In the cable industry, the rule usually dictates that the dosage of masterbatch in plastic insulation is kept at around 2%. However, Delta Tecnic has managed to reduce this amount by half without compromising quality, enabling manufacturers to cut costs by up to 30% and improve the sustainability of their processes. This innovation marks a turning point in the way cable manufacturers approach efficiency and resource optimization in their production.
The plastic insulation of a cable is composed of 98% polymer and 2% masterbatch, which is the colorant that gives it its characteristic shade. The key to Delta Tecnic's breakthrough lies in optimizing the pigment concentration within the masterbatches for cables, making it possible to reduce the amount used without affecting the homogenization of the final color. “We have managed to develop a proprietary technology that allows optimal dispersion of pigments within the polymeric base, allowing our customers to use less masterbatch without losing quality in the finish,” says Andreu Carol, CEO of Delta Tecnic.
This development brings with it environmental and logistical benefits. The reduction in the use of masterbatch leads to a reduction in the generation of plastic waste, less need for storage and a very substantial reduction in the carbon footprint. In many cable production plants, where storage space is limited, this optimization in the cable manufacturing process translates into a significant improvement in resource management.
The change in dosing also allows cable manufacturers to reduce the number of masterbatch bags used in each production run. Where two sacks were previously required, one is now sufficient, which also minimizes the use of packaging and pallets. This optimization can be extrapolated to other industries that rely on polymer coloring.
An easy-to-adopt, no-cost solution
Delta Tecnic has successfully implemented this technology in several customers, obtaining outstanding results. Prominent players in the cable industry have tested and moved to industrial use with the new methodology, achieving a significant reduction in the use of masterbatch for cables without altering the quality of the final product. In addition, one of the world's largest automotive cable manufacturers is currently in the process of approving this innovative solution.
This breakthrough positions Delta Tecnic as a benchmark in the industry, being the only company able to offer such significant savings without requiring modifications to production equipment. Unlike other solutions on the market, its technology does not require additional investment in machinery or complex adjustments to production lines. It is compatible with both gravimetric (weight-based) and volumetric (volume-based) dosing systems, which facilitates its adoption in different types of industrial facilities.
The cable industry is constantly searching for optimization and competitiveness, and Delta Tecnic's proposal represents a strategic breakthrough for manufacturers seeking efficiency without compromising the quality of their products.
“Our ability to develop solutions with high pigment concentration, without compromising dispersion or the quality of the final color, allows us to offer a unique differential value in the market,” concludes Andreu Carol. “We are helping the industry take a step forward in terms of efficiency, sustainability and profitability.”
