Data-Driven Modeling and Simulation for Optimizing Color in Polycarbonate: The Dominant Role of Processing Speed on Pigment Dispersion and Rheology

Maintaining color constancy in polymer extrusion processes is a key difficulty in manufacturing applications, as fluctuations in processing parameters greatly influence pigment dispersion and the quality of the finished product. Preliminary historical data mining analysis was conducted in 2009. This work concentrates on Opaque PC Grade 5, which constituted 2.43% of the pigment; it contained 10 PPH of resin2 with a Melt Flow Index (MFI) of 6.5 g/10 min and 90 PPH of resin1. It also employs a fixed resin composition with an MFI of 25 g/10 min. This research identified the significant processing parameters (PPs) contributing to the lowest color deviation. Interactions between processing parameters, for the same color formulation, were analyzed using statistical methods under various processing conditions. A principle-driven General Trends (GT) diagnostic procedure was applied, wherein each parameter was individually varied across five levels while holding others constant. Particle size distribution (PSD) and colorimetric data (CIE Lab*) were systematically measured and analyzed. To complete this, correlations for the impact of temperature (Temp) on viscosity, particle characteristics, and color quality were studied by characterizing viscosity, Digital Optical Microscopy (DOM), and particle size distribution at various speeds. The samples were characterized for viscosity at three temperatures (230, 255, 280 °C) and particle size distribution at three speeds: 700, 750, 800 rpm. This study investigates particle processing features, such as screw speed and pigment size distribution. The average pigment diameter and the fraction of small particles were influenced by the speed of 700-775 rpm. At 700 rpm, the mean particle size was 2.4 µm, with 61.3% constituting particle numbers. The mean particle size diminished to 2 µm at 775 rpm; however, the particle count proportion escalated to 66% at 800 rpm. This research ultimately quantifies the relative influence of particle size on the reaction, resulting in a color value of 1.36. The mean particle size and particle counts are positively correlated; thus, reduced pigment size at increased speed influences color response and quality. The weighted contributions of the particles, 51.4% at 700 rpm and 48.6% at 800 rpm, substantiate the hypothesis. Further studies will broaden the GT analysis to encompass multi-parameter interactions through design experiments and will test the diagnostic assessment procedure across various polymer grades and colorants to create robust models of prediction for industrial growth. The global quality of mixing polycarbonate compounding constituents ensured consistent and smooth pigment dispersion, minimizing color streaks and resulting in a significant improvement in color matching for opaque grades.