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
excessive shear work
D. Operating temperature too low causing
excessive work to pump high viscosity
material
2. Surging
Probable Causes
A. Bridging in feed section

1. Remove or reduce shear of mixing devices

2. Increase operating temperatures
1. Increase operating temperatures

1.
2.

B. Poor solids conveying in feed sections due 1.

to melting of resin in feed section
2.
3.
C. High compression ratio of screw generates 1.
heat which intermittently melts resin to
reduce solids conveying and then builds
pressure to overdrive metering section
D. Low compression ratio

E. Moisture
F. Extruder Malfunctions

1.
2.
3.
1.
2.
1.
2.
3.
4.

G. Air Entrapment

1.
2.
3.
4.

Suggested Course of Action

Decrease hopper drier temperatures
Positively feed regrind, check blending equipment
and ratio
Make sure throat cooling in on
Lower feed zone temperature
Reduce temperature of screw
Reduce compression ratio or starve feed

Increase back pressure

Reduce the amount of regrind
Increase screw compression ratio
Dry resin before use
Allow longer drying times on hot humid days
Reduce screw speed
Check for voltage variations
Check drive unit for malfunctions; correct slippage of
motor belts
Check thermocouples for calibration, shorts or
disconnections
Reduce screw speed
Lower drying temperature
Increase screw compression ratio and/or transition
length
Reduce feed zone temperature

3. Poor Color of Product

Probable Causes
A. Excessive Work on resin leading to high
material temperatures

B. Back pressure too high

C. Feed material too yellow
D. Residence time too long
E. Extruder Malfunction

4. Build-up of Brown on Die Lips

Probable Causes
A. Excessive melt temperatures

1.
2.
3.
4.
5.
1.
2.
1.
2.
1.
2.
1.
2.

1.
2.
3.

B. Operating die zones too high

5. Air Entrapment
Probable Causes
A. Early melting of resin

B. Resin conveys to metering section before

completely melted thus trapping air

1.

Suggested Course of Action

Reduce viscosity by increasing temperature
Reduce shear by decreasing RPM
Reduce shear by increasing channel depths
Reduce temperature settings to remove shear heat
Resin freezing on screw increase screw cooling
temperature
Increase diameter of adapter
Install a more streamlined die
Lower drier temperature
Reduce regrind level
Increase RPM
Use smaller extruder
Check thermocouples for malfunctions/overrides
Reduce drying temperatures

Suggested Course of Action

Reduce back pressure by increasing diameter of
adapter to die or die clearances
Reduce melt temperature by reducing compression
ratio
Reduce shear by reducing RPM increasing metering
channel depth
Check for thermocouple malfunctions

Suggested Course of Action

Decrease feed zone temperature
Reduce feed zone length
Check for bridging in hopper
Increase compression ratio to squeeze out air
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

1.
2.
3.
1.
2.

6. Gauge Control (Transverse)

Probable Causes
A. Die flow erratic due to uneven or faulty die
heaters
B. Die flow uneven due to uneven melt
temperature from extruder

C. Die design faulty

D. Improper die adjustment

E. Insufficient polishing roll pressure

F. Excessive bead buildup

7. Gauge Control (Machine Direction)

Probable Causes
A. Surging of material in extruder due to feed
conveying
NOTE: (amperage swings to confirm)

B. Pump ratio or second stage metering

section not properly designed
C. Equipment faulty

D. Moisture-air entrapment
E. Polishing rolls

Suggested Course of Action

Repair heaters
Adjust die zone temperature for even flow
Reduce back pressure in extruder
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
1. Die lips warped, replace
2. Improve die coat hanger design
3. Reduce back pressure
1. Readjust die lip gradually
1. Polishing roll air cylinder pressure must be adequate
to polish full width of sheet
2. Polishing rolls improperly adjusted
1.
2.
1.
2.

1. Adjust polishing roll speed

2. Check air pressure to cylinders
3. Check gap between polish rolls

Suggested Course of Action

1. Reduce feed zone temperature to improve conveying
2. Decrease compression ratio to improve cooling
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
1.
2.
1.
2.
3.
1.
2.
1.
2.
3.

Increase back pressure with screen packs

Decrease pump ratio
Check haul off unit drive
Check extruder drive belts
Check for swing controllers
Dry resin
Reduce screw speed
Check for eccentricity (repeating on roll)
Check polishing roll pressures
Check for excess bead in nip

F. Improper screw design

8. Discoloration or Lumps
Probable Causes
A. Contamination

B. Unmelted resin

1. Redesign screw
2. Increase back pressure
3. Increase screen pack

1.
2.
3.
4.
5.
1.
2.

C. High melt temperature

D. Equipment contamination

9. Dull or Rough Surface

Probable Causes
A. Melt temperature too low
B. Hang up inside die or head
C. Purge material is hung on die or head
surface

Suggested Course of Action

Check regrind operation
Check oil in air supply
Check for broken desiccant bags
Check loader and loader tubes
Use smaller mesh screen pack
Increase extruder temperatures to obtain melt
temperatures of 400-4200F (204-215C)
Increase back pressure by use of breaker plate or
screen pack
Increase compression ratio of screw

3.
1. Reduce stock temperature to prevent thermal
breakdown
2. Reduce back pressures
3. Check for thermocouple malfunctions

1. Check for contamination on screw screens, die

adapter, die lips, etc.

1.
2.
1.
1.

2.
D. Die surfaces do not have sufficiently smooth 1.
surfaces
E. Improper chrome roll temperature
1.
F. Improper chrome roll pressures
1.
2.
3.
4.
G. Improper die design
1.

Suggested Course of Action

Increase die temperatures
Increase extruder temperatures
Clean die and/or head surface
Use higher viscosity purge material (fractional melt
flow HDPE)
Start up on Barex 210 Resin
Buff tool to mirror finish
In general, increase temperatures to improve gloss
Check air cylinder pressures
Adjust speed to eliminate bead
Check for eccentricity
Check for damaged or dirty rolls
Reduce output to compensate for short lip land

H. Large die lip opening

I. Hot spots/sticking

1. Reset die lips

1. Check for scale buildup inside of chrome roll (use
acid flush)
2. Use treated water

J.

Moisture

Contamination

1.
2.
1.
2.
3.

Increase drying time

Reduce the amount or regrind
Check regrind for contamination
Check grinders, conveying tubes
Check machinery contamination (die, screw, etc.)

1.
2.
3.
1.
1.
2.
1.
2.

Suggested Course of Action

Insufficient pressure (check air cylinders)
Improperly adjusted
Excessive bead
Contamination from machinery, etc.
Check for nicks, pits, scratches, dirty die lips
Thermocouple malfunctions
Check for hangup areas, degradation
Remove dams

1.
2.
3.
4.
5.
1.
2.
3.

Suggested Course of Action

Reduce chrome roll temperature
Reduce stock temperature
Increase polishing roll pressure
Check for polishing roll eccentricity
Check for dirty or damaged rolls
Improper sheet tension
Check for worn rolls, gears, or sprockets
Eliminate backlash in drive train

1.
2.
3.
1.
2.
3.
1.

Suggested Course of Action

Improper chrome roll temperatures (increase)
Check for scale in chrome rolls
Check for hot spots on rolls (repeats)
Reduce back pressure
Reduce compression ratio
Lower controller temperatures
Adjust die lips for less draw down

10. Chill Marks or Marks-Off Lines

Probable Causes
A. Polishing roll

B. Contamination
C. Die damage
D. Blocked die

11. Lines (Transverse)

Probable Causes
A. Polishing roll

B. Pull rolls

12. Curling: Warping

Probable Causes
A. Polishing roll

B. High melt temperature

C. Die design

13. Orientation
Probable Causes
A. Polishing rolls
B. Die lip-roll nip distance
C. Low stock temperature
D. Die design

1.
2.
1.
2.
1.
2.
1.

Suggested Course of Action

Increase chrome roll temperature
Reduce excessive bead
Decrease this distance as much as possible
Check parallelism of rolls
Increase extruder temperature
Increase die temperature
Excessive flow in certain areas of die;
adjust heats

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email: info@ineosbarex.com
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June 2006

2006 INEOS USA LLC

A division of INEOS USA LLC