Black Spots

Black specks occur when heat gradually degrades

thermoplastic molecules, breaking them down into
carbon residues.
What is Black Spots in Moulding
What is Black Spots in Moulding
What is Black Spots in Moulding
On transparent plastic parts, white plastic
parts, or light colored plastic parts, black specs
often appear during the injection molding
production. The black specks on the surface of
plastic parts can affect the appearance quality
of products, resulting in a high rejection rate,
waste, and high cost in the production
process.
 Black Spots/ Specks
Black spots on or black specks in the moulded parts
are an annoying, time-consuming and costly
problem. The particles are released when starting
production and before or during regular cleaning of
the screw and cylinder. These particles develop when
material carbonizes due to overheating, which may
occur when the material flow is stopped for a longer
time without reducing the temperature in the
machine.
 Black Spots/ Specks
During these pauses, the plastic material remains
in the plasticizing unit and starts to carbonize on
the inner wall of the cylinder and on the screw
surface. Over time, this layer of carbonized
material becomes thicker and thicker until it
cracks, and black particles are injected into the
mould. When the machine is cleaned, additional
pressure is put on this layer due to the volume
expansion. The consequence: immediately after
cleaning, especially many black spots occur.
 Black Spots/ Specks
On transparent plastic parts, white plastic
parts, or light colored plastic parts, black specs
often appear during the injection molding
production. The black specs on the surface of
plastic parts can affect the appearance quality
of products, resulting in a high rejection rate,
waste, and high cost in the production
process.
Factors causing Black Spots
Black Specks/Spots due to Machine
 Process Effect
1. Prolonged residence during machine stops and
starts:
Overheating of the processing resin causing
degradation too much residence time in the barrel
results in degradation. Heat progressively breaks
down thermoplastic molecules into carbon
residues, resulting in the formation of black specks.
This frequently occurs when a machine shuts down
or starts up resins subjected to high temperatures
for an extended period of time in excess leads to
black specks
 Process Effect
2. Materials that behave differently at various operating
temperatures:
• Switching from a low to a high temperature
• It is not as easy as raising the temperature of the
barrels, to the next resin levels when production
demands that you switch to a material that operates
at least 30–40 °C higher than the one you are now
using.
• Resins like PVC, POM, and SAN resins are particularly
sensitive to these changes because they aren't really
made for these kinds of working conditions.
 Process & Raw Material
Excessive shearing of the resin caused by back pressure and
incorrect screw surface speeds.
Degradation of resin due to high hot runner temperature

Additives discolor due to degradation and decomposition.

Foreign matter mixing . If some particles in the feed hopper

are mixed with other resins with lower decomposition
temperature, black spots may be easily caused due to resin
decomposition. In addition, attention should be paid to
recycling plastics. This is because recycled plastics are
easier to decompose after multiple heats. In addition, it
may be contaminated by metals in the recycling process.
 Black Spots Caused by Mould
• The mold material is not good, with iron powders falling
off the parting surface the molding surface or the kiss-off
surface, thus causing black specks
• The ejector pin is rough and easy to burn, causing iron
powders to fall off and thereby the black specks.
• The slider generates iron powders, leading to black
speck.
• The slider rusts or generates other stains due to water
leakage inside the slider, which are thrown out by slider
movement, and black speck are caused when they fall
onto the product.
 Distinguish the Black Specks
• If the black speck appear on both the entire product surface and in the
depth of the part, they should be formed before injection molding; if the
black specks only appear on the surface, they should be formed during
injection molding. If at the same time they are only distributed in a
specific area of the surface, it is undoubtedly that they are black specks
formed during the injection molding process; if the black speck are large
(generally 0.5- 1mm), it should be caused by material carbonization; if
they are also dark, brittle and porous, it can be confirmed that they are
caused by carbonization: if the black specks are particularly dense and the
raw material is checked for no obvious impurities, it is usually caused
because the previous material is not immediately cleaned before the
material change, otherwise the material should be looked into to identify
the reason.
 Reduce the resin temperature
• Recommended temperature for all resins (also included in
product catalog or product packaging). Check whether the
setting temperature of the molding machine is out of the
range. If so, lower the temperature. In addition, the
temperature displayed on the molding machine is the
temperature of the sensor area, which is different from the
actual resin temperature. If possible, it is recommended to
use a resin thermometer, etc., to measure the actual
temperature. In particular, areas prone to resin retention
(such as check rings) may cause black spots, so pay special
attention to the temperature nearby.
• Make sure you are using at least 25% of the barrel capacity.
Long residence time can cause degradation, the source of
most black specks.
 Clean Barrel thoroughly until no
black spots appear.
• Black dots tend to stay in the check ring and
screw of the barrel. If there is a black spot, it is
estimated that the cause of the black spot is
likely to remain in the barrel. Therefore, after
the appearance of black spots, it is necessary
to thoroughly clean the barrel, and then take
countermeasures (otherwise, the black spots
will never disappear).
 Purging Compound For removal of
degraded material
• In order to avoid nozzle tip & adaptor cleaning or
removal of screw, Purging compound is the best
solution for purging the system of degraded
material so the processor can reestablish the
process with a clean screw and barrel. It is
always a good idea to use a purging compound
when changing over resins that will run on the
same press. This will ensure that the previous
resin that could be more heat sensitive is not
lingering in the system to possibly cause
problems with the next run.
Trouble Shooting Black Spots in brief