Masterbatches are the unsung heroes in plastic manufacturing, responsible for enhancing properties like heat resistance, colour stability and preventing bleeding in everything from food containers to packaging films. As the demand for sustainable packaging grows, so too does the role of masterbatch technology in meeting both aesthetic and functional needs, particularly in recycled and biodegradable materials.

AT the forefront of this transformation is Performance Colour Systems (PCS), a division of Ferro, based in Gauteng. Known for their expertise in masterbatch and pigment solutions, the team is innovating not just for today’s needs, but for the future demands of plastic packaging. Managing director Jacques Vally discusses the latest advancements and challenges PCS faces in an increasingly environmentally conscious market.

PCS has been pushing the boundaries of masterbatch applications, particularly when it comes to biodegradable resins. ‘We’ve expanded our capabilities to include the extrusion of masterbatches in biodegradable and bio-based resins,’ comments Jacques. ‘These developments are crucial as we respond to global environmental pressures. Although biodegradable and compostable masterbatches remain niche due to their cost, I’m confident that economies of scale will soon make them more accessible. Eventually, consumer and retailer pressure will tip the scales.’

Jacques is clear, however, that government policies will need to play a more active role. ‘Consumers will naturally gravitate towards the lowest price unless incentivised otherwise. Retailers might lead the way in adopting biodegradable options, but meaningful change will require government intervention,’ he asserts.

When it comes to colour consistency and preventing bleeding, PCS has a rigorous approach. ‘We simply don’t use pigments and dyes that bleed,’ Jacques says. ‘Our products are formulated with food safety in mind and we ensure they comply with stringent regulations.’

Moreover, he highlights a subtle shift in market demand: ‘There’s a growing trend toward clearer masterbatches, particularly in pre-packaging applications. For example, certain retailers have introduced clear plastic milk bottles, which are much easier to recycle. This is a significant step forward in sustainable packaging, where clear plastics simplify the recycling process.’

Recycling waste challenges

Despite these innovations, the journey isn’t without hurdles, particularly when it comes to sourcing quality post-consumer waste (PCW) materials. ‘Legislation mandates the use of a certain percentage of PCW in plastic products, but finding high-quality recycled polymer is a challenge,’ Jacques explains. ‘South Africa’s recycling infrastructure is still lagging behind, which drives up the cost of recycled materials. In fact, PCW is often nearly as expensive as virgin plastic.’

He stresses that this is where both the government and the industry need to step up. ‘We need a more robust supply chain for recycled plastics. Right now, it’s proving too costly to fully close the loop on waste recycling. There’s no comprehensive system in place to separate, clean and return plastics back into production efficiently,’ he notes. Without this, achieving widespread use of recycled masterbatches remains an uphill battle.

On the sustainability front, PCS isn’t just waiting for external forces to drive change; it’s leading by example. ‘We’ve made significant capital investments in sustainability. Our Brakpan site has 1.4 megawatts of solar power and 2800KVA of generator power,’ Jacques shares. ‘We’re planning to install even more solar panels and invest in massive water tanks fed by borehole to mitigate water restrictions in Gauteng.’

As plastic production evolves, masterbatch technology continues to play a pivotal role in shaping the industry’s future. However, as Jacques emphasises, the road to a sustainable future will require concerted efforts from all stakeholders – from consumers and manufacturers to government bodies.

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