Agricultural Film

Q : Uneven thickness in the machine line (MD)
1.1 Caused by intermittent extrusion
1.2 Balloons swing and shakes

A :
1.1 Check the plastic feeding system and increase the feed temperature if it is found that the coolant amount under insufficient pellet hopper
1.2 Check the temperature control system if found The forming temperature in the cylinder is not appropriate.
1.3 Reduce the temperature under the pellet tank appropriately if found that the temperature under the pellet container is too high can interupt the flow of the the pellets
2.1 Reduce the cylinder temperature. If the temperature too high liquid plastic
2.2 Adjust the rate and direction of the wind blowing, the air flow rate from the plate, the wind is too high

Q : The balloon is distorted and asymmetrical.
1.1 The liquid plastic temperature is too high.
1.2 The air flow rate from the wind disc is too high.

A :
1.1 Adjust the cylinder temperature down.
1.2 Adjust the rate and direction of the wind blowing

Q : The balloon shakes and swings.
2.1 Uneven thickness
2.2 Improper placement and level of the blower ring.
2.3 Pressure sieve

A :
2.1 Check and control the film thickness.
2.2 Adjust the air ring distance with the tool. with precision using caliper and split level
2.3 Replace the grille

Q : The balloon is popped, there are holes or air bubbles.
3.1 gel starts to form on the film surface
3.2 There is a foreign substance contaminated in the plastic.
3.3 Deterioration of the extruder plastic pellets
3.4 Wet raw materials

A :
3.1.1 Inspect the plastic pellet feeding system if any foreign matter such as dust, plastic scraps, etc. is found.
3.1.2 Replace the sieve with a new one if it is found to be broken.
3.1.3 Clean the extruder, die head if found. Plastic molten residue on the extruder or die
3.1.4 Check the quality of plastic pellets if found deterioration of the plastic resin during the mixing cycle
3.1.5 Change the raw material, or increase the temperature in the Mixing Zone to equal the end of the Extrusion section if high viscosity material is mixed.
3.2 Check the plastic pellet feeding system
3.3.1 Replace the sieve with a new one if it is found to be broken.
3.3.2 Clean the Extruder, die head if found. Plastic molten residue on the extruder or die
3.4 Drying raw materials such as drying in the sun

Q : Intermittent ripple extrusion.
4.1 The amount of coolant under the pellet tank is insufficient.
4.2 The forming temperature in the cylinder is not suitable.
4.3 The temperature under the pellet container is too high and causing the pellets to flow intermittently.

A :
4.1 Check the plastic feeding system and increase the feed zone temperature.
4.2 Check the temperature control system.
4.3 Reduce the temperature under the pellet tank appropriately.

Q : The fibers are uneven in size
1.1 The diameter of the die is not uniform due to the accumulation of dirt.
1.2 Uneven extrusion (Surging) or uneven stretching
1.3 The fibers slip or slide on the stretch roller

A :
1.1 Check and clean the die head.
1.2 Check the extrusion and stretching system
1.3.1 Check and smooth the surface of the retaining roller.
1.3.2 Increase the pressure of the clamping roller to make it tighter

Q : Fiber breaks at the die head
2.1 There are foreign substances in the plastic or caused by burning plastic
2.2 There are foreign substances in the plastic
2.3 The forming temperature is not suitable.

A :
2.1 Clean the extruder and die head.
2.2.1 Inspect the plastic used and the plastic feeding system.
2.2.2 Check the sieve
2.3 Adjust the forming temperature accordingly

Q : The fiber breaks while pulling.
3.1 Melt Fracture is forming.
3.2 A gap in the plastic texture (Void)
3.3 There is a foreign object contaminated in the plastic or caused by the burning plastic
3.4 There is a plastic deterioration in the die area.
3.5 The retaining roller is working or in an unsuitable condition.
3.6 Extrusion speed is too high.
3.7 Excessive retention rate
3.8 Hot tub temperature is too low.

A :
3.1 Increase the extrusion temperature
3.2.1 Increase the temperature of the cold water bath
3.2.2 Reduce extrusion temperature
3.2.3 Adjust the distance between the die face and the casting fluid to be wider
3.3.1 Examine the plastic used. and plastic feeding system
3.3.2 Remove and clean the extruder and die head
3.3.3 Check the sieve
3.4.1 Check for other ingredients such as pigments that may can deteriorate
3.4.2 Check the forming temperature
3.5.1 Adjust the operation of the stretching roller to stretch regularly
3.5.2 Fix the fibers on the roller surface from slipping
3.6 Decrease the extrusion speed
3.7 Reducing the rate of stretching
3.8 Increase the hot tub temperature

Q : Stains on the die head
4.1 The forming temperature is too high.
4.2 There is contamination with non-heat resistant substances.

A :
4.1 Reduce forming temperature and die temperature
4.2 Check the plastic pellets and ingredients used.

Q : The fiber has too much elongation % residual.
The stretch rate is too low.

A : Increase the rate of stretching

Q : Strength of fiber is too low.
The stretch rate is too low.

A : Increase the rate of stretching

Q : Cracks, not fully filled.
1.1 The flow of liquid plastic is too slow.
1.2 There is resistance to flow in the inlet system and the filling of liquid plastic into the mold.
1.3 The mold temperature is too low in which makes the plastic fudge badly.

A :
1.1 Adjust the injection temperature or increase the injection speed.
1.2.1 Increase the size of the gate or shorten the length of the gate.
1.2.2 Adjust the size of the Sprue and Runner to be larger or reduce the length of the Sprue and Runner to be shorter.
1.3 Increase the mold temperature.

Q : Weld seams.
2.1 The flow of liquid plastic is too slow.
2.2 Injection pressure is too low.
2.3 Mold temperature is too low.

A :
2.1.1 Increase the syringe temperature
2.1.2 Use plastic pellets with increased flow rate.
2.2 Increase the injection pressure.
2.3 Increase the mold temperature.

Q : Scorch or burn
3.1 The accumulation temperature of the plastic in the mold is too high.
3.2 Ventilation inside the mold especially in the end part is not enough thus causing burns from friction and collection of plastic.

A :
3.1 Decrease the syringe temperature
3.2 Add ventilation holes in the mold.

Q : Sink mark
4.1 Injection pressure is too low.
4.2 The amount of liquid plastic per shot is insufficient.
4.3 Excessive shrinkage of plastic when cooled due to temperature of liquid plastic is too high.
4.4 The cooling time of the workpiece (Cooling Time) is too short.

A :
4.1 Increase the injection pressure
4.2 Increase the amount of plastic
4.3 Lowering the syringe temperature
4.4 Decrease mold temperature and increase cooling time

Q : Flashing
5.1 Injection speed is too high.
5.2 Excessive injection pressure
5.3 The liquid plastic temperature is too high.

A :
5.1 Reduce injection speed
5.2 Reduce the injection pressure
5.3 Reducing the temperature of liquid plastic

Q : Warpage occurs
6.1 Excessive injection pressure
6.2 Repeat injection time is too long.
6.3 The cooling time is too short.

A :
6.1 Reducing the pressure
6.2 Reduce time for iteration
6.3 Longer cooling time

Q : The surface of products are not glossy.
7.1 caused by insufficient polishing of the inner surface of the mold.
7.2 Mold temperature is too low.
7.3 The temperature of the liquid plastic is too low.
7.4 The texture of the plastic is insufficiently in contact with the mold surface.

A :
7.1 Polish the surface in the mold
7.2 Increase the mold temperature
7.3 Increase the syringe temperature
7.4.1 Increase injection pressure and injection speed
7.4.2 Increase the amount of liquid plastic per injection
7.4.3 Add pressure to iterate

Q : Air bubbles inside the workpiece
1.1 Too much humidity
1.2 Heating up too fast
1.3 Uneven forming temperature

A :
1.1.1 Bake or heat the sheet before it should go into the heat forming process
1.1.2 The baking or heating time depends on the desired sheet thickness
1.1.3 Heat the sheet on both sides
1.1.4 Set the temperature lower (increase the duration of evaporation of food or moisture)
1.2.1 Reduce the forming temperature
1.2.2 Reduce the speed of heating
1.2.3 Increase the distance between the heating device and the sheet
1.3.1 Check heating equipment
1.3.2 Optimize the temperature of each molding part
1.3.3 Install a strainer to avoid excessive heat build-up in one area

Q : The workpiece has changed color
2.1 The molding temperature is too high.

A :
2.1.1 Reduce the forming temperature
2.1.2 Reduce the time it takes to form
2.1.3 Check heating equipment there is a reoccuring problem repeats in the same area.

Q : Lines appear on the sheet or workpiece
3.1 The temperature of the extrusion head is too low.
3.2 The mold temperature is too low.
3.3 Mold temperature control is not good enough.
3.4 The temperature of the sheet is too high.

A :
3.1.1 Increase the temperature of the extrusion head
3.2.1 Increase mold temperature
3.3.1 Increase the volume or size of the cooling device
3.3.2 Check the equipment to prevent clogging
3.4.1 Reduce the temperature and time required for forming

Q : Sheet prolapse occurs
4.1 The temperature of the sheet is too high.
4.2 The flow rate of plastic pellets is too high.

A :
4.1.1 Reduce the temperature and time required for forming
4.2.1 Choose grades with lower flow rates

Q : The workpiece is incomplete forming.
5.1 The temperature of the sheet is too low.
5.2 The vacuum suction power is not enough.
5.3 Vacuum suction is not fast enough.

A :
5.1.1 Increase the heating time of the sheet
5.1.2 Increase the forming temperature
5.1.3 Add heating equipment
5.1.4 Check heating equipment there is a reoccuring problem repeats in the same area.
5.2.1 Increase the number and / or size of vacuum chambers
5.3.1 Check for leaks of the vacuum suction device
5.3.2 Use a larger vacuum chamber in the necessary area

Q : There is a point on the sheet on the side that touches the mold.
6.1 The temperature of the sheet is too high.
6.2 The vacuum hole is too large.

A :
6.1.1 Reduce the temperature and time required for forming.
6.2.1 Close or resize the vacuum hole.

Q : The workpiece is mounted on the mold.
7.1 The temperature of the workpiece is too high.
7.2 The mold has an undercut that prevents disassembly.
7.3 Work out of pattern

A :
7.1.1 Increase the cooling cycle
7.1.2 Slightly lower the mold temperature
7.2.1 Increase air pressure
7.3.1 Move the workpiece after forming out of the mold faster.

Q : The thickness of the workpiece is uneven.
8.1 Inappropriate digestion of the sheet
8.2 Hot or cold spots in the sheet
8.3 The mold temperature is too low.

A :
8.1.1 Heat the sheet evenly
8.2.1 Control the heat evenly
8.2.2 Check heating equipment
8.3.1 Increase mold temperature
8.3.2 Check the temperature control system or blockage of the machine
8.3.3 Distribution

Q : The workpiece is deformed.
9.1 The cooling temperature of the workpiece is uneven.
9.2 The distribution of the workpiece surface is uneven.
9.3 Inappropriate mold
9.4 mold temperature is too low.

A :
9.1.1 Increase the coolant channel in the mold or increase the size
9.1.2 Check the connection of the cooling device
9.2.1 Solve the problem according to item 8
9.3.1 Increase the vacuum channel
9.3.2 Added coolant channels in the cutting section
9.4.1 Increase the mold temperature

Q : Burnt sheet
10.1 The temperature of the sheet surface is too hot.

A :
10.1.1 Reduce heating time
10.1.2 Reduce the heating speed

Q : Sheet or workpiece looks wrinkled
11.1 The temperature of the sheet is too hot.
11.2 Excessive digestion of the sheet
11.3 The vacuum suction power is not enough.

A :
11.1.1 Reduce the forming temperature
11.1.2 Reduce heating time
11.2.1 Reduce the heat used appropriately
11.3.1 Check the function of the mold vacuum cleaner
11.3.2 Add a hole or vacuum inlet if needed

Q : White stripes on the sheet
12.1 The temperature of the sheet is too low.

A :
12.1.1 Increase the temperature in the process
12.1.2 Increase the speed of the vacuum cleaner

Q : Surface defects
13.1 The mold surface has embossing
13.2 Dirty sheets or molds

A :
13.1.1 It is stored with air inside. This may be solved by sand blasting (Sand blast) size #30.
13.2.1 Clean sheet and/or die surface prior to machining

Q : Spots or bright lines appear on the workpiece
14.1 The sheet was overheated in some areas

A :
14.1.1 Optimize the temperature of the thermostat in the affected area
14.1.2 Install a strainer to avoid excessive heat build-up in one area

Q : The wall at the corner of the workpiece is thinner than usual
15.1 Vacuum suction technique to obtain the shape of the workpiece
15.2 The temperature of the sheet is uneven.

A :
15.1.1 The sheet is fixed before entering the vacuum process.
15.2.1 Adjust the heating temperature evenly throughout the sheet
15.2.2 Extend the range of heating by about 10% from the center

Q : The sheet is torn during the vacuum suction process.
16.1 Improper mold design
16.2 The sheets were too cold

A :
16.1.1 Increase the degree of angle
16.2.1 Increase the heating time and temperature
16.2.2 Try to maintain the temperature evenly throughout the sheet

Q : Uneven pipe wall thickness
1.1 The die head shaft is not properly installed.
1.2 The die head unit and the pipe puller are installed unevenly.
1.3 Temperature in the die head is hot/cold intermittently.

A :
1.1.1 Adjust the die head spindle position accordingly
1.2.1 Adjust the die head unit and the tube puller unit evenly
1.3.1 Check the heating device inside the die head unit

Q : Defects that occur on the surface of the pipe in front of the die
2.1 Plastic granules moisture problem
2.2 Mixing of plastic granules and granular additives unsuitable plastic
2.3 Contaminated
2.4 Overheating

A :
2.1.1 Dry the plastic pellets before use
2.1.2 Reduce the speed of the screw
2.1.3 Check the plastic pellet storage location to keep it in a closed place
2.2.1 Increase the rpm or reduce the porosity of the screen pack to create a large back pressure for better mixing
2.3.1 Check for contamination secondary to plastic pellets and plastic pellet additives before use
2.3.2 Keep plastic pellets in a place that is free from moisture and dust.
2.4.1 Check the temperature control system

Q : The outer/inner tube surface is uneven.
3.1 The melting temperature range of plastic pellets is too low.
3.2 Contaminants are attached to the mandnal or sizing sleeves.
3.3 Excessive extrusion speed may cause melt.
3.4 If a defect forms on the bottom surface of the pipe, the problem may be that the coolant system is inadequate.
3.5 The sizing device does not match the die head unit.
3.6 Plastic granules moisture problem.
3.7 The die distance is too narrow.

A :
3.1.1 Increase the temperature of the die
3.1.2 Increase the extrusion temperature
3.2.1 Check the cleanliness of the mandrel or sizing sleeves
3.3.1 Increase the melting temperature and reduce the extrusion cycle
3.4.1 Install the coolant system in the lower section
3.5.1 Check the installation to match
3.6.1 Dry the plastic pellets before use
3.6.2 Reduce the speed of the screw
3.6.3 Check the plastic pellet storage location by keeping it in a sealed place
3.7.1 Adjust the die distance

Q : Non-round pipe diameter.
4.1 Improper or incorrectly sized device
4.2 The tube temperature is not cold enough while in the ducting section.

A :
4.1.1 Check the sizing device
4.2.1 Check the coolant temperature to keep the pipes cool enough before entering the pipe pulling section.

Q : The formation of air holes in the pipe
5.1 Plastic granules moisture problem
5.2 Deterioration of plastic pellets
5.3 Dirty die head set

A :
5.1.1 Dry the plastic pellets before use
5.1.2 Reduce the speed of the screw
5.1.3 Check the plastic pellet storage location to keep it in a closed place
5.2.1 Reduce the temperature of liquid plastic
5.2.2 Increase the screw speed in the extruder
5.2.3 Reduce back pressure in the extruder 5.3.1 Clean off dust and contaminants. It's on the dyne page regularly.

Q : Burnt deposits accumulated on the face of the die
6.1 The melting temperature of the pellets is too high
6.2 The die face temperature range is too high.

A :
6.1.1 Reduce back pressure by increasing the diameter of the die or the gap of the die
6.1.2 Reduce the liquid plastic temperature by reducing the extrusion rate
6.1.3 Shear is reduced by reducing the screw speed or increasing the depth of the screw slot.
6.2.1 Check the die face temperature range appropriately