Issues in injection-molded plastic products and troubleshooting
Wednesday June 16, 2021
The injection molding process requires many parts for producing plastic products such as a machine, materials and a mold. Therefore, several issues can be occured during process and can cause machines to shut down, more wastes or defects in the production line. To ensure production continuity and the quality of end-products, we will delve into each problem and troubleshooting.
Injection issues
Black Spot or foreign material contaminated on finihed products would be a major problem of injection molding process. It is diectly effected to increasing number of defects and the decreasing in productivity. The residue of plastic resin accumulated in the screw or cylinder is the major root cause of this problem.Futhermore, using coventional plastic resin for sealing machine during long-period shut down would be one of the factors which could generate black spot in the system. The reason is the resin could be degraded by accumulated heat in cylinder. Last but not least, the screw surface would be another factor, if there is any corrosive area or any scatch on the srew. It will be the area for depositing. Therfore, the black spot occued by both two factors can be randomly evaculated with finished product when being continueously production.
X PURGE is the best solution. These problems can be rectified by purging the screw and cylinder with X PURGE regulary so as to eliminate the plastic residue or contaminants accumulated in your machine. X PURGE works on the machine in 2 mechanisms. The first key mechanism is by physical cleaning. The second mechanism is by chemical cleaning. The active ingrdient in X PURGE works by swelling and penetrating into hard-to-reach ares in the barrels and remove the contamination and deposits togeher with X PURGE without any damage. Moreover, X PURGE offers the heat stability performance therefore it can be used to seal machine for long-period shutdown. These outstanding performace of X PURGE would be help you to increase the productivity and less wastes and defects in your production line.
Material and color contamination
Customers who manufacture a diverse range of products and have storage limitations may need to change materials frequently, which not only incurs expenses and requires downtime for purging but can also lead to material contamination and discoloration. To address this issue, X PURGE can be used during changeovers to purge leftover color or materials from the machine. The compound also reduces the amount of material and the time required for purging.
Gels or fisheyes
Gels are common issues in film production that can be caused by the presence of other plastic materials, insufficient heat long run production, or poor additive mixing. They become more prevalent after prolonged production. X PURGE can be used to help eliminate this particular problem, either by conducting a preliminary purge of the machine with the compound or by packing the purging compound in the machine during downtime.
Die lines and residues on the die head and the film blowing machine
Die lines are lines in the machine direction that produce unevenness in films and are caused by the friction of the plastic at the die head or by plastic residues. This issue can be solved by adjusting production conditions, which include decreasing or increasing the temperature at the die head, reducing production cycles, or removing the die head from the machine for cleaning. X PURGE, however, allows for fuss-free die head cleaning as the purging compound can be forced through the screw to the die head without any disassembly needed.
Pores
This problem is caused by the corrosion and oxidation of the part of the plastic product that is in contact with the mold. The compromised density allows moisture to penetrate into the mold and the plastic material. This issue can be solved by cleaning the screw and the barrel with X PURGE to dislodge any plastic deposit inside the machine without any need for disassembly.