South Asian Petrochem Limited

TROUBLESHOOTING GUIDE
Problem
1. SHORT SHOTS

Injection Molding Possible causes

Injection Pressure low Barrel temperature low Mould manifold temp. low Mould cavity temp. low

Possible Solutions
Increase injection pressure Increase barrel temperature Increase mould manifold temperature Increase mould cavity temperature. Increase injection speed Increase back pressure Clean vent on split, core and cavity C eck t at no foreign object is in gate area. C eck t at t e gate pin is moving all t e way back !In valve gate ot runner" Increase olding pressure Increase olding time %ecrease mould temperature C eck cooling water flow & temperature. Increase cooling time Clean vents on split, core and cavity C eck oses on mould for damage C eck mould for leaks C eck t at de umidifier is working properly C eck t at t e mac ine enclosures as no major gaps

Incomplete formation of preform.

2. SINK MARKS

Depression in the preform surface / body

3. WATER MARKS

#olding pressure low #olding time low #ig mold temperature Inade$uate coolant supply Cooling time low Blocked venting 'eaking oses 'eaking mould Insufficient de umidification Mold enclosure inade$uate

Wavy water marks, due to absorption of water by hot melt.

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Fins along the partings line created by out flowing polymer. 5. BLACK SPECS /CONTAMINATION
4. FLASH 6. FLOW LINES POOR.
Injection pressure ig #ig injection speed (nwanted material in cores (nwanted material in splits (nwanted material in cavity #ig mold temperature #ig barrel temperature Clamping pressure low Contaminated resin #ig residence time prior to restart of t e mac ine %egradation of resin Injection pressure low Mould temperature low Barrel temperature low Injection speed low %rier inefficient Back pressure low Manifold and mold eater Malfunction. Barrel temperature ig *oreign matter in t e gate Page 62 C eck temperature of mould cavity eaters and Manifold C eck barrel temperature C eck t at no foreign material is in gate area C eck for resin cleanliness Clean t e resin opper Purge t e barrel t oroug ly on restart )educe melt temperature )educe back pressure Increase injection pressure Increase mould temperature Increase barrel temperature Increase injection speed C eck resin drier Increase back pressure %ecrease Injection pressure %ecrease injection speed Clean cores Clean splits Clean cavity %ecrease mould temperature %ecrease barrel temperature Increase clamp pressure

Wavy flow lines, observed in the polarized light.

7. HEAT SPLAY

White / orange shaded flow marks, visible to naked eyes.

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8. PET INCLUSIONS

n!melted polymer " fine dusty appearance in preform.

'ow barrel temperature 'ow mould temperature Back pressure low Mi+ing ead damage C eck valve damage Injection speed ig Injection core bent

C eck barrel temperature C eck mould temperature Increase back pressure C eck t at t e mi+ing ead of t e screw or t e screw is not broken. Inspect t e c eck valve on t e screw !not #usky Mac ine" %ecrease injection speed C eck t at t e injection core is not bent and straig ten it. C eck t at t e cavity eater is working Increase t e cavity temperature Increase t e manifold temperature C eck t at t e drier is working %ecrease injection old pressure C eck t at no foreign object obstructs t e cavity gate Increase cooling time C eck water to injection core and cavity C eck cooling tube in gate is straig t and flow is ok. C eck cavity eater Increase cavity temperature C eck t at t e gate valve is working C eck t at t e barrel s ut-off no..le is working Increase decompression time Customer Technical Service +91-9933035193

9. CONCENTRICITY

1 . CRYSTALLINE !ATE Cavity eater malfunction

White crystalline appearance of area around gate.

Cavity temperature low Manifold temperature low %rier malfunction #old pressure ig *oreign material in gate Cooling insufficient Core cooling inade$uate Cavity eater malfunction Cavity eater low ,ate valve malfunction S ut-off no..le malfunction Page 63

11. LON! !ATE

#$tended %ate length

South Asian Petrochem Limited

#ntrapped air or gas or vacuum bubble. 13. STRESS PATTERN Waviness in &olarized light. 14. STRIN!IN! 'ong fine string e$tending from the gate. 15. CLOU"Y PREFORMS Dull color preforms. 'ack of clarity.
12. AIR BUBBLES
S ort decompression time Barrel temperature low Inefficient drying 'ow back pressure Barrel temperature ig . Mi+ing ead damage #ig injection pressure #ig s ot si.e 'ong old time #ig cavity temperature 'ow cooling time 'ow old time Inade$uate coolant to cavity ,ate valve malfunction Inefficient %rying Blocked drier filters /ir leaks on t e drier /ir leaks on mac ine oppers 'ow air flow to drying opper 'ow process air temperature Page 64 C eck drier temperature and dew point Clean drier air filters C eck for air leaks on drier C eck for air leaks on mac ine opper C eck air flow to opper Increase drier process temperature Increase barrel temperature S ut mac ine down for 0 our and dry material Increase back pressure Customer Technical Service +91-9933035193 %ecrease injection pressure )educe s ot si.e %ecrease injection old time )educe cavity temperature Increase cooling time Increase injection old time C eck water flow to cavities C eck t at gate valves are working C eck barrel temperature C eck drier temperature Increase back pressure 'ower temperature at last e+truder .one C eck e+truder mi+ing ead

South Asian Petrochem Limited

16. HOLLOW !ATES
Barrel temperature low Insufficient drying Back pressure low #olding pressure low #old time low Insufficient cooling time #ig cavity eater temperature *oreign material in gate #ig barrel temperature #ig mold temperature #ig drying temperature Contaminated splits 'ow packing pressure Insufficient packing time #ig cavity temperature Insufficient cooling #old time low Insufficient cooling 'ower barrel temperature 'ower injection mould temperature 'ower drier process temperature Clean splits Increase packing pressure Increase packing time )educe cavity temperature #ig core and cavity temperatures Increase cooling time Increase injection old time C eck water temperature and water flow to injection Mould C eck temperature of injection cores and Customer Technical Service +91-9933035193 Increase olding pressure Increase olding time Increase cooling time 'ower cavity eater temperature C eck for foreign material in gate area.

(ole in the center of gate.

17. "ISCOLORE" PREFORMS 18. O#ER FINISH

19. BURNT !ATES 2 . O#AL FINISH

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South Asian Petrochem Limited

cavities

21. !AS BURNS 22. C$%&'( )*+,**+.$*%/( 0 NSR 1H2$342-+%56 23. #*$+3&%5 &$%&' 3- +.* 7$*82$9 537 (:$8%&*.

#ig injection speed Contaminated splits Improper air venting in neck rings, causing melt flow une$ually and form a weld line at t is point. 1+treme ig packing at neck finis area, leading to e+pansion crack. More prevalent in unbalanced gating system. #ig residual // in resin #ig barrel temperature #ig back pressure #ig screw speed #ig injection speed #ig mold manifold temperature #ig no..le tip temperature 'ong cycle time #ig e+truder & screw cus ion Page 66

%ecrease injection speed Clean splits C eck e$ual air vents along t e circumference of t e neck ring core insert. Clean dirt accumulations around vent area. )educe packing pressure. )educe barrel & melt temperature.

24. HI!H ACETAL"EHY"E

C eck for resin // levels )educe t e barrel temperature )educe back pressure )educe screw )PM )educe injection speed )educe mold manifold temperature )educe cycle time )educe cus ion Increase inlet resin temperature

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'ow inlet resin temperature (nsuitable screw

TROUBLESHOOTING GUIDE
Problem
1. PEARLESCENCE 2 ite Pearl s ade on t e bottle surface.

Stretc Blow Molding Possible causes Possible Solutions

Pearlescence results from stretc ing of molecules faster t an t ey can respond past it3s natural stretc limit. Small tears appear on material surface. 4 is can also be due to t e Pre bottle condition Material too t in at pearlescent area. Increase eat ot er t an w ere pearl is evident. Material too t ick at pearlescent area. Increase eat at pearl area. Increase overall preform temperature. Pearlescence on t e bottle s oulder may be t e result of a blow air leak t roug nose from eit er pre-valve, ig blow valve or stretc rod. )educe Pre blow volume, increase Pre blow Customer Technical Service +91-9933035193

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considerably smaller t an t e mold cavity, 5 67 8. time and reduce Pre blow pressure. 1nsure Pre blow bottle is not to large. 1+cessive petal formation in Pre blow will cause pearl in t e petal area. Pearlescence in t e body in t e form of a ring is t e result of insufficient Pre blow. 'ow levels of orientation )educe over all perform temperature allowing results in t e material not t e bottle to be blown closer to its natural stretc aving enoug strengt to limit. (nder t is condition slig t pearlescence resist t e stretc force. may be evident

2. EXCESSIVE FILL POINT ROP 'ow fill volume of t e bottle

!. CLEAR "REA# ALON$ 2eld line formation along C eck 9Preform Problem : )emedy; point no.66. NSR % rou&h 'ee( the crac) t is circumference due to 4 ere may be c ances a fine crack at injection sur'ace* low melt temperature, low molding stage, is not noticed. C eck crack fill velocity, improper presence by polari.ed lig t table. venting. !Preform defect"

Problem

Possible causes

Possible Solutions
)educe lamp eat in .one 0. )aise t e level of lamp in .one 0. C eck preform mandrel are not too cold. )educe preform temperature. )educe body eat.

4. BURST BELOW NSR <ver eating of area near (smooth feel of crack t e =S), leading to surface) separation of softened and ard amorp ous portions. +. LO, "-RST Insufficient orientation PRESS-RE %"O .* !4oo ot" 'ow I> /. LO, "-RST 1+cessive crystallinity at

Base of bottle blown too cold producing Customer Technical Service +91-9933035193

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PRESS-RE %"ASE* t e gate 'ow I> 1+cessive stress in preform Incorrect eating profile, resulting in a poor distribution of material. <ver stretc ing of t e body & s oulder. 1+cessive stretc ing of t e taper. Stations producing a smaller Pre blow container will be typically affected. Poor s ield positioning, allowing e+cessive stretc ing of t e t in part of t e taper. e+cessive stress Increase eat below t e preform Stretc rod clearance too s ort. )eset stretc rod clearance. )educe stretc rod pressure. )educe eat in t e body and& or s oulder until pearlescence occurs, t en increase eat at t e base. )epeat until t e base weig t is correct.

0. 1EAV. "ASE ,EI$1T

2. T1IN S1O-L ER

Move s ield into a t icker part of t e preforms taper. )educe pre blow delay time )educe stretc rod pressure Increase Pre blow pressure )educe eat in t e neck. If t ickening occurs below desired area.

Problem
3. ROP TEST FAIL-RES

Possible causes
1+cessive crystallinity above gate. 'ower base weig t.

Possible Solutions
Preform end cap blown too cold. Increasing eat at t e gate or below wit out loosing base weig t usually improves drop test failure. 'ig t base weig t. Increase base weig t.

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14. S,-N$ $ATE *irst impacted mark is evident and is not centered to t e gate, an alignment problem is usually t e cause. Inade$uate mould cooling, If t e gate is centered to t e stretc rod impact mark and yet not centered to t e mould base at t e end of blow. If t e first impact mark is centered, t e stretc rod as lost control of t e gate during blow. <ften gate control is lost due to e+cessive rate of growt of e+panding film during pre blow. Ideally growt s ould start ig in t e preform and s ould reac t e base after t e stretc rod as reac ed t e base. Misalignment of t e preform to t e mould, no..le or stretc rod.

C eck blow mould cooling 'ower alf of preform too ot

)educe low bottle si.e Increase air delay time )eset stretc rod eig t 'ow blow pressure too ig /ir delay time too s ort 2orn stretc rod guides 1+cessive preform eccentricity 4 ick crystallinity near gate

Problem
11. FOL ARO-N T1E

Possible causes
<ver eating of t e Page 70

Possible Solutions
)educe eat around gate area. Customer Technical Service +91-9933035193

South Asian Petrochem Limited

STRETC1 RO preform end cap, material wraps around t e end of t e stretc rod. In effect anot er t ick& t in transition forms <ver eating of t e finis area w ic allows blow pressure air to stretc t e material. <ven ambient temperature to ig . Incorrect loading eig t, too muc of t e finis is e+posed to t e elements. Misalignment of t e preform, blow mould and blow no..le usually caused by poor transfer arm positioning. Blow mold position. =o..le position. <ver stretc ing of t e preform by t e stretc rod prior to pre blow. 'ow blow delayed or missing Increase pre blow pressure. )educe stretc rod pressure.

12. "LO,N FINIS1

Move s ield away from finis into a t icker part of t e preforms taper. Bring s ield close to preform Increase oven e+ aust )educe neck element eat

1!. SEALIN$ S-RFACE A5A$E

)ealign transfer arm )ealign blow mould or no..le if necessary

16. C1OC#E NEC#

)educe air delay time )educe stretc rod pressure Move s ield into a t icker part of t e taper Increase eat in t e body or base Increase low blow pressure )educe eat in t e neck

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Problem
1+. "ENT NEC#

Possible causes
Misalignment of t e preform to t e mould or nose. %istortion below t e flange Insufficient mould cooling <ne mould alf wit poor cooling 1+cessive material remained in t e neck and s oulder. Initial stretc ing occurs too low into t e preforms taper. Preform location incorrect t roug oven. /ir leak into preform before t e start of low blow. Preform temperature above crystal growt range for to long. Insufficient cooling of

Possible Solutions
)ealignment of t e preform to t e nose or mould. )educe material t ickness in t e s oulder by reducing eat in t e body. Increase ig blow time Improve mould cooling

1/. 1AR NEC#

10. 1OT "OTTLES

)educe eat in t e body and& or base until pearlescence occurs t en increase neck temperature. Increase stretc rod pressure Increase air delay time )educe low blow pressure Move s ield into t e t inner part of t e taper C eck eig t of preform t oug oven. C eck for air leak t roug nose )educe eat adjacent to t e a.e portion until pearlescence is evident somew ere on t e bottle. )educe eat over all until pearlescence is evident. Customer Technical Service +91-9933035193

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preform outside surface for t e amount of eat absorbed by t e P.1.4. Increase air circulation t roug oven. Increase blower speed, clean blowers

Problem
12. FLAT SI ES

Possible causes
Poor venting of mold.

Possible Solutions
1nsure ade$uate mold venting, and clean clogs. Increase low blow pressure ensuring bottle diameter is close to blow mould si.e. 'ow blow bottle too small. In t is case t e volume of air trying to escape during ig blow is more t an t e venting can allow. 'ow blow bottle blown to fast. 1+cessive ig blow pressure at t e end of low blow to minimi.e air t at remains in t e blow mould before ig blow starts. )educe low blow pressure and e+tend low blow time if t e body of t e bottle as reac ed t e mould. )educe ig blow pressure. Inade$uate e+ aust time, c eck e+ aust valve activation. Increase ig blow time or reduce material t ickness )educe material t ickness )educe preform temperature Customer Technical Service +91-9933035193

13. EFOR5ATION AT 5O-L PARTIN$ LINES

Pressure remaining in t e bottle w en blow moulds open. Insufficient ig blow & cooling time Material too ot and&or

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South Asian Petrochem Limited

24. C1OC#E "O . too t ick Insufficient or no low blow Insufficient eat beside c oke Increase low blow pressure Increase eat in t e body )educe eat in t e base and& or neck. )educe air delay time )educe stretc rod pressure

Problem
21. LI$1T "ASE ,EI$1T

Possible causes
Poor eating profile resulting in poor distribution of material, insufficient stretc ing of t e body or s oulder.

Possible Solutions
)educe eat near t e base of t e preform until pearlescence occurs t en increase eat to t e s oulder and body. )epeat until base weig t is correct Increase air delay time Increase stretc rod pressure )educe low blow pressure )educe oven s ielding of t e taper C eck ig pressure. C eck for ig blow leaks from no..le or stretc rod. Increase ig blow time. 1+cessive low blow pressure or time. If too muc of t e material will be left to form t e feet correctly. Corners are likely to be t in. Swung gate. *eet will not form in t e corners Customer Technical Service +91-9933035193

22. NOT F-LL. FOR5E

Insufficient ig blow pressure. )ate of ig blow too slow, material movement stalls before reac ing t e corners. <ften as a result of blow no..le

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leak. Insufficient ig blow time. #eavy baseweig t. #ig blow pressure inade$uate to move material into t e corners. Inconsistent preform rotation t roug t e oven. Insufficient surface cooling of t e preform. Insufficient orientation and&or material t ickness to deliver t e re$uired p ysical strengt opposite t e gate movement unless e+tra eat is applied near t e end cap. )educe preform temperature until pearlescence is evident t en increase preforms lower body temperature C eck pre bottle si.e. )educe if necessary. C eck t e preform for drag marl. 1nsure oven s ields are not touc ing t e preform. C eck spindle or mandrel rotation Increase air flow onto t e surface of t e preform )educe over all preform temperature )educe eat beside failure point 2 ere failures occur between neck and s oulder adjust s ield into a t icker part of t e taper

2!. 1OT SI ES

26. LO, 1EA LOA

Problem
2+. POOR CLEARANCE

Possible causes
Preform temperature too ig . #eavy base weig t.

Possible Solutions
Base weig t correct or lig t, reduce eat beside and&or below t e gate. 1nd cap temperature too ig /ged preforms. Insufficient mould cooling 1+cessive in erent preform stress Base weig t too eavy, reduce preform temperature Increase ig blow time.

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2/. FOL IN "ASE AT EN CAP LINE Preform temperature too ot Preform end cap area to cold /n e+cess of material in t e vicinity of t e fold 'ack or loss of low blow volume 1+cessive force applied by t e stretc rod /ged or stressed preforms Preform end cap too cold 1+cessive stretc rod pressure Clearance between t e stretc rod and mould base too small 4 ick crystallinity above t e gate )educe eat in t e areas ot er t an t e base. If t e fold remains after pearlescence as formed. #eat may be applied to t e preform end cap area. Increase low blow pressure )educe air delay time )educe stretc rod pressure

20. CRAC#E "ASE

Increase eat beside or below t e gate )educe stretc rod pressure C eck preform for e+cessive crystallinity, if so c ange preforms. Increase stretc rod, mould base gap

Problem
22. STRESS CRAC#IN$

Possible causes
<ff center gates. 2ebs wit t e t innest material will stress crack early. 1+cessive post mould

Possible Solutions
*i+ swung gate. )educe preform temperature to pearlescence, reduce base weig t if necessary. Increase ig blow time )educe eat in t e preform lower body Customer Technical Service +91-9933035193

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c ange. /s clearance deteriorates web s ape c anges increasing t e risk of stress cracking. 4emperature of t e lower alf of t e preform3s body is too ig . C emical reaction by some line lubricants. 'ow I.>. material 'ig t base weig t. Inade$uate t ickness to resist movement. 23. EXPLOSIONS -RIN$ #ot bottles !)efer #ot "LO,IN$. Bottles" *olds in t e base 'ig t base weig t 1+cessive post mould growt 'ow I.>. Contamination /ir bubbles above t e gate 'ine lubricants generally cause severe stress cracking in all feet. Increase base weig t

)efer Causes Stress Cracking Cracked bases 1+cessive crystallinity

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