Technical Information
Injection Molding Processing Guide for
VERSIFY Plastomers and Elastomers
When processing VERSIFY Plastomers and
Elastomers in injection molding applica-
tions, start with a clean extrusion system:
Completely purge other polymers from
the system prior to molding part
Make sure all mold surfaces are clean
and free of buildup
VERSIFY Plastomers and Elastomers can
be easily run following the extrusion of
prime quality low density polyethylene
(LDPE), linear low density polyethylene
(LLDPE), or polypropylene (PP) resin
Screw/Injection Types: The use of a
single flighted or high shear barrier screw
is suggested. Low shear screws optimized
for super high output may result in poor
melt quality.
Machine/Mold Types:
Any injection molding machine or mold
may be used
It is important to have CHILLED water
available to the mold
Gates: Should be in the thickest part of
the mold, positioned to allow the melt to
impinge on the core, a core pin, or the
cavity wall
Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow
Runners: Insulated or hot runners are Temperature Measurement: A variable
acceptable, should be minimal in length, depth thermocouple or IR gun can be used
balanced, and terminated in a slug to accurately determine melt temperature.
weld. Hot runner molds need molding Variation in melt temperature across the
machines with screw decompression flow channel can be minimized through
(suck-back) to prevent gate drool adjustment of temperature profile.
Ejection: Air or plate ejection is sug-
Concentrates:
gested. Air assist is also suggested.
These resins are fully formulated and
Venting: Located at the end of melt fronts
ready to use for injection molding. If
or where melt welding will occur. Parting
additional additives must be added, a
lines, ejector pins, cores, or perforated or
high flow LDPE or high MFR PP concen-
pressed metal surfaces may be used for
trate is acceptable
venting. Small vent holes are not sug-
Colors may be added as concentrates
gested as they can become clogged
(in the VERSIFY polymer, LDPE, or PP)
Sprues: Should be short as possible
or as dry powder
Start with the following temperature
Blending:
profile and make adjustments as
VERSIFY Plastomers and Elastomers
necessary:
are readily dry or melt blended with all
374F (190C) melt temperature, 68F
types of polyolefins to improve cycle
(20C) mold temperature, medium hold
times and part stickiness issues
pressure, low back pressure
VERSIFY Plastomers may be blended
Keep barrel temperature the same,
with 5-15 percent polyolefin to lower cycle
except the feed throat which should stay
times, lower part stickiness to the mold,
below 293F (145C)
and only slightly increase modulus, with-
Use injection speed to fill part
out decreasing optical properties
Control part size first with mold tem-
VERSIFY Elastomers may be blended
perature, then with hold pressure
with 20-40 percent polyolefin to lower
Increase mold temperature to decrease part size, OR cycle times and lower part stickiness to
decrease mold temperature to increase part size. the mold.
Increase hold pressure to decrease part size, OR
decrease hold pressure to increase part size.
Dow Elastomers
Table 1: Troubleshooting Suggestions for Injection Molding VERSIFY Plastomers and Elastomers

To Resolve This Issue Suggested Solution

Black Specks
Burned resin on cylinder walls flakes off Purge extruder
Airborne dirt Cover hopper
Processing temperatures too high Lower melt temperature
Hang-up in extruder, nozzle, or runner Rework extruder, nozzle, or runner
Black Spots
Air trapped in mold, causing burning Reduce injection pressure or speed, clean vents
Too much suck-back Reduce suck-back
Black Streaks
Clogged vents Clean vents
Frictional burning of material between plunger and cylinder wall Avoid finely ground material that can locate between plunger and wall
Burning in nozzle (too hot) Reduce nozzle temperature
Wide cycling of nozzle temperature Avoid on-off controller; use variable controller
Plunger or screw off center Relocate plunger
Nozzle or gate tips incorrect, causing burning Use through tips, use shorter tips
Brown Streaks
Overheated cylinder Check for run-away heater, check molten resin temperature, reduce heater temperatures,
Hang up in cylinder of nozzle, causing burning reduce screw RPM, reduce back pressure
Purge barrel, remove nozzle and clean
Bubbles or Voids
Insufficient resin in the mold caused by: Take action to:
- Short packing time / pressure - Increase packing time / pressure
- Short hold time - Increase hold time
- Un-melted resin in flow - Decrease rear zone temperatures
- Insufficient shot size - Increase shot size
- Heavy sections, bosses, ribs - Redesign mold
Moisture on granules Dry granules before molding
Non-uniform mold temperature Rearrange water lines to mold to obtain uniform mold temperature
Air not escaping through vents Clean vents, add vents
Degrading additives especially some pigments Lower all zone temperatures; lower final zone temperature by 20-50F
Cracking
Packing excess resin into the mold Reduce feed, reduce injection pressure, reduce injection forward time, reduce barrel
Resin degraded temperature, reduce packing pressure
Resin stressed Reduce melt temperature
Improper mold draft or undercuts Increase melt temperature
Ejector pins or ring poorly located Rework mold
Relocate the ejector pins, better to push off than pull off, use air assist
Curled Parts
Parts sticking in mold See Parts Sticking to the Mold conditions (next page)
Parts dragging Check mold plate alignment
Use silicone or other mold release spray on sticky areas
Dry blend in 5-40% polyolefin
Flash
Resin too cold, pushing the mold open Heat resin, increase clamp tonnage
Resin too hot, flowing beyond the closed mold Cool down resin
Mold too hot, allowing resin to flow too easily Cool down mold
Injection speed or pressure too slow / low, increasing the Speed up injection
resin viscosity pushing the mold open Slow down injection, increase clamp tonnage
Injection speed too fast, pushing the mold open Repair mold
Parting line condition poor Align mold
Mold out of alignment Increase clamp pressure, run in larger molding machine
Clamp tonnage too low
Delamination at Gate
Resin too cold, mold too cold Increase extruder temperature, increase nozzle temperature, increase mold temperature
Temperature variation in shot pot Use flat temperature profile, increase screw recovery time
Injection speed too slow Increase injection speed
Injection pressure too low Increase injection pressure
Injection forward time too long Reduce injection time

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

2
 To Resolve This Issue Suggested Solution
Delamination at Gate (continued)
Incompatible color concentrate Check base resin in color concentrate, try to use a carrier resin containing VERSIFY
Runner / gates combination too different Plastomer or Elastomer, LDPE, or PP
Excessive mold heat, particularly at sprue or center gates Adjust runner / gate relative size
Contamination of material Decrease mold temperature, decrease cylinder temperatures, increase overall cycle time,
provide auxiliary cooling at mold surface
Examine resin for contamination, purge cylinder thoroughly
Nozzle Drool
Resin not solidifying, nozzle temperature too high Cool down resin at nozzle
Mold half not cooling Ensure water flow to mold
Not enough suck-back Increase suck-back (last resort)
Nozzle too large Use smaller nozzle

Parts Ejected Too Hot, Deforming the Part

Resin too hot Use lower extruder temperatures, reduce screw RPM, reduce back pressure
Mold too hot Decrease water temperature to the mold, increase water circulation
Clamp time (mold close) too short Increase time
Dry blend in 5-40% polyolefin
Parts Sticking to the Mold
Injection pressure too high, part overpacked Reduce injection pressure, reduce pack pressure, reduce injection time, reduce shot size
Resin temperature too high Reduce barrel temperature, reduce screw RPM, reduce back pressure
Unbalanced gates Balance gates
Undercuts in mold Remove draw polish and provide draft
Too much vacuum Provide adequate venting, add a poppet valve
Part sticking only on cavity side = hot mold or hot resin Reduce mold temperature, reduce resin temperature
Part sticking on core side = overpacking, hot resin, flash Reduce mold temperature, reduce resin temperature, correct inserts, spray mold release
into insert on mold, add mold release to resin
Poor mold finish Change mold finish
No air assist Add air assist
Dry blend in 5-40% polyolefin
Short Shots
Resin too cold Increase barrel temperature
Injection time too slow Decrease injection time (increase speed)
Shot size too small Increase shot size
Mold too cold Increase mold water temperature
Packing time / pressure too low Increase packing time / pressure
Mold temperature not uniform Rearrange water lines
Screw recovery time too slow Increase mold close times, increase screw RPM, decrease back pressure on screw
Shot size larger than machine capacity Use larger machine
Non-return valve leaking Repair non-return valve
Resin is degrading Decrease resin temperature
Gates too small Enlarge gates
Entrapped air Increase number and or size of vents, clean vents
Short / Flash in the Same Shot
Resin too cold, pushing open the mold and freezing off Increase resin temperature
before filling Increase clamp tonnage
Not enough tonnage on the machine Align mold
Poor mold alignment Redesign runner or gate
Poor runner or gate design
Sink Marks
Insufficient resin in the mold due to: Take action to:
- Thick sections, bosses, ribs - Rework mold, raise injection pressure
- Shot size too small - Increase shot size
- Cavity pressure too low - Reduce injection pressure
- Injection forward time too short - Increase injection forward time
Resin temperature too high Reduce resin temperature
Unbalanced gates Restrict flow through gates nearest nozzle to balance flow
Ejecting the part too hot Increase hold time
Injection speed too slow Increase injection speed
Mold too hot Reduce water temperature to mold, clean mold water channel

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

3
 To Resolve This Issue Suggested Solution
Surface Imperfections
Mold or resin too cold Increase barrel temperature, increase mold temperature
Injection speed too slow Increase injection speed
Unbalanced flow in gates and runners Rebalance gates and runners
Poor flow within mold cavity Re-gate or redesign part
Un-melted Granules
Rear zone in barrel too hot Decrease rear zone temperature
Cycle too fast for barrel capacity Increase cycle time, reduce screw speed
Insufficient restriction to flow Use restricted nozzle
Screw compression too low Use reverse temperature profile (raise heat in rear zone), change screw
Resin temperature too low Increase melt temperature, increase screw back pressure
Warping
Part ejected too hot Reduce resin temperature, reduce mold temperature, increase mold-closed time, reduce
Resin too cold screw RPM, reduce back pressure
Variation of section thickness Increase barrel temperature, increase mold temperature, increase screw back-pressure
Shot size too large Operate mold halves at different temperatures, make part uniform thickness throughout
Unbalanced gates Reduce shot size, reduce injection pressure, change screw position
Poorly designed or operated ejection system Restrict flow of resin through gates near sprue
No air assist on ejection system Redesign ejection system
Mold temperature not uniform Add air assist to eject parts
Excessive resin discharged from or packed into the gate area Maintain uniform mold surface temperature
Decrease injection forward time, decrease injection pressure, decrease feed
Dry blend in 5-40% polyolefin

North America Europe/Middle East + 800 3694 6367 dow.com

U.S. & Canada 1 800 441 4369 + 31 115 672626 dowelastomers.com
1 989 832 1426 Italy + 800 783 825
Mexico + 1 800 441 4369
South Africa + 800 99 5078
Latin America
Asia Pacific + 800 7776 7776
Argentina + 54 11 4319 0100
+ 603 7965 5392
Brazil + 55 11 5188 9000
Colombia + 57 1 219 6000
Mexico + 52 55 5201 4700

The principles of Responsible Care and Sustainable Development influence the production of printed literature for The Dow Chemical Company (Dow). As a contribution towards the protection of our environment,
Dows printed literature is produced in small quantities and on paper containing recovered/post-consumer fiber and using 100 percent soy-based ink whenever possible.
NOTICE: Any photographs of end-use applications in this document represent potential end-use applications but do not necessarily represent current commercial applications, nor do they represent an endorsement
by Dow of the actual products. Further, these photographs are for illustration purposes only and do not reflect either an endorsement or sponsorship of any other manufacturer for a specific potential end-use product
or application, or for Dow, or for specific products manufactured by Dow.
NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, the
Customer is responsible for determining whether products and the information in this document are appropriate for the Customers use and for ensuring that the Customers workplace and disposal practices are in
compliance with applicable laws and other governmental enactments. Dow assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.
NOTICE: If products are described as experimental or developmental: (1) product specifications may not be fully determined; (2) analysis of hazards and caution in handling and use are required; (3) there is greater
potential for Dow to change specifications and/or discontinue production; and (4) although Dow may from time to time provide samples of such products, Dow is not obligated to supply or otherwise commercialize
such products for any use or application whatsoever.
NOTICE REGARDING MEDICAL APPLICATION RESTRICTIONS: Dow will not knowingly sell or sample any product or service (Product) into any commercial or developmental application that is intended for:
a. long-term or permanent contact with internal bodily fluids or tissues. Long-term is contact which exceeds 72 continuous hours;
b. use in cardiac prosthetic devices regardless of the length of time involved (cardiac prosthetic devices include, but are not limited to, pacemaker leads and devices, artificial hearts, heart valves, intra-aortic
balloons and control systems, and ventricular bypass-assisted devices);
c. use as a critical component in medical devices that support or sustain human life; or
d. use specifically by pregnant women or in applications designed specifically to promote or interfere with human reproduction.
Dow requests that customers considering use of Dow products in medical applications notify Dow so that appropriate assessments may be conducted.
Dow does not endorse or claim suitability of its products for specific medical applications. It is the responsibility of the medical device or pharmaceutical manufacturer to determine that the Dow product is safe, lawful,
and technically suitable for the intended use. DOW MAKES NO WARRANTIES, EXPRESS OR IMPLIED, CONCERNING THE SUITABILITY OF ANY DOW PRODUCT FOR USE IN MEDICAL APPLICATIONS.
This document is intended for global use.
Published September, 2013.
2013 The Dow Chemical Company

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Responsible Care is a service mark of the American Chemistry Council. Dow is a partner in the American Chemistry Council Responsible Care initiative. Form No. 746-06401-0913X SMG
SMG 12549