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Extrusion additives and plastic fillers are essential components in polymer formulation, introduced to adjust material properties according to application needs. While many plastic materials perform well in their base form, they can be brittle, flammable, or too rigid for certain uses. Controlled addition of extrusion additives optimizes material behavior during and after the extrusion process, while preserving the functional strengths of the original resin. In this context, Bausano does not supply additives. Bausano provides advanced technical consulting to help customers define the best process configurations. The goal is operational efficiency, production stability, and consistent product quality, starting from the formulation itself.
Process additives and functional additives: a direct impact on extrusion
In polymer processing, two categories are distinguished:
- process additives, which improve thermal stability and flowability;
- functional additives, which modify final characteristics such as UV resistance, color, flexibility, or flame-retardant behavior.
The presence and type of these additives affect critical operating variables: thermal profile, screw geometry, melt pressure, and the overall design of the extrusion line. Bausano lines are configured starting from these requirements, to maximize the value of every formulation.
Effect of filler particle size and shape on extruded product properties The size and morphology of plastic filler particles play a key role in determining the mechanical, optical, and rheological performance of the finished plastic product. Finer, more uniform fillers distribute more evenly within the polymer matrix, improving tensile strength, surface gloss, and dimensional stability. At the same time, coarser or irregularly shaped fillers can introduce discontinuities in the blend, increasing the risk of breakage, localized brittleness, or settling during extrusion. Particle shape also affects compound viscosity: needle-shaped or lamellar fillers tend to increase flow resistance, directly influencing extruder internal pressure and the required temperature profile. From an optical and functional standpoint, particle size can influence transparency, opacity, or barrier behavior. Very fine fillers, such as micronized talc or treated calcium carbonate, are preferred for applications requiring smooth surfaces, printability, or uniform coloring. Through its rheological analysis and process testing activities, Bausano supports customers in selecting the most suitable filler type, ensuring melt uniformity, consistent surface quality, and production repeatability, even with complex or recycled-material formulations.
A partner for processing complex formulations
Through its Research and Development department, Bausano runs tests on pilot plants and supports customers in selecting the process parameters best suited to filled formulations, on both single-screw and twin-screw extruders.
Variables analyzed include:
- melt homogeneity;
- pressure stability;
- surface quality of the finished product.
The goal is to offer reliable, customized extrusion lines, capable of processing even the most complex compounds with maximum precision.
