Broadway has specialised in the manufacture of custom colour masterbatches for over 25 years

More recently they’ve broadened their offering to include additive masterbatches and custom compounds. Broadway’s colourants are specified by international consumer goods companies including Unilever and Reckitt for use in their branded packaging. Their materials are used in many market sectors including food and drink, as well as cosmetics and personal care.

Outside Broadway’s 90,000 ft2
site

Situated in the Suffolk countryside and reachable in around 135 minutes from London, their manufacturing site offers customers the benefit of a custom colour matching suite. This facility gives moulders or brand owners the opportunity to approve a range of new colours in a single day – saving precious time on product development. It’s particularly useful for brands looking to exceed the 30% PCR threshold in order to avoid the UK Plastic Packaging Tax. Introducing high levels of PCR means new colour formulations are required due to the inherent tint of the recycled polymer. Broadway are able to swiftly formulate new colour samples using their customers’ PCR base material. The colour suite allows customers to review and approve colours as each new sample is made.

Brand owner reviewing a colour
match in Broadway’s colour suite

Broadway’s Sales Manager Chris Bird, explained; I’m proud to be able to offer the colour suite to assist brands in product development. We help to facilitate the transition to recycled materials in consumer packaged goods wherever possible. We can demonstrate first-hand the visual impact of using high levels of PCR. We’re passionate about educating and inspiring our customers, our products and services can help brands improve the cost and sustainability of their packaging. I firmly believe we can make a real difference in the food and drink industry. We were delighted to achieve our own Ecovadis Sustainability Rating earlier this year.

In the wake of the pandemic, the trusted plastic materials manufacturer continued to invest – expanding their workforce and infrastructure. This included a new R&D lab at their North-Suffolk site which aided the development of new products such as PCR-based masterbatches and odour neutralisers for use in PCR material. Broadway say their biggest breakthrough is their EU food contact compliant, NIR-detectable piano black for PET and Polypropylene. These masterbatches produce a high-quality gloss ‘piano’ black finish. Achieving a premium appearance, whilst safeguarding the ability to sort the component in standard recycling waste streams.

Colour wall in Broadway’s colour suite

High opacity, high gloss black plastics are a popular packaging choice in the food and drink sector, commonly used to offer products a premium appearance. Conservative estimates suggest that 30,000 – 60,000 tonnes of black plastic packaging may be entering the UK waste stream each year. The most common technology used for the automated sorting of plastics relies on Near Infrared (NIR) spectroscopy to characterise the polymer and send it to the correct waste stream. NIR is the technology of choice due to its good accuracy at identifying polymers commonly used to manufacture containers and bottles. The ability to recycle much of this is restricted by high levels of carbon black pigments used in traditional black masterbatches. As strong absorbers of radiation, they limit the infrared signal returned to the NIR detectors. This impacts the system’s ability to characterise and sort the polymers. Resulting in otherwise recyclable material going to landfill.

Broadway’s in-house laboratory called upon its extensive experience in colour chemistry to overcome this technical barrier. The new product range has undergone extensive and successful in-house NIR spectroscopy based tests, returning a distinct and statistically significant spectroscopic signature.

Broadway’s new laboratory

Dr Stephen Rayner – R&D Scientist at Broadway discussed the breakthrough; “Our new NIR Detectable Piano Black Masterbatch is real achievement for the team. After months of development work, the result is a masterbatch which provides a rich, high-gloss black, whilst remaining detectable in NIR recycling streams. This important step demonstrates Broadway’s commitment to diverting materials away from landfill whilst also maintaining a resolute focus on the aesthetics of the moulded component. With a genuine commercial appeal, we see this as a real solution for the packaging industry and we’re welcoming new enquiries for this material.”

Moulders throughout the UK and Europe rely on Broadway’s accurate, cost-efficient formulations, fast lead times and personable service. Broadway are a key supplier to Berry Global.

Louise Soloman – Divisional Purchasing Manager, Berry CPI spoke highly of them; Broadway have supported M&H for many years. They have a vast array of knowledge and work hard to support the requirements of their customers. They understand the need to respond quickly and efficiently with high quality products. I would not hesitate to recommend Broadway.

Broadway’s FREE colour matching service means you have nothing to lose in allowing them to provide an accurate match, a competitive price and the promise of great service. Their friendly team are always happy to discuss new enquires.

Contact them today on 01986 875 100 or by emailing sales@broadwaycolours.com. For further information visit www.broadwaycolours.com

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Broadway’s NIR detectable piano black masterbatch and sample plaques
moulded in PET

Yellow masterbatch in production

Staff in Broadway’s colour suite

Colour mixing in the lab