How to improve production efficiency and reduce costs by filling masterbatch with sodium sulfate
Customer Case Study: Improving Production Efficiency and Reducing Costs with Sodium Sulfate Filler Masterbatch
Customer Background
Our customer is a manufacturer specializing in plastic packaging materials, primarily producing high-transparency plastic bags and packaging films. These products need to maintain excellent transparency and strength while meeting the market's demand for cost-effective and environmentally friendly materials. With increasing competition, the customer faced rising production costs and shrinking profit margins.
Challenges Faced by the Customer
The customer used pure polyethylene (PE) to produce transparent packaging films. While the product quality was high, production costs were becoming unsustainable. As the market became more price-sensitive, the customer needed a solution that could reduce raw material costs without compromising product performance. Additionally, they sought to reduce energy consumption during production and improve overall production efficiency.
Solution
After analyzing the customer’s needs and conducting a technical evaluation, we recommended our Sodium Sulfate Filler Masterbatch (Na₂SO₄ Filler Masterbatch). This filler is specifically designed to enhance the transparency, strength, and cost-effectiveness of plastic products, allowing for a significant reduction in the amount of pure polyethylene used without sacrificing quality.
The specific solution included:
Reduction in Polyethylene Usage: By incorporating sodium sulfate filler masterbatch, the customer was able to reduce the amount of polyethylene in the raw material mixture by 30%, thereby lowering raw material costs.
Maintaining Transparency:Sodium sulfate filler masterbatch has minimal impact on the transparency of the packaging film and can still meet high transparency requirements.
Improved Production Efficiency: The filler’s excellent flow properties enhanced production efficiency, reducing material stickiness during processing and lowering energy consumption.
Results
Since implementing sodium sulfate filler masterbatch, the customer has achieved the following results:
20% Cost Reduction: By cutting down on pure polyethylene usage, the customer successfully reduced production costs by approximately 20%.
15% Increase in Production Efficiency: The sodium sulfate filler masterbatch optimized the production process, reduced cleaning frequency for equipment, and improved production line speed.
Consistent Product Performance: The customer’s packaging films maintained their high transparency and strength, receiving positive feedback from the market and enabling the customer to capture a larger market share.
Customer Feedback
"Since adopting the sodium sulfate filler masterbatch, we’ve significantly reduced our production costs while maintaining a competitive edge in the market. The quality of our products hasn’t declined at all, and the efficiency of our production lines has increased. This is a win-win solution, and we are very satisfied."
