Zinc Oxide for Tyre Manufacturers & Rubber Industry
Bhatti Chemicals Industry is Pakistan's premier manufacturer of high-purity Zinc Oxide (99.99% pure guaranteed). Pakistan's large tyre industries—including leading automotive passenger car radial (PCR), commercial truck & bus radial (TBR), motorcycle, and industrial conveyor belt manufacturers—use our French Process Zinc Oxide for optimal vulcanization kinetics, superior thermal dissipation, and scorch safety.
From Goodyear's Discovery to High-Purity French Process Zinc Oxide
The rubber industry consumes over 55% of global Zinc Oxide production annually. Understanding why Zinc Oxide replaced historical alternatives clarifies why no other metal oxide can replicate its synergistic curing mechanism.
The Transition from Toxic Litharge to Pure Zinc Oxide
Following Charles Goodyear's discovery of sulfur vulcanization in 1839, early rubber manufacturers struggled with agonizingly long curing cycles (often exceeding 4 to 6 hours at elevated temperatures) and unpredictable mechanical stability. Early vulcanizates degraded rapidly due to severe oxidative reversion.
In the late 19th and early 20th centuries, toxic heavy metal compounds like litharge (lead monoxide, PbO), white lead, and calcium oxide (CaO) were tested as crude vulcanization accelerators. However, lead compounds caused catastrophic worker toxicity, extreme compound darkening, and uncontrolled scorching during milling.
The development of the indirect French Process—pioneered industrially and refined by manufacturers like Bhatti Chemicals Industry—revolutionized rubber compounding. By vaporizing high-purity metallic zinc in controlled furnaces and reacting the zinc vapor with preheated atmospheric oxygen, an ultra-pure (≥ 99.9%), fine particle size powder with consistent crystalline morphology was produced. Zinc Oxide demonstrated unprecedented synergistic activation with organic sulfur accelerators, reducing cure times from hours to minutes while boosting tensile strength by more than 300%.
| Metal Oxide Candidate | Primary Activation Efficiency | Thermal Conductivity | Scorch Safety & Processing | Industrial Viability |
|---|---|---|---|---|
| Zinc Oxide (ZnO 99.9%) | Optimal; forms soluble zinc carboxylate accelerators | High (~25–30 W/m·K) | Excellent scorch induction safety and sharp t90 cure rate | Global industry standard (95%+ of all sulfur-cured rubber) |
| Magnesium Oxide (MgO) | Low in diene rubbers; acts primarily as acid acceptor in CR | Moderate (~15 W/m·K) | Inadequate activation of sulfenamide accelerators | Restricted to polychloroprene (Neoprene) and halogenated butyl |
| Calcium Oxide (CaO) | Very poor activator; lacks catalytic coordination | Low (~1.5 W/m·K) | Highly hygroscopic; causes severe moisture porosity and gassing | Used solely as a moisture desiccant in low-pressure extrusion |
| Cadmium Oxide (CdO) | Moderate activation kinetics | Moderate (~12 W/m·K) | Unacceptable environmental and occupational bio-toxicity | Strictly banned worldwide under global environmental laws (REACH / RoHS) |
Official In-House Quality Assurance Test Report
Certified 99.99% Pure Zinc Oxide for Automotive Radial Tyres & Industrial Rubber Compounding
Bhatti Chemicals Industry guarantees 99.99% pure Zinc Oxide (ZnO) engineered specifically for Tyre & Rubber Manufacturing. Every commercial production batch is tested in our dedicated on-site analytical laboratory in Gujranwala, Pakistan, utilizing spectrophotometry, EDTA titration, and sub-micron sieve analysis to verify optimal reactivity and ultra-low heavy metal concentrations (Pb ≤ 50 ppm, Fe ≤ 0.003%, Cd ≤ 10 ppm). For domestic procurement and multinational export orders, independent SGS (Société Générale de Surveillance) testing reports are provided upon request.
Why Pakistan's Large Tyre Industries Use Bhatti Chemicals Zinc Oxide
From major automotive radial tyre manufacturers to leading commercial vehicle, motorcycle, and industrial conveyor belt producers, Pakistan's rubber compounding giants rely on Bhatti Chemicals Industry for guaranteed purity, technical performance, and dependable supply.
Guaranteed 99.99% Purity
Manufactured exclusively from pure special high-grade (SHG) virgin zinc via the French indirect thermal process. Zero recycled ash contamination, ensuring predictable cure rates and maximum vulcanizate tensile strength.
Certified On-Site & SGS Verification
Every commercial batch is tested in our dedicated on-site laboratory for chemical assay, 325-mesh residue (≤0.05%), and heavy metals. Third-party testing from internationally recognized laboratories like SGS is provided with every bulk order.
Large Domestic Scale & Fast Dispatch
With an annual production capacity of 5,000 metric tons, we provide immediate factory dispatch from Gujranwala with dedicated freight routes to Karachi, Lahore, Sheikhupura, and Rawalpindi, guaranteeing zero plant shutdowns.
Moisture-Proof 25 kg Bagging
Packaged in heavy-duty 3-ply kraft paper bags with heat-sealed polyethylene inner liners that block atmospheric moisture and CO₂ absorption, preserving full active surface area during long warehouse storage.
The Chemical Mechanism: How Zinc Oxide Drives Sulfur Cross-Linking
Zinc Oxide is not an inert filler or simple pigment; it is an active coordination reagent that chemically participates in every intermediate stage of sulfur vulcanization.
Step-by-Step Reaction Mechanism
Vulcanization without an activator proceeds via free-radical mechanisms that are sluggish, inefficient, and consume vast quantities of elemental sulfur (S8), generating weak, thermally unstable polysulfidic cross-links (C–Sx–C, where x ≥ 3).
When Zinc Oxide is introduced alongside stearic acid (C17H35COOH), the chemical sequence unfolds in four precise stages:
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1. In-Situ Zinc Stearate Formation: During the initial thermo-mechanical mixing in the Banbury mixer (110°C–140°C), solid ZnO particles react at their crystalline boundaries with stearic acid to yield soluble zinc stearate:
ZnO + 2C17H35COOH → Zn(C17H35COO)2 + H2O. This converts insoluble surface zinc into a lipophilic complex capable of dissolving seamlessly into non-polar hydrocarbon rubber polymers. -
2. Accelerator Coordination & Ligand Exchange: The dissolved Zn2+ cations coordinate with primary accelerators (e.g., sulfenamides such as TBBS, CBS, or thiazoles such as MBT). The d-orbitals of the zinc ion polarize and weaken the accelerator's S–N or S–C bonds, forming highly reactive zinc-perthiomercaptide active complexes.
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3. Sulfur Ring Opening & Curing Acceleration: These zinc-accelerator complexes catalyze the rapid nucleophilic opening of cyclooctasulfur (S8) rings at vulcanization temperatures (145°C–180°C). Rather than random fragmentation, sulfur is transferred systematically to the allylic hydrogen sites along the polyisoprene or polybutadiene polymer backbones.
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4. Network Maturation & Cross-Link Desulfuration: Crucially, excess Zinc Oxide scavenges labile sulfur from thermally vulnerable polysulfidic bridges, converting them into stable mono-sulfidic (C–S–C) and di-sulfidic (C–S–S–C) cross-links while forming microscopic, non-deleterious zinc sulfide (ZnS) micro-crystals. This prevents cross-link shortening, hardening, and embrittlement during prolonged dynamic tyre service.
Rheometer Cure Kinetics Impact
On moving die rheometer (MDR) traces, proper Zinc Oxide dosing (3.0–5.0 PHR) establishes an extended, safe scorch induction time (ts2), preventing premature scorched lumps during extrusion and calender frictioning. Once mold cure temperature is achieved, ZnO induces an aggressive cure rate (t90 − ts2), maximizing maximum torque (MH) and cross-link density while preventing cure reversion (MH − M30min).
Thermal Conductivity & Hysteresis Dissipation in Radial Tyres
How Zinc Oxide protects tyres from internal heat buildup, carcass fatigue, and high-speed catastrophic delamination.
The Viscoelastic Heat Problem in Tyres
Every vehicle tyre is a complex viscoelastic polymer structure subjected to cyclical deformation as it rolls across pavement under load. At highway speeds (100–120 km/h), passenger car tyres deform over 800 times per minute; commercial 18-wheeler truck tyres endure immense cyclic compression under loads exceeding 3,000 kg per wheel.
Due to viscoelastic hysteresis (characterized by the material loss tangent, tan δ), a portion of the mechanical energy expended during deformation is not recovered elastically but is converted into internal thermal energy.
Raw rubber polymers and carbon black are notorious thermal insulators with extremely low thermal conductivity:
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Natural Rubber (NR): Thermal conductivity of ~0.13 to 0.15 W/(m·K).
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Synthetic SBR / BR Matrix: Thermal conductivity of ~0.16 to 0.19 W/(m·K).
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Zinc Oxide (ZnO Crystals): Exceptional thermal conductivity of 25.0 to 30.0 W/(m·K)—over 180 times higher than the rubber matrix!
Preventing Tread Separation & Blowouts
Without sufficient Zinc Oxide dispersion, the temperature within the heavy shoulder and belt package of a truck radial tyre can rapidly escalate beyond 120°C–140°C. At these extreme internal temperatures, rubber undergoes thermal anaerobic reversion: cross-link bonds cleave, modulus collapses, and the rubber compound softens into an unstable gel-like consistency. This thermal degradation leads directly to:
Belt Edge Looseness & Tread Stripping
High heat buildup at the shoulder reduces adhesive shear strength between the breaker plies. Zinc Oxide conducts this heat outward toward the rim and air stream, preserving interlaminar adhesion.
Dynamic Flex Fatigue Life
Tyre sidewalls undergo continuous cyclic bending. Zinc Oxide reinforces the polybutadiene/natural rubber network, maintaining elastic recovery across millions of revolutions without fatigue micro-cracking.
Lower Rolling Resistance & Fuel Economy
By optimizing cross-link network uniformity, Zinc Oxide lowers compound tan δ at 60°C (the standard predictor of rolling resistance), directly reducing vehicle fuel consumption and CO2 emissions.
Zinc Oxide Dosage (PHR) Across Tyre & Rubber Components
Engineering formulations detailing base polymers, carbon black grades, accelerator packages, and Zinc Oxide loading in parts per hundred rubber (PHR).
| Rubber Component | Elastomer System (PHR) | Reinforcing Filler | ZnO Loading (PHR) | Stearic Acid | Vulcanization Accelerator Package | Engineering Rationale |
|---|---|---|---|---|---|---|
| Passenger Car Radial (PCR) Tread | Solution SBR (70.0) + High-cis BR (30.0) | Silica 1165MP (80.0) + N234 (15.0) | 3.0 – 4.0 PHR | 2.0 PHR | TBBS (1.5) + DPG (1.2) + Sulfur (1.4) | Balances wet grip, low rolling resistance, and heat dissipation under high speeds. |
| Truck & Bus Radial (TBR) Tread | Natural Rubber TSR20 / RSS3 (100.0) | Carbon Black N115 / N220 (50.0) | 4.0 – 5.0 PHR | 2.5 PHR | CBS (1.2) + PVI (0.2) + Insoluble Sulfur (1.6) | Extreme chip/cut resistance, heavy load bearing, and thermal dissipation against casing blowout. |
| Tyre Sidewall Compound | Natural Rubber (50.0) + BR 1220 (50.0) | Carbon Black N330 / N660 (45.0) | 2.5 – 3.5 PHR | 2.0 PHR | TBBS (0.8) + TMQ (1.5) + 6PPD (2.5) + S (1.8) | Maximum flex fatigue resistance, broadband UV resistance, and ozone weathering protection. |
| Steel Belt Skim (Cord Adhesion) | Natural Rubber RSS1 (100.0) | Carbon Black N326 (55.0) | 5.0 – 6.5 PHR | 1.0 PHR | DCBS (1.0) + Cobalt Naphthenate (1.0) + S (4.5) | Forms durable copper-zinc-sulfide bonding layer with brass-plated steel cords; prevents moisture debonding. |
| Inner Liner (Tubeless Tyre) | Bromobutyl (BIIR) or Chlorobutyl (100.0) | Carbon Black N660 (60.0) | 2.0 – 3.0 PHR | 1.5 PHR | MBTS (1.2) + Phenolic Resin (4.0) | Cross-links halobutyl resin while preserving extreme air impermeability and flex crack resistance. |
| Heavy Mining Conveyor Belts | Natural Rubber (70.0) + SBR 1502 (30.0) | Carbon Black N220 (55.0) | 4.0 – 5.0 PHR | 2.5 PHR | MBS (1.4) + TMTD (0.2) + Sulfur (2.2) | Withstands severe impact tearing, abrasive mineral gouging, and continuous thermal flex cycles. |
| Automotive Engine Mounts (NVH) | High-purity Natural Rubber Pale Crepe (100.0) | Semi-reinforcing N774 (35.0) | 4.0 – 5.0 PHR | 2.0 PHR | EV cure: TMTD (2.5) + CBS (1.0) + Low Sulfur (0.5) | Ultra-low compression set, minimal dynamic creep, and superior vibration dampening stability. |
| Shoe Soles & Microcellular EVA | EVA Resin (70.0) + Natural Rubber (30.0) | Precipitated Silica (25.0) + CaCO3 (15.0) | 2.0 – 3.0 PHR | 1.5 PHR | DCP (Peroxide 1.2) + ADC Blowing Agent (3.0) | Activates blowing agent decomposition; ensures uniform microcellular pore distribution and resilience. |
Brass-Coated Steel Cord Adhesion in Radial Tyres
The steel belt package gives modern radial tyres their structural stiffness, cornering stability, and puncture resistance. However, steel wire cannot bond directly to raw rubber. Steel cords are electroplated with a micro-thin layer of brass (typically 63% to 70% copper, 30% to 37% zinc, with a coating thickness of 0.15 to 0.30 µm).
The adhesion mechanism between the rubber compound and brass is a chemical sulfidation reaction controlled directly by Zinc Oxide:
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Formation of the Copper Sulfide (CuxS) Bonding Layer: During curing, copper from the brass coating reacts with sulfur to grow a dendritic, interlocking cuprous sulfide (CuxS) crystalline film that physically and chemically anchors into the rubber matrix.
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Zinc Oxide Prevents Over-Sulfidation: If copper sulfidation proceeds unchecked, the CuxS layer grows excessively thick and brittle, flaking off under mechanical shear. Zinc ions from Zinc Oxide compete for sulfur, forming a self-limiting zinc sulfide (ZnS) barrier that arrests excessive copper corrosion.
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Moisture & Salt Corrosion Resistance: When road moisture or winter deicing salts penetrate microscopic tread cuts, galvanic corrosion can attack the steel core. High-purity Zinc Oxide acts as a sacrificial corrosion buffer, neutralizing acidic moisture and maintaining adhesion retention above 85% after 14-day humidity chamber testing (95% RH @ 70°C).
Technical Specifications & ASTM D4295 Compliance
Bhatti Chemicals Industry manufactures rubber-grade Zinc Oxide adhering strictly to ASTM D4295, ISO 9298, and ISO 9001:2015 quality management benchmarks.
| Quality Parameter | Test Method Standard | Bhatti Chemicals Industry Spec | Compounding Significance |
|---|---|---|---|
| Zinc Oxide (ZnO) Content | ASTM D3280 / ISO 9298 Titration | ≥ 99.9% | Maximum chemical reactivity with accelerators; zero inert ash dilution. |
| Physical Appearance | Visual / Colorimetry | Fine White Powder (Whiteness ≥ 94%) | Uniform dispersion without black carbonaceous furnace specks. |
| Specific Surface Area (BET) | ASTM D3037 / Nitrogen Adsorption | 4.5 – 6.0 m²/g | Optimal interfacial contact area with stearic acid without excessive Banbury viscosity spike. |
| Sieve Residue (325 Mesh / 45 µm) | ASTM D185 / Wet Sieve Test | ≤ 0.05% | Eliminates micro-voids, surface blemishes, and stress risers in thin inner liners and tyre beads. |
| Moisture Content (at 105°C) | ASTM D280 Oven Gravimetric | ≤ 0.3% | Prevents steam blistering, porosity, and pinhole defects during curing press vulcanization. |
| Lead (Pb) Content | AAS / ICP-OES Spectroscopy | ≤ 0.005% (50 ppm) | Guarantees low heavy metal impurities, complying with global REACH and environmental export norms. |
| Cadmium (Cd) Content | AAS / ICP-OES Spectroscopy | ≤ 0.001% (10 ppm) | Avoids environmental contamination and regulatory non-compliance in overseas markets. |
| Iron (Fe) Content | Spectrophotometric | ≤ 0.003% (30 ppm) | Prevents pro-oxidant catalytic degradation of natural rubber hydrocarbon chains. |
| Water Soluble Salts | ASTM D2448 Conductivity | ≤ 0.2% | Prevents moisture absorption and electrical insulation breakdown in cable sheathing. |
| Loss on Ignition (at 850°C) | Gravimetric Calcination | ≤ 0.4% | Confirms total conversion from zinc carbonate, hydroxide, and organic residues. |
Banbury Mixing Sequence & Compounding Troubleshooting
Achieving uniform Zinc Oxide dispersion is essential to prevent localized scorch, unreacted agglomerates, and premature dynamic failure.
Recommended Internal Mixer (Banbury) Addition Sequence
In modern tyre and rubber manufacturing facilities, the addition order within internal mixers (Banbury / Intermix) determines the dispersion quality of Zinc Oxide:
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0:00 – 1:00 min (Initial Polymer Breakdown): Charge natural rubber (NR) or synthetic polymers (SBR, BR) into the mixing chamber. Masticate to reduce Mooney viscosity.
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1:00 – 2:30 min (Zinc Oxide & Stearic Acid Stage): Add Zinc Oxide together with stearic acid and initial processing aids. Adding ZnO early ensures intimate contact with stearic acid while shear stresses are highest, initiating the formation of active zinc-stearate complexes.
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2:30 – 4:00 min (Reinforcing Fillers & Oils): Add carbon black or silica along with aromatic or naphthenic processing oils. High shear breaks down agglomerates.
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Dump & Final Pass (Sulfur & Accelerators): Dump masterbatch at 145°C–160°C. In the cool second pass (under 105°C), add sulfur and accelerators (TBBS, CBS, MBTS). This strictly prevents premature scorching.
Common Compounding Defects & Corrective Actions
Defect 1: White Specks on Cured Rubber Surface
Cause: Incomplete dispersion of coarse ZnO particles or agglomeration due to moisture.
Correction: Ensure ZnO sieve residue is ≤ 0.05% on 325 mesh; add ZnO with stearic acid in the first 60 seconds of mixing.
Defect 2: Short Scorch Time (ts2) & Pre-Cure in Extruder
Cause: Excessive mixing temperature during second pass or moisture in ZnO.
Correction: Use low-moisture (≤ 0.3%) Zinc Oxide; maintain second-pass dump temperature below 105°C.
Defect 3: Severe Thermal Reversion in Thick Curing Parts
Cause: Under-dosing Zinc Oxide (below 3.0 PHR), leading to excessive polysulfidic cross-links.
Correction: Increase ZnO to 4.5–5.0 PHR to promote heat-stable mono-sulfidic cross-links.
Packaging Specifications, Palletizing & Safe Handling
Preserving physical dry flowability and chemical reactivity from factory dispatch to factory mixing.
Standard 25 kg Multi-Wall Bags
Packed in heavy-duty, 3-ply kraft paper or woven polypropylene (PP) bags with an inner heat-sealed polyethylene (PE) moisture-barrier liner. Protects against ambient humidity and carbon dioxide absorption.
Palletizing & Container Shipping
Standard export configuration: 40 bags per wooden/plastic pallet (1,000 kg net weight), stretch-wrapped and strapped. One 20-foot FCL accommodates 20 metric tons (20 pallets). Custom jumbo bulk bags (500 kg / 1,000 kg) available on request.
Warehouse Storage Recommendations
Store in a cool, well-ventilated, dry warehouse away from strong acids and moisture. When kept in original sealed packaging, Bhatti Chemicals Zinc Oxide maintains complete chemical stability and flowability for over 24 months.
Frequently Asked Questions — Zinc Oxide in Rubber & Tyre Compounding
Authoritative answers for compounding chemists, process engineers, and plant procurement managers.
Zinc Oxide serves as an essential inorganic activator. Rather than acting as a simple catalyst, it reacts in-situ with stearic acid to form soluble zinc carboxylates (Zn2+ ions), which coordinate with organic sulfur accelerators. This activates sulfur ring cleavage (S8), shortens scorch induction to an optimal level, accelerates cross-linking, and produces thermally stable mono- and di-sulfidic bridges that give vulcanized rubber high tensile modulus, resilience, and fatigue life.
Under heavy cyclic loads and high speeds, tyres generate intense friction heat through viscoelastic hysteresis (tan δ). While natural and synthetic rubbers are poor thermal conductors (~0.15 W/m·K), Zinc Oxide has an intrinsic thermal conductivity of 25 to 30 W/(m·K). Incorporating 3 to 5 PHR of pure ZnO creates microscopic thermal pathways that evacuate internal heat outwards to the wheel rim and atmosphere, keeping the tyre below the critical 120°C reversion threshold where tread delamination occurs.
Dosage varies by the specific dynamic stresses of the tyre component:
• PCR Tread: 3.0 to 4.0 PHR (optimizes wet traction, abrasion resistance, and rolling resistance).
• TBR Truck Tread & Casing: 4.0 to 5.0 PHR (enhances thermal dissipation and prevents carcass fatigue).
• Tyre Sidewalls: 2.5 to 3.5 PHR (provides dynamic flex fatigue and UV/ozone cracking resistance).
• Steel Belt Skim: 5.0 to 6.5 PHR (regulates brass sulfidation for steel cord bonding).
• Inner Liner: 2.0 to 3.0 PHR in halobutyl formulations.
In steel-belted radial tyres, bonding depends on a cuprous sulfide (CuxS) layer formed between sulfur in the rubber and copper in the brass coating. Zinc Oxide controls the kinetics of this reaction: zinc ions compete for excess sulfur, preventing the CuxS layer from growing too thick and brittle. This creates a resilient, interlocking metallurgical bond that withstands harsh shear forces and protects steel cords from moisture-induced corrosion.
While active nano Zinc Oxide has higher surface area and can activate curing at lower dosages (1.5 to 2.0 PHR), standard microcrystalline French Process Zinc Oxide (4.5 to 6.0 m²/g) remains the global industry preference for tyres. Standard ZnO provides vital bulk thermal conductivity and brass cord adhesion that reduced nano dosages cannot achieve, while avoiding severe mixing viscosity spikes and dispersion clumping common to nanopowders.
The benchmark international standards are ASTM D4295 (Standard Classification for Rubber Compounding Materials—Zinc Oxide) and ISO 9298 (Rubber Compounding Ingredients—Zinc Oxide Test Methods). Key compliance thresholds include ZnO content ≥ 99.0% (Bhatti Chemicals guarantees ≥ 99.9%), surface area 4.0–6.5 m²/g, sieve residue on 325 mesh ≤ 0.05%, moisture ≤ 0.3%, and lead (Pb) content ≤ 50 ppm.
Zinc Oxide has a wide direct band gap (3.37 eV) that strongly absorbs ultraviolet radiation across the UVA and UVB spectrum (290–400 nm). In tyre sidewalls, weatherstripping, and outdoor conveyor belts, Zinc Oxide dissipates solar UV energy as harmless low-grade heat, preventing photo-oxidative chain scission and surface micro-crazing.
Agglomeration is typically caused by: (1) high ambient moisture absorption in damp warehouse storage, (2) adding Zinc Oxide late in the mixing cycle after polymer viscosity has dropped, or (3) insufficient stearic acid to wet the polar ZnO surface. Adding Zinc Oxide during the first 60 seconds with stearic acid under high Banbury shear eliminates agglomerates.
When stored in its original, unopened 25 kg bags with sealed polyethylene liners in a cool, dry warehouse below 35°C and away from acid vapors, Bhatti Chemicals Zinc Oxide has a shelf life exceeding 24 months with no loss of chemical assay or flowability.
Bhatti Chemicals Industry dispatches trial sample bags (25 kg) for laboratory compounding evaluations up to multi-ton truckloads for full production runs from our manufacturing facility in Gujranwala, Pakistan. Contact our sales department via email at info@bhattichemicalsindustry.com.pk or call/WhatsApp +92 304 1462460.
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