It is important to consider several key areas when specifying a metal detectable masterbatch for use in injection moulding and extrusion of detectable polymer products.
1. Detectability
Radical Materials has invested years of development and testing surrounding metal detectable masterbatch to identify the most effective and optimum performing solutions when it comes to enhancing levels of detection and providing the highest possible levels of safety in application. The same can also be said for X-ray detectable solutions.
2. Mechanicals
To enhance the level of detectability of polymers, it is necessary to incorporate very specific additives into the polymer in question. The drawback here is that these additives invariably reduce the toughness of the base polymer and so, even though now detectable, actually increase the risk of fragments breaking off in the first place.
Over the years Radical Materials, via the SCOPIC brand, has worked extensively to offer metal detectable masterbatch and compound solutions which help to alleviate such problems by utilising techniques to increase the toughness of the final polymer material. The detectable additives now utilised for metal and also X-ray detection have been developed to offer extremely high levels of detectability, hence meaning that lower addition levels can be utilised than of other, less detectable, additives. In addition, much work has been focussed on the use of impact modification systems, specific to individual polymers.
As well as standard solutions, full support is available to assist in the development and testing of custom formulations to suit a specific application. Compounds/masterbatches are firstly developed on in-house lab extruders. These can then very quickly be injection moulded and tested for tensile strength, elongation and impact performance and modifications subsequently made if and as required.
3. Compatibility
Masterbatch is a convenient method of imparting metal and/or X-ray detectable properties to existing polymers. A range of standard metal detectable masterbatch solutions are available, based upon universal carriers and typically compatible with many standard polymers such as polyethylene, polypropylene, nylon, ABS and acetal.
For specific requirements, masterbatch can also be offered with bespoke carriers as required (for example TPU) and specific for elastomeric materials such as silicone, natural rubber and NBR. For applications where the use of masterbatch is not possible or desired, ready to use compounds are available, tailored to a specific application.
4. Regulatory
Metal detectable masterbatch and compound are commonly utilised to manufacture polymer components which are used on or in the vicinity of food processing equipment. Some of these components are designed to have varying degrees of direct food contact, whilst others are designed with no direct food contact in mind at all. Regardless of the final application, the fact that detectable polymers are used in and around food processing equipment means that the regulatory side relating to food contact is a key consideration.
It is for the end user of the final article into which metal detectable masterbatch, compounds and additives are incorporated to determine that any specific and applicable regulatory limitations on use are complied with and that all relevant migration testing and regulatory demands are in-place to allow use in the specific end-use conditions. However, this process is much easier, and the masterbatch/compound/additive itself can be used with much more confidence if supported by a sound regulatory declaration under a defined set of conditions.
Whilst understanding that not every material, application and operating conditions can necessarily be accounted for, Radical Materials ensures that solutions offered are backed by sound declarations according to both EU and FDA regulations.
All statements and conditions are available on request and help to support regulatory assessment of the final product.
