Greener
solutions
from your
colouring
experts

Use less material, save money!

MasterFoam is our new endothermic blowing agent masterbatch. The product works by creating a fine foam structure in the material whilst the polymer is in a liquified state. Tiny pockets of gas mean the moulding material is less dense, resulting in a lighter end component and a reduction in the volume (and therefore cost) of the polymer required to manufacture it. Reducing material usage of course offers environmental benefits too.

The utilization of an endothermic reaction has benefits over exothermic blowing agents which are more widely available. An endothermic chemical foaming agent is less hazardous – it doesn’t release harmful gasses or emit heat, making it a safer choice. There’s also very little chance of an uncontrolled runaway reaction (generating excessive heat). Broadway’s MasterFoam is not an imported, traded product. It was developed by our in-house technical team and is manufactured at our factory in the UK, offering enhanced security of supply.

In 2023 trials, MasterFoam outperformed competitor alternatives. Dosed at low addition rates, it achieved weight reductions of almost 10% in thin walled packaging components. There were no notable differences in the dimensions of the moulding or any perceivable difference when compared to the control mouldings. Projected figures suggest that in just two specific packaging applications, the use of MasterFoam will deliver cost savings of around £110,000 and a polymer reduction of 105 Tonnes over a five-year period. When combined with the introduction of recycled polypropylene, the moulder estimates a carbon saving of 58% associated with the lifecycle of these components.

Other advantages for the customer over thin-walling or resizing the component are that there are no tooling costs, no changes to filling and packaging lines and no changes to the product’s appearance. Lightweighting components, (without reducing dimensions/strength) can offer great benefit in other market sectors where plastics play a vital role, including automotive, aerospace and construction.

In extrusion trials, our extrusion grade blowing agent; MasterFoam–Ex doubled the running speed of a customer’s extrusion. This effectively doubled the capacity of their operation, without the need for any machinery upgrades. Increased running speeds and shorter cycle times have also reduced the energy demands of customer operations.

Reduce odours in smelly materials

Whilst there are obvious circularity advantages to using recycled materials, there are challenges too, such as the smell! Recycled plastics can come from a range of sources and carry a multitude of contaminants, many of these cause odours which are problematic during production and can remain present in the end component. Even some virgin plastics can carry smells which need eliminating. Whilst these can be masked with a fragrance, this isn’t always desirable, particularly in applications such as toiletries or food packaging. It’s also a temporary solution, which soon fades, meaning end products can still present undesirable odours.

Our R&D scientists invested months of research, exploring odour neutraliser additives for plastics. They consider these a more effective and permanent solution than attempting to mask smells with a fragrance. Specialist chemicals within our new odour neutraliser additives act to absorb and trap VOCs and other odour molecules. This significantly reduces the amount of odorous particles which are released, therefore reducing the perceived smell of the material. We’ve explored a number of functional additives in order to find a commercially viable solution which delivers optimum performance.

Improve recycling compatibility with our NIR detectable ‘piano black’ masterbatches

High opacity, high gloss black plastics are a popular packaging choice, commonly used to offer products a premium appearance. Carbon black pigments – traditionally utilised to achieve such a finish, present inherent difficulties to the NIR detection systems used at waste sorting plants. They are strong absorbers of radiation both in the visible and infrared regions. This limits the amount of infrared radiation which can be reflected into the NIR detectors, placing considerable limitations on the system’s ability to characterise and sort the polymers. Conservative estimates from industry indicate that 30,000 – 60,000 tonnes of black plastic packaging may be entering the UK waste stream each year as a result of this issue.

The in-house laboratory at Broadway has called upon its extensive experience in colour chemistry to overcome this technical barrier. Our NIR-detectable piano blacks have undergone extensive and successful in-house NIR spectroscopy based tests, returning a distinct and statistically significant spectroscopic signature. Compatible with both PET and PP, these masterbatches produce a high-quality gloss ‘piano’ black finish whilst meeting standard food contact regulations. It redefines what can be achieved when it comes to maintaining a premium appearance, whilst safeguarding the ability to sort the end component in standard recycling waste streams.

We’re experts in colouring recycled plastics

With the world focused on reducing plastic waste; brand owners, moulders and consumers are rightly seeking sustainable options. PCR (Post Consumer Recycled) plastics offer an obvious solution – reprocessing waste packaging into usable materials for re-moulding. Our colourists are well-versed in colouring PCR, our team delivers dozens of matches for use in recycled plastics every week.

Many brands already enjoy the benefits of working directly with us. Broadway’s colour suite allows you to join us on-site to approve matches. This process means several new colour samples can be approved in a single day, saving time on product development. This facility is particularly useful when colouring recycled plastics. Our team can use a sample of your base material to demonstrate exactly how a specific batch of recyclate will impact the end colour of your moulded component. We’ll produce samples whilst you wait.

We’re also able to formulate masterbatches using PCR carrier resins. A significant proportion of each masterbatch is polymer, so for a brand to legitimately claim their product or packaging is “made from 100% recycled plastic“, their masterbatch must contain a PCR carrier resin (and no virgin plastic). The polymer within the masterbatch will typically form between 0.5% and and 2.5% of the finished moulding, although this can be higher.