High-Performance Solutions for Hygiene, Medical & Industrial Packaging
Breathable Masterbatch
In high-value film applications where controlled air and moisture vapor transmission is critical, conventional polyolefin films fail to meet performance expectations. Breathable Masterbatch enables the production of microporous films that allow water vapor transmission while remaining liquid-water impermeable, making it an essential material for hygiene, medical, protective, and industrial applications.
At an industrial scale, breathable film performance is not determined by filler loading alone—it is governed by particle morphology, dispersion efficiency, polymer compatibility, and stretching behaviour. Our Breathable Masterbatch is precision-engineered to deliver consistent microporosity, stable processing, and export-grade performance, even in high-speed film extrusion and stretching lines.
What Is Breathable Masterbatch?
Breathable Masterbatch is a high-loading functional filler masterbatch, primarily based on specially surface-treated Calcium Carbonate (CaCO₃) dispersed in a polyolefin carrier resin (LLDPE/LDPE/PP, application-dependent).
During film stretching, the filler particles create micro-voids within the polymer matrix, forming a microporous structure that enables controlled permeability without compromising mechanical integrity.
Key Technical Performance Characteristics
▪ Controlled Microporosity Formation
Optimized CaCO₃ particle size distribution
Uniform void initiation during MD/CD stretching
Stable pore geometry across film thickness variations
▪ High Water Vapor Transmission Rate (WVTR)
Optimized Thermoregulation: Facilitates efficient moisture vapor dissipation and evaporative cooling, maintaining a stable microclimate and preventing heat accumulation.
Enhanced Skin Integrity: Promotes continuous vapor transport to prevent tissue maceration, dermatitis, and interfacial dehydration in medical and hygiene applications.
Selective Permeability: Maintains a high-performance hydraulic barrier against liquid ingress and pathogens while allowing gaseous exchange for moisture management.
Atmospheric Control: Regulates internal package humidity to prevent condensation and anaerobic spoilage, extending the shelf life of perishable goods.
▪ High Moisture Vapor Transmission Rate (MVTR)
Enables breathability without liquid leakage
Ideal for hygiene and medical packaging
Consistent MVTR values across production batches
Comparison Table for WVTR And MVTR Test
| Parameter | MVTR | WVTR |
|---|---|---|
| Accuracy | Medium | High ✅ |
| Industry Acceptance | Limited | Global standard |
| Export / Compliance | ❌ | ✔ Yes |
| Suitable for Barrier Films | ❌ | ✔ Yes |
| Preferred by Buyers | ❌ | ✔ Yes |
▪ Excellent Dispersion & Process Stability
High-shear compounded for uniform filler distribution
Minimal agglomeration and die build-up
Smooth film surface with reduced pin-holing risk
Typical Applications of Breathable Masterbatch
Breathable Masterbatch is widely used in high-growth, export-oriented industries, including:
Baby diapers & adult incontinence products
Sanitary napkins & feminine hygiene products
Medical gowns, drapes & protective wear
Surgical packaging & sterilizable wraps
Industrial protective laminates
Agro – textile & specialty membrane films
Advantages for Purchase Managers & Exporters
For procurement and export teams, breathable masterbatch performance directly impacts cost efficiency, product compliance, and customer satisfaction.
Commercial & Operational Benefits:
Higher breathability at optimized dosage levels
Reduced film rejection due to uniform pore structure
Compatibility with high-speed blown & cast film lines
Consistent quality suitable for global supply chains
Lower cost per square meter of breathable film
Technical Formulation Excellence
▪ Filler Engineering
High-purity CaCO₃ with controlled aspect ratio
Surface-modified for improved polymer wetting
Reduced impact on tensile strength after stretching
▪ Carrier Resin Compatibility
Available in LLDPE, LDPE & PP carrier systems
MFI matched to base polymer for uniform melt flow
Ensures consistent dispersion during extrusion
▪ Stretching Performance
Designed for mono-axial and bi-axial stretching
Stable pore development without film tearing
Maintains mechanical balance post-orientation
Processing Compatibility
Our Breathable Masterbatch is compatible with:
- Blown film extrusion lines
- Cast film extrusion systems
- Inline & offline stretching units
- Multilayer film structures (as core or functional layer)
Processing windows are optimized to ensure consistent microporous formation without sacrificing line productivity.
Quality & Export Compliance
For exporters and global brands, consistency is non-negotiable.
Our Breathable Masterbatch is manufactured under:
Strict raw material selection protocols
Batch-to-batch consistency controls
Internal quality validation for dispersion & pore formation
Compliance with international hygiene & packaging norms (application-dependent)
Why Choose Our Breathable Masterbatch?
Engineered for high breathability with mechanical integrity
Proven performance in hygiene & medical applications
Optimized for cost efficiency and process stability
Suitable for large-scale export production
Backed by technical support & application guidance
Final Note for B2B Decision Makers
Breathable film manufacturing is not a trial-and-error process—it is a precision-driven technology. The right breathable masterbatch determines pore uniformity, WVTR consistency, and long-term product reliability.
Our Breathable Masterbatch is designed to help film manufacturers, exporters, and global suppliers achieve consistent breathable performance at industrial scale, without compromising productivity or quality.
About Bajaj Plast Pvt. Ltd.
Bajaj Plast Pvt. Ltd. is a leading manufacturer of high-quality masterbatch solutions, dedicated to innovation, sustainability, and excellence. With a strong focus on customer satisfaction and cutting-edge technology, we are committed to delivering superior products that meet the evolving needs of the polymer industry.
