs while enhancing hardness and durability. These benefits make calcium carbonate become an important additive in the film industry.
4. What Types Of Calcium Carbonate Are Used In Plastics?
There are two main kinds of calcium carbonate used in the plastic industry:
| Ground Calcium Carbonate (GCC) | Precipitated Calcium Carbonate (PCC) | |
| Production Method | Obtained by grinding natural minerals (calcite, marble, limestone, chalk) | Produced from limestone via calcination, carbonization, and drying processes |
| Bulk Density | 0.8 – 1.3 g/cm³ (higher density) | 0.5 – 0.7 g/cm³ (lower density); nano products can be ~0.28 g/cm³ |
| Whiteness | 89% – 93% (up to 95% in some cases) | 92% – 97% (higher purity and whiteness) |
| Moisture Content | 0.2% – 0.3% (low and stable) | 0.3% – 0.8% (fluctuates and less stable) |
| Price | About 30% cheaper due to simpler production methods | More expensive due to complex chemical processes |
5. How Does Calcium Carbonate (CaCO3) Compare To Other Plastic Fillers?
Here is a comparison of calcium carbonate with some commonly used fillers:
| Calcium Carbonate (CaCO3) filler masterbatch | Talc filler masterbatch | Barium Sulfate (BaSO4) filler masterbatch | Glass Fibers filler masterbatch | |
| Advantages | Cost-effective and enhances mechanical properties of plastics. | Improves thermal resistance and stability, suitable for various production processes. | Increases clarity, barrier properties and focuses gloss performance. | Offers excellent transparency, compressive resistance, and consistent shaping ability. |
| Disadvantages | May have lower purity compared to other fillers. | Higher cost than calcium carbonate; limited to specific applications. | Low transparency and high cost; require large amounts for desirable clarity. | Low surface quality, high viscosity when melted, poor weldability, and prone to warpage. |
| Applications | Primarily used in filler masterbatches for plastics, accounting for up to 75% of total usage. | Initially added to polypropylene to increase rigidity; also used in polyethylene and polyamides | Used to increase polymer density and enhance transparency in plastic bags. | Commonly applied in the automotive industry and household appliance production. |
6. Sustainability & Environmental Impact
Some believe that fillers result in augmentation of the weight and bulk of the product, thus increasing resource consumption and waste generation. However, this is not entirely correct as there are many benefits associated with the use of fillers for environmental sustainability, particularly calcium carbonate:
6.1. Environmental benefits
Incorporating calcium carbonate in the plastic product lowers greenhouse gas emissions during production. It is also noted that using 40% calcium carbonate loading in polypropylene can save nearly 23% of greenhouse gases through savings in petrochemical and energy consumption.
6.2. Energy efficiency
Calcium carbonate enables the attaining of the proper rate of heating and cooling required in production processes. The replacement of 20% petrochemicals with calcium carbonate results in:
- 15-20% total savings on energy
- 16-20% reduction in crude oil usage
- 15-19% reduction in natural gas used
6.3. Emissions reduction
The use of calcium carbonate also leads to a reduction of the following emissions:
- 13-17% reduction in greenhouse gases
- 15-20% reduction in sulfur oxides SOx
- 13-17% reduction in nitrogen oxides NOx
7. About EuP Egypt’s Calcium Carbonate Filler Masterbatch
EuP Egypt stands out as a key player in the filler masterbatch market, combining quality, sustainability, and innovation. Our dedication to providing effective and environmentally responsible solutions makes us trusted partners for manufacturers looking to enhance their products.
At EuP Egypt, we offer a wide range of calcium carbonate (CaCO3) filler masterbatch tailored to diverse applications, including:
- PE filler masterbatch
- EFPE 1001 filler masterbatch
- PP filler masterbatch
- EFPP 1001 filler masterbatch
- HIPS filler masterbatch
Contact us for more information!
8. Conclusion
Calcium carbonate plays a crucial role in the plastic industry, offering numerous benefits in various applications. By understanding the properties and advantages of calcium carbonate, manufacturers can make informed decisions that enhance their products.
