Troubleshooting guide for Wovensack Extrusion Applications
Wovensack Extrusion Troubleshooting
Problem
Probable Cause
Suggested Remedy
Temperature Setting
Temperature setting are crucial parameter for proper plastic processing ,hence one should check temperature controller, thermocouple and solid state relay(SSR)
- when you cold start the machine ,wait for 2hours.
Film Puncture
- Hold-up particles in the material
- Inadequate heat stability of master batch
- Insufficient moisture control in raw materials
- Replace the screen pack
- Verify the moisture content of raw materials
- Assess the heat stability of the master batch
Gels, Hard or Unplasticized Profile
- Improper back pressure and temperature gradient
- Moisture presence in the master batch
- Die lip opening too wide
- Adjust temperature and back pressure settings
- Implement finer wire mesh
- Reduce die lip opening and adaptor flow area
- Pre-dry master batch before processing
Denier Variation
- Extruder surging
- Variations in film thickness and spacer thickness
- Inconsistent drive performance
- Optimize extrusion parameters
- Control throughput rate and die volume
- Ensure uniform die temperature and spacer thickness
- Check drive performance and orientation unit temperature distribution
Tape Breakage
- Excessive stretch ratio
- Low orientation temperature
- Presence of hold-up particles or excessively stiff film
- Adjust stretch ratio and orientation temperature
- Address issues related to film puncture and gels
- Increase distance between die opening and water levels in quenching tank
Low Tenacity / Higher Elongation
- Insufficient stretch ratio
- Film too soft
- Low orientation temperature
- Increase stretch ratio and orientation temperature
- Modify quenching tank parameters for better cooling
Tape Fabrillation
- Stiff tape material
- Surface scratches on the tape moving path
- Utilize anti-fabrillation master batches
- Maintain smooth surfaces on tape moving paths
- Use wear-resistant materials for components
Shrinkage in Fabric / Curved Tape
- Residual stress in the tape
- Inadequate annealing or cooling efficiency
- Verify and adjust annealing system parameters
- Increase annealing temperature
- Ensure efficient cooling of rollers
