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Barex® Resins Extrusion Troubleshooting Guide

1. Overloading of Extruder
Probable Causes Suggested Course of Action
A. Extruder Motor torque too low at operating 1. Increase gear ratio to give more torque at low RPM
RPM torque at low RPM
B. Compression ratio of screw too high 1. Decrease screw compression to approach volume
causing feed to overdrive metering section. compression
2. Starve feed screw
C. Mixing sections too severe causing 1. Remove or reduce shear of mixing devices
excessive shear work 2. Increase operating temperatures
D. Operating temperature too low causing 1. Increase operating temperatures
excessive work to pump high viscosity

2. Surging
Probable Causes Suggested Course of Action
A. Bridging in feed section 1. Decrease hopper drier temperatures
2. Positively feed regrind, check blending equipment
and ratio
B. Poor solids conveying in feed sections due 1. Make sure throat cooling in on
to melting of resin in feed section 2. Lower feed zone temperature
3. Reduce temperature of screw
C. High compression ratio of screw generates 1. Reduce compression ratio or starve feed
heat which intermittently melts resin to
reduce solids conveying and then builds
pressure to overdrive metering section
D. Low compression ratio 1. Increase back pressure
2. Reduce the amount of regrind
3. Increase screw compression ratio
E. Moisture 1. Dry resin before use
2. Allow longer drying times on hot humid days
F. Extruder Malfunctions 1. Reduce screw speed
2. Check for voltage variations
3. Check drive unit for malfunctions; correct slippage of
motor belts
4. Check thermocouples for calibration, shorts or
G. Air Entrapment 1. Reduce screw speed
2. Lower drying temperature
3. Increase screw compression ratio and/or transition
4. Reduce feed zone temperature
3. Poor Color of Product
Probable Causes Suggested Course of Action
A. Excessive Work on resin leading to high 1. Reduce viscosity by increasing temperature
material temperatures 2. Reduce shear by decreasing RPM
3. Reduce shear by increasing channel depths
4. Reduce temperature settings to remove shear heat
5. Resin freezing on screw increase screw cooling
B. Back pressure too high 1. Increase diameter of adapter
2. Install a more streamlined die
C. Feed material too yellow 1. Lower drier temperature
2. Reduce regrind level
D. Residence time too long 1. Increase RPM
2. Use smaller extruder
E. Extruder Malfunction 1. Check thermocouples for malfunctions/overrides
2. Reduce drying temperatures

4. Build-up of Brown on Die Lips

Probable Causes Suggested Course of Action
A. Excessive melt temperatures 1. Reduce back pressure by increasing diameter of
adapter to die or die clearances
2. Reduce melt temperature by reducing compression
3. Reduce shear by reducing RPM increasing metering
channel depth
B. Operating die zones too high 1. Check for thermocouple malfunctions

5. Air Entrapment
Probable Causes Suggested Course of Action
A. Early melting of resin 1. Decrease feed zone temperature
2. Reduce feed zone length
3. Check for bridging in hopper
B. Resin conveys to metering section before 1. Increase compression ratio to squeeze out air
completely melted thus trapping air 2. Increase feed zone and transition zone
temperatures thus eliminating trapping the air
3. Reduce RPM
4. Increase transition section length
5. Reduce amount of regrind
6. Gauge Control (Transverse)
Probable Causes Suggested Course of Action
A. Die flow erratic due to uneven or faulty die 1. Repair heaters
heaters 2. Adjust die zone temperature for even flow
B. Die flow uneven due to uneven melt 1. Reduce back pressure in extruder
temperature from extruder 2. Decrease screw cooling temperature if center of
web has high flow - increase if low
3. Improve screw design to lower shear, lower
compression ratio to reduce melt temperatures
4. Reduce RPM
C. Die design faulty 1. Die lips warped, replace
2. Improve die coat hanger design
3. Reduce back pressure
D. Improper die adjustment 1. Readjust die lip gradually
E. Insufficient polishing roll pressure 1. Polishing roll air cylinder pressure must be adequate
to polish full width of sheet
2. Polishing rolls improperly adjusted
F. Excessive bead buildup 1. Adjust polishing roll speed
2. Check air pressure to cylinders
3. Check gap between polish rolls

7. Gauge Control (Machine Direction)

Probable Causes Suggested Course of Action
A. Surging of material in extruder due to feed 1. Reduce feed zone temperature to improve conveying
conveying 2. Decrease compression ratio to improve cooling
NOTE: (amperage swings to confirm) capability
3. Check feed system for bridging in hopper
4. Screw temperature too high in feed zone
5. Reduce RPM
6. Reduce the amount of regrind
B. Pump ratio or second stage metering 1. Increase back pressure with screen packs
section not properly designed 2. Decrease pump ratio
C. Equipment faulty 1. Check haul off unit drive
2. Check extruder drive belts
3. Check for swing controllers
D. Moisture-air entrapment 1. Dry resin
2. Reduce screw speed
E. Polishing rolls 1. Check for eccentricity (repeating on roll)
2. Check polishing roll pressures
3. Check for excess bead in nip
F. Improper screw design 1. Redesign screw
2. Increase back pressure
3. Increase screen pack

8. Discoloration or Lumps
Probable Causes Suggested Course of Action
A. Contamination 1. Check regrind operation
2. Check oil in air supply
3. Check for broken desiccant bags
4. Check loader and loader tubes
5. Use smaller mesh screen pack
B. Unmelted resin 1. Increase extruder temperatures to obtain melt
temperatures of 400-4200F (204-215°C)
2. Increase back pressure by use of breaker plate or
screen pack
3. Increase compression ratio of screw
C. High melt temperature 1. Reduce stock temperature to prevent thermal
2. Reduce back pressures
3. Check for thermocouple malfunctions
D. Equipment contamination 1. Check for contamination on screw screens, die
adapter, die lips, etc.

9. Dull or Rough Surface

Probable Causes Suggested Course of Action
A. Melt temperature too low 1. Increase die temperatures
2. Increase extruder temperatures
B. Hang up inside die or head 1. Clean die and/or head surface
C. Purge material is hung on die or head 1. Use higher viscosity purge material (fractional melt
surface flow HDPE)
2. Start up on Barex® 210 Resin
D. Die surfaces do not have sufficiently smooth 1. Buff tool to mirror finish
E. Improper chrome roll temperature 1. In general, increase temperatures to improve gloss
F. Improper chrome roll pressures 1. Check air cylinder pressures
2. Adjust speed to eliminate bead
3. Check for eccentricity
4. Check for damaged or dirty rolls
G. Improper die design 1. Reduce output to compensate for short lip land
H. Large die lip opening 1. Reset die lips
I. Hot spots/sticking 1. Check for scale buildup inside of chrome roll (use
acid flush)
2. Use treated water
J. Moisture 1. Increase drying time
2. Reduce the amount or regrind
K Contamination 1. Check regrind for contamination
2. Check grinders, conveying tubes
3. Check machinery contamination (die, screw, etc.)

10. Chill Marks or “Marks-Off” Lines

Probable Causes Suggested Course of Action
A. Polishing roll 1. Insufficient pressure (check air cylinders)
2. Improperly adjusted
3. Excessive bead
B. Contamination 1. Contamination from machinery, etc.
C. Die damage 1. Check for nicks, pits, scratches, dirty die lips
2. Thermocouple malfunctions
D. Blocked die 1. Check for hangup areas, degradation
2. Remove dams

11. Lines (Transverse)

Probable Causes Suggested Course of Action
A. Polishing roll 1. Reduce chrome roll temperature
2. Reduce stock temperature
3. Increase polishing roll pressure
4. Check for polishing roll eccentricity
5. Check for dirty or damaged rolls
B. Pull rolls 1. Improper sheet tension
2. Check for worn rolls, gears, or sprockets
3. Eliminate backlash in drive train
12. Curling: Warping
Probable Causes Suggested Course of Action
A. Polishing roll 1. Improper chrome roll temperatures (increase)
2. Check for scale in chrome rolls
3. Check for hot spots on rolls (repeats)
B. High melt temperature 1. Reduce back pressure
2. Reduce compression ratio
3. Lower controller temperatures
C. Die design 1. Adjust die lips for less draw down
13. Orientation
Probable Causes Suggested Course of Action
A. Polishing rolls 1. Increase chrome roll temperature
2. Reduce excessive bead
B. Die lip-roll nip distance 1. Decrease this distance as much as possible
2. Check parallelism of rolls
C. Low stock temperature 1. Increase extruder temperature
2. Increase die temperature
D. Die design 1. Excessive flow in certain areas of die;
adjust heats
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The product and uses described herein may require global product registrations
and notifications for chemical inventory listings, or for use in food contact or
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Health and Safety Information
The product described herein may require precautions in handling and use
because of toxicity, flammability, or other consideration. The available product
health and safety information for this material is contained in the Material Safety
Data Sheet (MSDS) that may be obtained by calling 1-302-838-3278, or by
sending an e-mail to: Before using any material, a
customer is advised to consult the MSDS for the product under consideration for
The Material Safety Data Sheet for this product contains shipping descriptions
and should be consulted, before transportation, as a reference in determining the
proper shipping description. If the material shipped by INEOS is altered or
modified, different shipping descriptions may apply and the MSDS of the original
material should not be used.
For additional information, samples, pricing and availability, please contact:
INEOS Barex For Sales in Europe
PO. Box 537 Velox GmbH
1389 School House Road Brandstwiete 1
Delaware City, DE 19706-0537 D-20457 Hamburg
USA Germany
Customer Service: +(1) 302-838-3278
Tel: +(49) (0) 40 36 96 88-0
Fax: +(1) 302-838-3222
Fax: +(49) (0) 40 36 96 88 88

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Because conditions of use may vary and are beyond our control, INEOS makes no representation about, and is not responsible or
liable for the accuracy or reliability of data, nor for toxicological effects or Industrial Hygiene requirements associated with particular
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June 2006 © 2006 INEOS USA LLC A division of INEOS USA LLC