Calcium Carbonate in Plastic Extrusion

Versatile additive for thermoplastic extrusion

Calcium carbonate is a mineral filler widely used in plastic compounds to reduce raw material costs, improve dimensional stability and optimize surface finish. It is particularly effective in PVC, PP and PE-based formulations, where it can be added in high percentages without compromising the product's characteristics.
Bausano does not supply calcium carbonate, but designs extrusion lines specifically engineered for processing filled compounds. The client is supported in selecting the most suitable technical solutions for managing mineral fillers, ensuring melt quality and protection of mechanical components.

Integrating calcium carbonate into extrusion blends

The use of calcium carbonate requires careful process management. While it helps contain costs and improve certain compound properties, it also calls for specific processing precautions, particularly regarding screw wear and homogeneous filler distribution.

Calcium carbonate is widely used in:

Rigid PVC profiles and pipes, for construction and infrastructure
Rigid packaging, where opacity and dimensional stability are required
Electrical cables, to optimize insulation mass
Industrial components, with rigidity and finish requirements

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The balance of mineral filler affects yield and product stability

Integrating calcium carbonate changes the polymer's behavior during extrusion and in the finished product. Key advantages include:

Reduced unit cost thanks to the high filler percentage
Increased rigidity of the extruded material
Opacifying effect, useful for aesthetic or functional needs
Shrinkage control and good dimensional stability
Partial barrier effect against gas and moisture

However, an unbalanced formulation or non-optimized extrusion can lead to issues such as reduced melt homogeneity or premature plant wear.

Extrusion of PVC and filled compounds: why line configuration makes the difference

Due to its abrasive characteristics and the need for uniform dispersion, calcium carbonate requires purpose-designed lines. The screw and barrel configurations of Bausano solutions are designed to ensure high mixing performance, thermal control and mechanical protection.

According to a Bausano study, fully intermeshing co-rotating twin screws – typical of conical twin-screw extruders – are ideal for processing calcium carbonate-filled PVC. In particular, conical geometry systems offer higher torque at low speeds, lower stress on the material and reduced risk of thermal degradation. This makes them preferable to parallel extruders in the case of high filler content.
The client is supported by Bausano in choosing the most suitable extruder and defining the most efficient recipe, ensuring consistent performance and reduced line downtime.

A starting point to define the right solution together

By filling in the form below, it is possible to describe specific technical or production requirements. The technical team will carefully evaluate the request in order to propose the most suitable extrusion line or extruder.