Troubleshooting Guide for Nonwoven Extrusion Applications
NonWoven Extrusion Troubleshooting
Problem
Probable Cause
Suggested Remedy
Melt Fracture and Poor Surface Finish
- High shear forces, excessive melt temperature
- Poor die design
- Inadequate die maintenance
- Adjust screw speed and temperature
- Use processing aids
- Regular die cleaning and polishing
Voids, Bubbles, and Air Traps
- Excessive moisture in resin
- Inadequate extruder venting
- Poor material mixing
- Proper material drying
- Optimize extruder vents
- Use high-quality resin
Dimensional Inaccuracy and Uneven Thickness
- Inconsistent screw speed
- Inadequate temperature control
- Die design flaws, uneven cooling
- Consistent process parameters
- Proper die alignment and cleanliness
- Uniform cooling
Warping and Bowing
- Uneven cooling,
- High internal tensions
- Controlled cooling
- Proper die and take-off system alignment
Shark Skin, Surging, and Clogging
- High extrusion speeds (shark skin)
- Unbalanced temperatures (surging)
- Impurities (clogging)
- Adjust process parameters
- Use melt filters
- Regular cleaning
Poor Fiber Formation and Web Uniformity
- Inconsistent polymer melt
- Improper spinneret design
- Inadequate quenching air flow
- Improper drawing/stretching
- Maintain melt homogeneity
- Regular spinneret maintenance
- Optimize quenching air
- Adjust drawing speed
Unacceptable Physical Properties
- Incorrect polymer selection
- Degraded polymer
- Inconsistent bonding
- Wrong process parameters.
- Review material selection
- Optimize process parameters
- Calibrate bonding equipment
Die Build-up and Contamination
- Polymer degradation
- Impurities in raw material
- Poor die maintenance
- Control temperatures
- Filter the melt, implement regular cleaning schedules
- Use purging compounds
Equipment-Related Problems
- Screw and barrel wear
- Die or spinneret damage
- Misalignment
- Sensor malfunction
- Implement preventive maintenance
- Ensure proper installation
- Use high-quality components
- Regularly calibrate sensors
Polymer Degradation and Gels
- Excessive heat
- Shear heating
- Contamination
- Moisture
- Optimize temperature profile
- Control screw speed
- Proper material handling and drying
- Use purging compounds
Inconsistent Fiber Attenuation
- Unstable melt flow
- Air drag system issues
- Spinneret problems
- Calibrate air system
- Maintain spinneret cleanliness
- Optimize melt stability
Electrostatic Discharge and Static Cling
- Friction
- Low humidity
- Use static eliminators
- Control humidity
- Incorporate antistatic additives
