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
material

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
disconnections
G. Air Entrapment 1. Reduce screw speed
2. Lower drying temperature
3. Increase screw compression ratio and/or transition
length
4. 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
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
Suggested Course of Action
1. Reduce viscosity by increasing temperature
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
temperature
1. Increase diameter of adapter
2. Install a more streamlined die
1. Lower drier temperature
2. Reduce regrind level
1. Increase RPM
2. Use smaller extruder
1. Check thermocouples for malfunctions/overrides
2. Reduce drying temperatures
Suggested Course of Action
1. Reduce back pressure by increasing diameter of
adapter to die or die clearances
2. Reduce melt temperature by reducing compression
ratio
3. Reduce shear by reducing RPM increasing metering
channel depth
1. Check for thermocouple malfunctions
Suggested Course of Action
1. Decrease feed zone temperature
2. Reduce feed zone length
3. Check for bridging in hopper
1. Increase compression ratio to squeeze out 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
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
1. Repair heaters
2. Adjust die zone temperature for even flow
1. Reduce back pressure in 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
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. 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. Increase back pressure with screen packs
2. Decrease pump ratio
1. Check haul off unit drive
2. Check extruder drive belts
3. Check for swing controllers
1. Dry resin
2. Reduce screw speed
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
breakdown
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
surfaces
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
A. Polishing rolls
B. Die lip-roll nip distance
C. Low stock temperature
D. Die design
Suggested Course of Action
1. Increase chrome roll temperature
2. Reduce excessive bead
1. Decrease this distance as much as possible
2. Check parallelism of rolls
1. Increase extruder temperature
2. Increase die temperature
1. Excessive flow in certain areas of die;
adjust heats
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because of toxicity, flammability, or other consideration. The available product
health and safety information for this material is contained in the Material Safety
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customer is advised to consult the MSDS for the product under consideration for
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