Troubleshooting Guide

Polypropylene (PP) Injection moulding

Article not complete

Cause Solution

Insufficient material dosed Increase dosing by altering switch over position

(distance-dependent or pressure-dependent) Note:
Ensure that material buffer is large enough.

Insufficient holding-pressure Increase the holding-pressure.

increase the holding-time.

Injection speed or maximum machine injection Adjust the injection speed.

pressure incorrect Check maximum machine injection pressure.

Polymer temperature too low
Adjust the cylinder temperature profile and/or increase
the nozzle temperature setting and/or increase the
hot-runner(s) temperature setting(s).
Note: Compare temperature settings with actual
polymer temperature by discharging the cylinder and
measuring in the melt.
Check the sensors and the auxiliary equipment used
for temperature measurement of cylinder, nozzle
and/or hot-runner(s).
Increase the back-pressure and adjust screw speed.

Polymer melt contains air Increase the back-pressure and increase the screw
speed. Decrease decompression.

Mold too cool Increase the mould temperature.

Check the mold cooling.

Machine faults Check the non-return valve for leakage. Check the

Mold venting not sufficient
Cone/hot-runner and/or gate dimensions not correct
Brown streaks
Cause
Polymer has degraded due to excessive temperature
Polymer has degraded due to excessive residence time
in cylinder or in hot-runner
clearance between screw and cylinder. Note: If
necessary, replace the cylinder and/or screw.
Check the maximum shot volume of the plasticating
unit. Check the length/diameter ratio of the screw.
Note: If necessary, replace the injection unit.
Increase the plasticizing time (when plasticizing time
is longer than the cooling time, cycle time can be
longer).
Check the hydraulic system by f.i.:
measuring the oil pressure.
measuring the oil temperature.
controlling the quantity of oil
controlling for oil leakage.
controlling cleanness of the oil filter.
Check for air-entrapment at spots where the article is
not full. Note: If necessary, fit vents or vent pins.
Check the gate(s) for blockage (contamination).
Check the dimensions of the gate(s).
Note: If necessary, enlarge the gate(s).
Solution
Decrease the cylinder temperature and decrease the
nozzle temperature setting and/or decrease the hot-
runner(s) temperature setting(s).
Decrease the back-pressure.
Decrease the screw speed.
Decrease the injection speed or decrease the injection
speed profile.
Ensure that material buffer is not too large, adjust
accordingly, by altering switching point (distance- or
pressure-dependent).
Reduce cycle time by:
Decrease the cooling time.
Note: If cooling time is determinating the residence
time of polymer in cylinder. Increase the screw speed
setting and/or decrease the back pressure.
Note: If plasticizing time is determinating the
residence time of polymer in cylinder. Decrease hot-
runner temperature setting.

Too much air may be reaching the polymer during
fusion
Polymer has degraded due to excessive mechanical
and thermal loading in the gate
Burnt surface, diesel effect
Cause
Air in mold unable to escape
Brittleness
Cause
Colorant and base resin incompatible
Check shot volume of the plasticating unit.
Decrease temperature of the entry zone.
Check if degassing zone is sealed.
Decrease the screw speed.
Increase the back pressure.
Decrease injection speed.
Decrease cylinder temperature.
Decrease nozzle temperature.
Decrease hot-runner temperature.
Decrease back pressure.
Decrease screw speed.
Increase gate dimension or number of gates.
Solution
Decrease the cylinder temperature and decrease the
nozzle temperature setting and/or decrease the hot-
runner(s) temperature setting(s).
Decrease the back-pressure.
Decrease the screw speed.
Decrease the injection speed or decrease the injection
speed profile.
Check for air entrapment at spots where the article is
not full.
Note; if necessary, fit vents or vent pins.
Check the mold venting for contamination.
Check the gate(s) for blockage (contamination).
Check the dimensions of the gate(s).
Note: If necessary, enlarge or reposition the gate(s)
(balancing).
Solution
Change base resin.
Melt flow is too high Use resin with lower melt flow.

Calcium carbonate or talcum in polymer Remove or lower the filler.

Wax in polymer Remove or lower the wax.

Polymer temperature too low Increase the heating.

Mold temperature too low Increase the mold temperature.

Polymer degraded (yellowing) Decrease the heating.

Contamination Check polymer, hopper and cylinder.

Improper part design Redesign the article.

Excessive regrind Reduce percentage of regrind.

Delamination

Cause Solution

Polymer contaminated or contains moisture Check granulate for contamination.

Avoid condensation on granulate.
Note: Don't bring the material out of a cooler
(storage) area immediately prior to processing.
Dry the granulate, especially filled materials.

Polymer temperature too low or non-homogeneous Increase the cylinder temperatures and/or increase
 the nozzle temperature setting and/or increase the
hot-runner(s) temperature setting(s).
Increase the back pressure and increase the screw
speed.
Check maximum shot volume of plasticating unit.
Adjust the injection speed.
Increase or reposition gate dimensions.

Mold temperature too low (polymer cooled too quickly Increase the mold temperature.
on the mold wall) Adjust the mould cooling locally.
Note: Particularly around the gate(s).

Master batch incompatible Check master batch for compatibility with chosen
polymer and processing conditions (temperatures) by
injection without master batch.

Lubricant on mold surface Use less lubricant, whether internal (in polymer) or
external (mold release agent).

Dimensional deviations in article

Cause Solution

Incorrect shrinkage due to irregular mould Check mould cooling for evenness and/or blockages.
temperature Adjust the mold temperature.
Note: A lower mold temperature produces less
shrinkage in the article.

Incorrect shrinkage due to incorrect holding-pressure Adjust the holding-pressure and/or adjust the holding-
time.

Incorrect shrinkage due to incorrect polymer Adjust the cylinder temperature profile and/or adjust
temperature the nozzle temperature setting and/or adjust the hot-
runner(s) temperature setting(s).

Incorrect shrinkage after demoulding Adjust the cooling time.

 Distortion

Cause Solution

Incorrect operation of the mould cooling system Check mold cooling for evenness and/or blockages.
Regulate mould cooling on opening and/or closing
sides separately.

Difference in longitudinal and perpendicular shrinkage
due to orientation
Increase the cylinder temperatures profile.
Adjust the injection speed.
Check position of the gate(s).
Note: If necessary, add more or reposition gate(s)
(balancing).

Warpage caused by master batch Check master batch for compatibility with chosen
polymer and processing conditions (temperatures) by
injection without master batch.

Incorrect aftershrinkage Adjust the cooling time.

Note: If this is not a solution, then use cooling
fixtures.

Ejector rings

Cause Solution

Difference in mould platten - and ejector pin Decrease holding pressure.

deformation Decrease holding time.
Increase dosing by switching over to holding pressure
later.
Decrease mold temperature.
Check ejector pin retraction system.

Difference in heat transfer between ejector pin and Decrease ejector pin surface.
mold Use ejector pin cooling.
 Flash
Cause
Polymer is injected too fast
Holding-pressure is too high
Too much material dosed
Parting-line of mold dirty or damaged
Clamping force of machine insufficient
Polymer temperature too high
Vents too deep.
Gloss
Solution
Decrease the injection speed.
Decrease the holding-pressure (profile).
Reduce dosing f.i. by switching over to holding
pressure earlier.
Check the mould sealing surface(s) for contamination.
Note: If necessary, clean and polish.
Check the mold sealing for damage.
Note: If necessary, repair and polish.
Increase the clamping force.
Note: If necessary, use higher-locking machine.
Decrease the cylinder temperatures and adjust the
nozzle temperature setting and/or adjust the hot-
runner(s) temperature setting(s).
Note: Compare temperature settings with actual
polymer temperature by discharging the cylinder and
measuring in the melt.
Check the sensors and the auxiliary equipment used
for temperature measurement of cylinder, nozzle
and/or hot-runner(s).
Reduce vents.
Note: Maximum depths of vents should be 0.02 mm
for standard materials and 0.01 mm for high-flow
materials.
Cause Solution

Mold temperature too low or irregular Increase the mould temperature.

Mold does not have the correct surface finish Check mold cooling for evenness and/or blockages.
Check the mold surface(s) for contamination.
Note: If necessary, clean and polish.

Polymer temperature too low Adjust the cylinder temperature and increase the
nozzle temperature and/or increase the hot-runner(s)
temperature setting(s).

Injection speed incorrect. Adjust the injection speed.

Gramophone record effect

Cause Solution

Polymer temperature at melt front to low Increase injection speed.

Increase cylinder temperature.
Increase nozzle temperature.
Increase hot runner temperature.
Increase back pressure.
Adjust screw speed.

Mold too cold Increase mold temperature.

Jetting

Cause Solution

Polymer is injected into the free space of the mould
without resistance
Decrease the injection speed.
Adjust the cylinder temperature profile.
Check the dimensions of the gate(s) and check the
gate(s) for blockage (contamination) and if necessary,
adjust position of the gate(s) or introduce resistance
into the mold.
 Note: if necessary, enlarge the gate(s).
Note: Reposition gate(s) so that the flow of molten
polymer is disrupted earlier.
Note: Resistance is introduced so that the polymer,
coming out of the gate, is first injected against a
barrier.

Poor finish

Cause Solution

Mold temperature too low Increase mold temperature.

Injection pressure too low Increase injection pressure.

Dirty cavity surface Clean the mold.

Inadequate venting Use test molded parts to identify location for additional
venting.
Implement extra venting points
Decrease the injection speed.

Excessive use of mold surface lubricant Lower the use of lubricant.

Incorrect gate location or gate design Relocate gate and/or adjust.

Flow distance too long Relocate gates and/or increase the number of gates.

Poor pigment dispersion

Cause Solution
Pigment not fully dispersed in polymer.
Colour master batch incorrect or incorrectly dosed
Injection speed or injection pressure incorrect
Polymer temperature too low
Machine faults
Cone/hot-runner and/or gate dimensions not correct
Increase the back-pressure and increase the screw
speed.
Use a mixing device in the injection unit.
Check operation of dosing equipment of master batch,
specially for percentage master batch dosed.
Check master batch for:
melt flow index (must be comparable to the base
polymer),
pigment dispersion (by pressing a thin film),
percentage of pigment.
Adjust the injection speed.
Adjust the cylinder temperature profile and increase
the nozzle temperature setting and/or increase the
hot-runner(s) temperature setting(s).
Note: Compare temperature settings with actual
polymer temperature by discharging the cylinder and
measuring in the melt.
Check the sensors and the auxiliary equipment used
for temperature measurement of cylinder, nozzle
and/or hot-runner(s).
Increase the back-pressure and adjust screw speed.
Check the length/diameter ratio of the screw.
Note: If necessary, replace the injection unit or use a
mixing device.
Increase the plasticizing time (when plasticizing time
is longer than the cooling time, cycle time will be
longer).
Check the hydraulic system by f.i.:
measuring the oil pressure,
measuring the oil temperature,
controlling the quantity of oil,
controlling for oil leakage,
controlling cleanness of the oil filter.
Check the gate(s) for blockage (contamination).
Check the dimensions of the gate(s).
Note: If necessary, enlarge the gate(s).
 Poor release from the mould
Cause
Incorrect operation of the mold temperature
Incorrect shrinkage due to holding-pressure
Incorrect shrinkage due to polymer temperature
Article creates vacuum on removal from mold
Core not properly centered (wall thickness difference)
Article does not release properly from part of the mold
Machine runs unevenly
Solution
Check mold cooling for evenness and/or blockages.
Adjust the mold temperature. (Eventually one mould
halve only).
Note: A lower mold temperature produces less
shrinkage in the article.
Adjust the holding-pressure and/or adjust the holding-
time.
Adjust the cylinder temperature profile and adjust the
nozzle temperature setting and/or adjust the hot-
runner(s) temperature setting(s).
Improve the airflow between the article and the mold.
Make vent channels along the ejector pins or use air
ejection.
Align the core.
Check the mold surface(s) for damage.
Note: Especially the sides perpendicular to direction of
motion. If necessary, clean or repair and polish (in
direction of release).
Use lubricant, whether internal (in polymer) or
external (mold release agent).
Adjust ejectors control.
Use of stepped ejectors may be required.
Make ejection easier by using air ejection.
Note: If necessary, use more and/or larger ejectors.
Check mold:
adjust release angle,
adjust undercut,
adjust radii.
Check the hydraulic system by f.i.:
measuring the oil pressure,

Shrinking voids
Cause
Incorrect operation of the mold temperature
Incorrect shrinkage due to holding-pressure
Incorrect shrinkage due to polymer temperature
Article creates vacuum on removal from mould
Core not properly centered (wall thickness difference).
Article does not release properly from part of the mold
measuring the oil temperature,
controlling the quantity of oil,
controlling for oil leakage,
controlling cleanness of the oil filter.
Check motors and ejectors control system.
Solution
Check mold cooling for evenness and/or blockages.
Adjust the mold temperature. (Eventually one mold
halve only).
Note: A lower mold temperature produces less
shrinkage in the article.
Adjust the holding-pressure and/or adjust the holding-
time.
Adjust the cylinder temperature profile and adjust the
nozzle temperature setting and/or adjust the hot-
runner(s) temperature setting(s).
Improve the airflow between the article and the
mould. Make vent channels along the ejector pins or
use air ejection.
Align the core.
Check the mold surface(s) for damage.
Note: Especially the sides perpendicular to direction of
motion. If necessary, clean or repair and polish (in
direction of release).
Use lubricant, whether internal (in polymer) or
external (mould release agent).
Adjust ejectors control.
Use of stepped ejectors may be required.
Make ejection easier by using air ejection.
Note: If necessary, use more and/or larger ejectors.
Check mold:
 adjust release angle,
adjust undercut,
adjust radii.

Machine runs unevenly Check the hydraulic system by f.i.:

measuring the oil pressure,
measuring the oil temperature,
controlling the quantity of oil,
controlling for oil leakage,
controlling cleanness of the oil filter.
Check motors and ejectors control system.

Silver streaks

Cause Solution

Moisture in or on the granulate Avoid condensation on granulate.

Note: Don't bring the material out of a cooler
(storage) area immediately prior to processing.
Dry the granulate, especially filled materials.

Condensation on mold Increase the mold temperature.

Note: Condensation on mold can be avoided by
increasing the mold opening and closing speed.

Air trapped during plasticizing Decrease decompression.

Increase back pressure.

Sink marks

Cause Solution

Insufficient material dosed Increase dosing and consequently weight of article

(check weight).

Injection speed/pressure incorrect. Increase the injection speed.

Holding-pressure too low or not effective in
compensating for shrinkage
Increase the holding-pressure and/or increase the
holding time.
Check the gate(s) for blockage (contamination).
Note: If necessary, enlarge or reposition the gate(s)
(balancing).

Excessive shrinkage due to high polymer temperature Decrease the cylinder temperatures.

Excessive wall thickness differences in article (uneven Use blowing agent.

shrinkage)

Mold temperature too high Decrease mold temperature.

Specks

Cause Solution

Granulate contaminated Check granulate for contamination.

Note: Avoid contamination in transport and dosing
systems.

Incorrect master batch Check master batch for compatibility with chosen
polymer and processing conditions (temperatures) by
"natural" injection.
Check master batch for contamination.

Contamination in cylinder Check and clean cylinder.

Note: Inject cleaning compound, if necessary
dismantle cylinder. Check cleanliness by carrying out a
"natural" injection.

Contamination in runner(s) and gate(s) systems Check and clean the runner(s) and gate(s) systems.
Check the hot-runner(s) system(s) for dead corners.
Contamination in the dosing system
Polymer has degraded due to excessive residence time
in cylinder or in hot runner
Sprue remains in the mould
Cause
Sprue not released due to insufficient shrinkage
Insufficient release of the sprue
Sprue brakes because it is not frozen
Stress whitening (blushing)
Cause
Check dosing system for possibility of contamination.
Ensure that buffer is not too large, adjust accordingly,
by altering switching point (distance- or pressure-
dependent).
Reduce cycle time by:
Decrease the cooling time.
Note: If cooling time is determining the residence time
of polymer in cylinder.
Increase the screw speed setting and/or decrease the
back pressure.
Note: If plasticizing time is determining the residence
time of polymer in cylinder.
Decrease hot-runner temperature setting.
Decrease nozzle temperature.
Decrease cylinder temperature.
Check shot volume of plasticating unit.
Solution
Decrease the holding-pressure.
Decrease the back-pressure (if no shut-off nozzle is
used).
Check the sprue for release angle and damage.
Check dimensions and of radii of sprue bush and
nozzle.
Check if undercut on sprue-puller is insufficient.
Note: If necessary, increase.
Decrease the cylinder temperature profile and adjust
the nozzle temperature.
Use smaller sprue(s).
Solution
Too much material dosed, causing the article to adhere Reduce dosing.
too firmly to the part of the mould containing the Decrease the holding-pressure and/or decrease the
ejectors holding-time.

Article has shrunk onto the part of the mould Adjust the cooling time.
containing the ejectors Adjust the mold temperature.
Note: If necessary, locally for each mold part.
Adjust the holding-pressure and/or adjust the holding-
time.
Decrease cylinder temperature.
Decrease nozzle temperature.
Decrease hot-runner temperature.

Adhesion between article and mold too high for the Check the mold surface(s) for damage.
ejectors Note: Especially the sides perpendicular to direction of
motion. If necessary, repair and polish.
Use lubricant, whether internal (in polymer) or
external (mold release agent).
Check mold:
adjust release angle,
adjust undercut,
adjust radii.
Avoid creation of vacuum.
Make ejection easier by using air ejection.

Ejectors too small, incorrectly positioned or incorrectly Adjust ejector control.

controlled (movement and speed) Use of stepped ejectors may be required.
Note: If necessary, use more and/or larger ejectors.

Surface defects around gate

Cause Solution

Mold too cold Increase mold temperature.

Increase injection speed.
Increase injection pressure.

Mold too hot Lower mold temperature near the gate.

 Tiger stripes, ice lines, slip sticks
Cause
Adjust polymer temperature
Variable cycle time
Cause
Plasticizing time sometimes longer than cooling time
due to stagnation in material feed
Injection time varies due to incorrect polymer
temperature
Injection time varies due to leaking non-return valve
Incorrect injection time due to contaminated gate(s)
system
Solution
Adjust cylinder temperature.
Adjust nozzle temperature.
Adjust hot runner temperature.
Adjust back pressure.
Adjust screw speed.
Solution
Check the dosing system for blockages and ensure
presence of sufficient material.
Adjust the cylinder temperature profile.
Adjust the back-pressure and adjust the screw speed.
Increase the plasticizing time (when plasticizing time
is longer than the cooling time, cycle time will be
longer).
Check the sensors and the auxiliary equipment used
for temperature measurement of cylinder.
Note: Compare preset polymer temperature with
actual polymer temperature by discharging the
cylinder.
Adjust the cylinder temperature profile.
Note: Compare preset polymer temperature with
actual polymer temperature by discharging the
cylinder.
Check the sensors and the auxiliary equipment used
for temperature measurement of cylinder, nozzle
and/or hot-runner(s).
Check the non-return valve for leakage.
Check the gate(s) for blockage (contamination).
Check the dimensions of the gate(s).
Mold opening time or ejection time varies
Fault in hydraulic system of machine
Weld line, strength or visibility
Cause
Flow fronts do not adhere adequately (polymer
temperature too low or non-homogeneous)
Flow front contaminated
Entrapped air
Polymer melt contains master batch with poor welding
properties
Check motors, electrical and ejectors control systems.
Check function of robots and other mechanical
equipments.
Check the hydraulic system by f.i.:
measuring the oil pressure,
measuring the oil temperature,
controlling the quantity of oil,
controlling for oil leakage,
controlling cleanness of the oil filter.
Check motors and electrical controls system.
Solution
Increase the injection speed.
Increase the mold temperature.
Increase the cylinder temperature profile and/or
increase the nozzle temperature setting and/or
increase the hot-runner(s) temperature setting(s).
Increase the holding-pressure and/or increase the
holding-time.
Switch point injection pressure and holding pressure
later.
Increase back pressure.
Adjust screw speed.
Check the dimensions of the gate(s).
Note: If necessary, enlarge, reposition or add more
gate(s) (balancing).
Clean the mold surface(s) for contamination.
Uses less or eliminate lubricant, whether internal (in
polymer) or external (mold release agent).
Introduce vent at point of weld-line.
Check master batch for compatibility with chosen
polymer and processing conditions (temperatures) by
injection without master batch.
 Windows

Cause Solution

Polymer insufficiently melted
Increase the cylinder temperature and increase the
nozzle temperature.
Increase the back-pressure and adjust the screw
speed.
Increase the plasticizing time (when plasticizing is
longer than the cooling time, cycle time will be
longer).
Check the length/diameter ratio of the screw.
Note; if necessary, replace the injection unit or use a
mixing device.

Granulate contaminated Check granulate for contamination by material with

different flow characteristics.