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The Picat software is a computer simulation programs that allows one to better understand the
polymer processing procedure and the final product specification problem that occurred when
changes is introduced to one or more parameters (temperature, pressure, screw speed and
others) of the process. In addition, this software also allows user to use their knowledge of
polymer science and processing to troubleshoot and fix common product faults that can occur
during polymer extrusion. Subsequently, this software aims to create an optimum processing
condition which then reduces the time of production and eventually production overall costs.






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The assessment chosen was the µSurface defects: Dull finish´. The simulation software
categorized it at fault level 21. Using the Picat reference book, the causes of the fault can be
due to several factors. These factors include:

O? Ñow melt and /or die temperature

O? ðxcessive screw speed
O? Êegrind percentage too high
O? Poor calibrator surface conditions

Using these factors as a guide, the examination of the process was started. The first step was
to check the melt temperature of the polymer in the screw (stated: 232 C). Adjustment was
done to die head and die tip temperature (stated: 228 C and 227 C). This result in dull finish
fault decrease to level 1 but new fault appeared (ovality level 3). Upon checking the reference
book again, ovality occurred due to wall thickness too low, insufficient cooling and excessive
haul off pressure. Die tip temperature was further increase to 231 C and dull finish fault was
no longer present, however ovality increase to level 5.

Next step, adjustment was done to water flow and haul off pressure, but ovality worsen to
level 17 and new faults juddering (level 2) and creasing (level 4) appeared. After analysing
the problems, we believe these faults occurred due to incorrect ratio of output to haul off
speed and incorrect cooling bath temperature. Adjustment was made again for water flow
from 67 to 62, haul off speed from 14.16 to 15.16. This resulted in ovality level drop to 6 and
juddering level 1. Upon changing coolant flow from 62 to 73 and increase weir flow by 2, all
faults were no longer present.

Hence, product specification was check with the requirement and the results shown below:

O? Diameter is too small by 0.1 mm, hence haul off speed was reduced from 15.16 to
13.73. Êeducing the haul off speed mean polymer is given more time to form bigger
diameter and greater wall thickness. Final result showed diameter was 10.8 mm and
wall thickness was 1.5 mm which both is within the product specification.
O? utput result was 32.2 kg/hr (within product specification)
O? Actual length was 2999.7 mm (0.3 off from product specification)
O? Polymer weight was 39.1 g/m (within product specification)
O? Impact strength test failed. Following the reference book guide, adjustment was done
to temperature processing at the barrel but proved to be futile. However, by checking
the grade of material proved to be working.
In summary, this assessment showed that dull finished can be corrected increasing the melt
and die temperature. vality, juddering and creasing can be corrected by adjusting the water
flow rate, coolant flow rate and haul off speed. Ñastly, impact strength failure occurred due to
poor grade quality of material used or contaminated material was used. The simulation
showed that the whole procedure last for 4 hours and 25 minutes and material used was 147.8
kg. ðxperience operators would probably take less time and material in troubleshooting this
problem as the specific faults only related to process adjustment and ensuring the correct raw
clean material is used. However, in the real time processing many other faults can be
expected and solving of specific faults can be different from the simulation as plant
processing involved more complex equipment and generally difficult to achieve optimum
operating condition. In addition, product specification always targeted at the middle range as
we do not want to give our customer too much or too little product.