BLACK SPECKS

entrapment and enter the melt stream appearing

as black specks or streaks.
Solution: Inspect the barrel liner, nozzle,
non-return valve, and check ring for nicks, cracks,
rough surfaces, peeled plating or stuck resin.
Then, stone and polish as required, replace any
damaged mechanisms, and inspect the main and
secondary runners, as well as the sprue bushing,
for nicks, rough surfaces or sharp corners. Round
off sharp corners and radius corners where

Black specks can be defined as small dark

particles or spots
on the surface of an opaque part or within a
transparent part.

possible to minimize material trapping and shear

points.
CONTAMINATION IN INJECTION BARREL
Explanation: Any type of contamination in the

MACHINE

injection barrel may be the cause of streaks,

EXCESSIVE RESIDENCE TIME IN BARREL

spots, and specks. It may be in the form of dust

Explanation: Under the best conditions, a shot

particles that fell from the ceiling into an open

size should represent 50% of the capacity of the

hopper, pellets from other materials, residual

injection cylinder (barrel). This will result in

resin from an improper changeover, or even

processing the material for one cycle while

pieces of food that accidentally fell into a

preparing the material for the next cycle. Thus, a

container of material ready to be placed in the

mold requiring a four-ounce shot should be run in

hopper.

a machine that has a barrel with an eight-ounce

capacity. The more material left in the barrel

Solution: To remove this type of contamination it

between shots, the greater the likelihood of

may be necessary to increase the temperature of

thermal degradation. This degradation is what

the injection barrel and, using a purging material

causes the black specks.

with a wide melt range, purge the contaminate(s)

Solution: Strive for a 50% shot-to-barrel ratio.

from the system.

This is ideal but can go as low as 20%, if the

UNCONTROLLED HEATER BANDS OR

material is not too heat sensitive (like

THERMOCOUPLES

polypropylene) and up to 80% if the material is

Explanation: Improperly sized or loose heater

extremely heat sensitive (like PVC). It is not a

bands or thermocouples can cause localized

good idea to empty the barrel for every shot

degradation of the material by exposing it to

because more time will be required to bring the

extreme heat. They may be calling for more heat

next mass of material up to proper heat and

than normal due to malfunction or improper sizing.

degradation may occur.

Even a heater band that is not working can be the

TRAPPED MATERIAL

cause of such overheating. The reason is that

Explanation: If any molten resin is trapped along

adjacent heater bands must increase heat to

the flow path (most notably in the heating

compensate for the nonworking band.

cylinder), it will stay there until it degrades. When

Solution: Check each heat zone to ensure that

this happens, the degraded material becomes

all heater bands are working properly, are

carbonized, then chars and becomes brittle. At

properly controlled, properly sized, and are tight

that point, it will flake away from the area of

against the barrel. A conductive sealant should

be used to ensure full contact with the barrel. Be

sure to replace bands with the proper size,

Explanation: Air is trapped in a closed mold and

voltage, and wattage requirements as stated in

incoming molten plastic will compress this air until

the machine manual.

it auto-ignites. This burns the surrounding plastic

DAMAGED BARREL OR SCREW

and results in charred material in the form of

Explanation: A cracked injection cylinder or

spots and specks.

pitted screw is a cause of material hang-up and

Solution: Vent the mold by grinding thin

degradation. Eventually this degraded material

(0.0005-0.002) pathways on the shutoff area of

breaks loose and enters the melt stream,

the cavity blocks. Vents should take up a

appearing as specks or streaks.

minimum of 30% of the perimeter of the molded

Solution: Inspect the injection unit for cracks and

part. Vent the runner, too. Any air that is trapped

nicks in the walls. Sometimes damaged cylinder

in the runner will be pushed into the part.

walls can be welded but it is usually more

CONTAMINATION FROM LUBRICANTS

effective to replace the cylinder liner. Pitted

Explanation: Excessive use of mold release will

screws must be welded, ground and replated, or

clog vents. The trapped air cannot be evacuated

replaced with new stock.

and burns. Also, grease that is used for

OIL LEAKS

lubricating cams, slides, ejector pins, etc., can

Explanation: Hydraulic components or fittings

seep into the mold cavity and contaminate the

that are in the proximity of the injection cylinder

molded part.

may leak. This leakage may get into raw material

Solution: The remedy is to keep the mold as

storage containers and find its way into the

clean as possible and clean the vents if they

material hopper. The oil will burn at the

become clogged. A white ash will be present if

temperatures needed for molding and will

the vents are clogged. Also, make every effort to

degrade and char. This degraded material is a

eliminate the use of external mold releases.

source for streaks and specks.

MOLD TOO SMALL FOR MACHINE SIZE

Solution: Eliminate all hydraulic leaks as soon as

Explanation: If the mold is placed in too large of

possible after they occur.

a machine, the chances are that the heating

MOLD

cylinder of that machine will be large enough to

SPRUE BUSHING IS NICKED, ROUGH, OR

result in extensive residence time of the raw

NOT SEATING

material in the heated cylinder. This will result in

Explanation: A damaged sprue may cause

degraded material that will be injected into the

material to stick and be held in residence at

mold causing streaks and specks.

elevated temperature until it degrades and

Solution: Place all molds in properly sized

decomposes. At that point, it will break loose and

machinery. A rule-of-thumb states that the

enter the melt stream as streaks or specks.

machine should inject between 20% and 80% of

Solution: Inspect the internal surfaces of the

its capacity every shot.

sprue bushing. Remove any nicks or other

MATERIAL

imperfections. The tapered hole should be highly

CONTAMINATED RAW MATERIAL

polished. Check the sprue bushing-to-nozzle seal

Explanation: The most common causes of black

with thin paper or bluing ink to ensure that the

specks and streaks are molding compound

nozzle is centered to the bushing and that the

contaminants. Such contamination is usually the

hole and radius dimensions are compatible for

result of dirty regrind, improperly cleaned hoppers

the nozzle and the bushing.

or granulators, open or uncovered material

IMPROPER VENTING

containers, and poor quality virgin material

supplied by the manufacturer.

Solution: This type of contamination can be

minimized by dealing with high quality, reputable
suppliers and by using good housekeeping
practices. Properly trained material handlers will
also help reduce contamination.
OPERATOR
INCONSISTENT PROCESS CYCLE
Explanation: It is possible that the machine
operator is the cause of delayed or inconsistent
cycles. This will result in excessive residence
time of the material in the injection barrel. If such
a condition exists, heat sensitive materials will
degrade, resulting in black specks or streaks.
Solution: If at all possible, run the machine on
automatic cycle, using the operator only to
interrupt the cycle if an emergency occurs. Use a
robot if an operator is really necessary. And,
instruct all employees on the importance of
maintaining consistent cycles.