As raw material costs rise and sustainability becomes a priority, the strategic blending of titanium dioxide (TiO₂) with functional extenders has emerged as a critical strategy for formulators in coatings, plastics, and paper. When implemented correctly, these blends can reduce costs by 15-30% while maintaining performance in non-critical applications. This guide outlines best practices for successful TiO₂-extender co-usage.
1. Why Blend TiO₂ with Extenders?
Key benefits driving adoption:
✔ Cost Reduction: Extenders like calcium carbonate (CaCO₃) or kaolin clay cost 80-90% less than TiO₂.
✔ Sustainability: Lower carbon footprint per ton of material.
✔ Performance Enhancement: Some extenders improve scrub resistance (e.g., wollastonite) or rheology (e.g., talc).
2. Selecting the Right Extender
| Extender | Best For | TiO₂ Replacement Potential | Key Consideration |
|---|---|---|---|
| Calcium Carbonate | Interior paints, plastics | 20-30% (non-critical applications) | Avoid exterior use (UV degradation) |
| Kaolin Clay | Paper coatings, primers | 15-25% | Improves suspension |
| Wollastonite | Reinforced plastics, textures | 10-20% | Enhances mechanical strength |
| Talc | Plastics, anti-corrosion coatings | 15-25% | Can reduce gloss |
3. Formulation Best Practices
A. Coatings Industry
- Architectural Paints:
- Blend rutile TiO₂ with 15% fine CaCO₃ for interior matte paints.
- Use wollastonite (10%) to improve wet scrub resistance without sacrificing opacity.
- Industrial Coatings:
- Barium sulfate (20%) enhances chemical resistance in epoxy primers.
B. Plastics Industry
- Polyolefins:
- Combine TiO₂ with talc (15-20%) for improved stiffness and whiteness in injection molding.
- PVC Profiles:
- CaCO₃ (25-30%) reduces cost while maintaining brightness for indoor applications.
C. Paper Industry
- Replace 10-15% TiO₂ with delaminated kaolin for equal brightness in standard paper grades.
4. Critical Technical Considerations
！Avoid Over-Replacement:
- Exceeding 30% extender content significantly reduces opacity and UV resistance.
！ Particle Size Matching:
- Ensure extenders have a similar particle size distribution to TiO₂ (0.2-0.3µm) to prevent settling.
！ Surface Compatibility:
- Use silane-treated extenders (e.g., coated CaCO₃) for better dispersion in polymers.
5. Optimization Tools & Testing
✔ Software Modeling:
- Tools like Formulus® predict opacity ( contrast ratio) at different replacement levels.
✔ Lab Validation: - Conduct Hegman grind tests (dispersion) and QUV aging (durability).
Case Study: A European paint maker achieved 22% cost savings using 20% wollastonite in interior paints without performance loss.
6. Future Trends
- Nano-Extenders: Surface-modified nano-CaCO₃ for higher replacement ratios (up to 40%).
- Smart Blends: Pre-mixed TiO₂-extender masterbatches for easier handling.
Conclusion
Strategic TiO₂-extender blending requires a balance of cost, performance, and application needs. By following these best practices, formulators can maintain quality while achieving significant savings.
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Post time: Aug-22-2025