Troubleshooting Guide

PVC Extrusion of rigid PVC pipes & profiles

Brittle extrudate
Cause

Solution

Poor fusion

Increase melt temperature, check the level of filler.

Insufficient impact modification

Increase the amount of impact modifiers.

Voids and contamination

See "section C & L".

Cold die lines

Increase melt temperature.

Over processing

Identify optimum process temperature.

Excessive shrinkage
Cause

Solution

Poor match between die and calibrator

Increase diameter of pin.

Reduce line speed.

Foreign objects in blend

Cause

Solution

Contamination in feed stock

Use hopper magnet for metallic contamination.

Consider sieving.

Poor acetone or methylene chloride test

Cause

Solution

Material too cold and not fully fused

Barrel and screw temperatures too low. Increase melt

temperature.

Formulation may be over-lubricated

Decrease external lubricant.

Add or increase process aid to promote fusion.

Wavy or lumpy internal surface

Cause

Solution

Wavy or lumpy internal surface is indicative of

different thermal or shearing histories in the melt

The screw and barrel in the metering zone should be

about the same temperature. A little higher heat in
both will help smooth out the internal surface.

Low gloss
Cause

Solution

Over lubrication

Reduce internal lubrication.

Melt too cold

Increase process temperature.

Poor gelation

Increase process aid level.

Not fully sized

Increase vacuum or increase air pressure on plug to

insure fully contact with sizing sleeve.

Possible inaccuracy in the mix blend

Check the mix room scales for accuracy.

Rough (orange peel) internal surface or outer surface leading to burn

Cause

Solution

Over heating

Reduce spider and cone heat zones.

Lower melt temperature.

Formulations may be under lubricated

Check formulation. Increase lubrication.

Uniform yellowing or discoloration of material

Cause

Solution

Level of stabilizer too low

Check level and adjust formulation if required.

Melt temperature excessive

Lower overall melt temperature.

Incorrect lubrication

Increase lubrication.

Rear barrel too hot

Reduce rear barrel temperature.

Visible spider lines on internal diameter

Cause

Solution

Spider and die heating zone may be too cold

Check operating temperatures.

Material may be over lubricated

Adjust lubrication.

Non-uniform outer diameter

Cause

Solution

Sizing sleeve may have build-up / plate out of

pigments, lubricants etc

Mineral spirits added drop-wise on hot melt just as it

enters vacuum sizing sleeve usually will remove most
of the plateout. Otherwise line should be stopped and
cleaned up.

On large pipe, die and head may not be uniformly

heated at the start of the run or heaters may be
hunting for set temperatures, controllers

It will take several hours to heat soak the large mass

of metal. Allow adequate time to heat up properly.
Also check heater bands and thermocouple and PID
controllers.

Pipe not round

Cause

Solution

Insufficient sizing

Check for full sizing for pressure or sufficient vacuum.

Cooling water not cold enough

Use a chiller for increase cooling.

The haul off may be applying excessive pressure

Lower the haul off pressure.

Inefficient cooling

On large pipes cascade or spray cooling is more

efficient than flooded tank.

Worn out plug

If this problem continues after a long run, replace plug

to insure no loss of air pressure for sizing.

Bubbles/voids

Cause

Solution

Degradation

Check barrel, screw, and die temperature control. Use

screw cooling. Reduce melt temperature.

Moisture or trapped air

Check material is not gelled at vent, check vacuum

pump if not blocked.

Internal diameter exhibits occasional tearing

Cause

Solution

Plug too close to die pulling material apart before it is

cooled sufficiently

Use longer chain at last 75% of the cooling tank

length.

Bridging in the throat section / non-uniform powder flow to the screw

Cause

Solution

Poor flow at the hopper throat

Turn the cooling water on at the throat section.

Use a crammer in the hopper.
Install a vibrator to encourage powder flow.

High amps / overloading

Cause

Solution

Material too cold

Increase barrel temperature.

Check barrel thermocouples for accuracy.

Under lubrication

Increase external lubricant.

Over feeding

Increase main screw speed or reduce feeder speed.

Check die is appropriate for the extruder.

Thin wall pipe in vacuum sizing collapsing, or jamming up, or drawing down too thin
Cause

Solution

Extrudate unstable entering into vacuum tank

Decrease the distance. Two to three inches between

the die and the tank should be sufficient.

Melt too hot

Reduce die temperature.

Pulling friction too high.

Lower the vacuum.

Non-uniform wall thickness around the pipe circumference

Cause

Solution

Thick thin wall opposite each other

Bushing is not centered. Adjust die bolts for even flow

out of die.

Thick thin opposite each other

Use segmented die heaters to adjust flow.

Increasing or decreasing wall thickness

Cause

Solution

Feed stock inconsistencies between batches or mixes

Adjust puller speed. Monitor feedstock consistency.

Bridging at the hopper

See section "high amps / overloading".

Surging
Cause

Solution

Partial plugging of screw channel with solids du to

excessive fillers i.e. not enough polymer to allow
fluxing

Raise process temperatures, adjust formulation.

Inconsistent feed rate

Check the feeding system.