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Polyethylene Bottle Trouble SHooting Guide
Polyethylene Bottle Trouble SHooting Guide
Terephthalate
(PET)
•Processing Guidelines
•Troubleshooting Guide
Injection Moulding
Stretch Blow Moulding
•Recommended Tests & Equipment
INDEX
PROCESSING GUIDELINES
Drying
Drying Conditions
Dryer Startup
Dryer Specification
Injection Moulding
Resin Inlet Temperature
Barrel Temperature
Nozzle Temperature
Manifold Hot Runner Temperature
Injection Speed
Stretch Blow Moulding
TROUBLESHOOTING GUIDE
14) Stringing
15) Cloudy Preforms
16) Hollow Gates
17) Discolored Preforms
18) Line Over Finish
19) Burnt Gates
20) Oval Finish
21) Gas Burns
26) Explosion
27) Drop Test Failures
PROCESSING GUIDELINES
THE processing guidelines set out below cover the two major processes involved in the
conversion of PET resin into preforms and containers, namely:
1. INJECTION MOLDING
2. STRETCH BLOW MOLDING.
The resin preparation conditions and barrel temperature profile recommended on the injection
molder could also be used on extrusion barrel, in converting PET resin into amorphous sheet.
DRYING:
Drying Conditions:
This is the first and most crucial step in converting PET resin into perform/container/sheet. If
the drying equipment is not adequate or is not functioning efficiently then it is highly unlikely
that you will produce an acceptable product. The dried resin should have a moisture content not
more than 50 PPM.
Recommended Drying Temperature: 160 - 180 °C
Recommended Drying Time
5- 6 hours
Dryer Start-Up :
The time / temperature profile recommended when first starting the dryer or starting from a
major shut down is as below. The first hour at 120 °The next two hours 150 °The next two hours
180 °C
Dryer Specification:
Able to heat air up to 200 °C Able to deliver air flow rate in the order of 0.062 metre cube/ min
per kg/ hr of resin being processed. Able to deliver hot dehumidified air with a minimum of
40.0°C dew point.
STRETCH BLOW MOLDING PROCESS:
The most commonly available stretch blow molding machines are the:Single stage stretch blow
molder ( preform & bottle made on the same machine).They are AOKI, NISSEI, UNILOY,
etc.Two stage stretch blow molder (reheating and blowing of preforms made onInjection
molder).They are SIDEL, KRUPP, SIPA, etc.The processing conditions depend on the type of
process used and the mostcommon parametersto be controlled are:
o Preform Temperature.o Re-heating oven profile and over all oven percentage.
o Oven sheilds o Bottle blowing speed, bottles/hour.
o Stretch rod speed
o Air delay time o Pre-blow pressure.
o High blow time.
o High blow pressure.
o Blow mold cooling.
Injection Moulding
1 Problem: SHORT SHOTS
POSSIBLE CAUSES
o Injection Pressure low
o Barrel temperature low
o Mould manifold temp. low
o Mould cavity temp. low
POSSIBLE SOLUTIONS
oIncrease injection pressure
o Increase barrel temperature
o Increase mould manifold temperature
o Increase mould cavity temperature
o Injection speed low
o Back pressure low
o Increase injection speed
o Increase back pressure
o Clean vent on split, core and cavity
o Check that no foreign object is in gate area.
o Check that the gate pin is moving all the way back
POSSIBLE SOLUTIONS
o Increase holding pressure
o Increase holding time
o Decrease mould temperature
o Check cooling water
o Increase cooling time
o Clean vents on split, core and cavity
3 Problem: FLASH
POSSIBLE CAUSES
o Injection pressure high
o High injection speed
o Unwanted material in cores
o Unwanted material in splits
o Unwanted material in cavity
o High mold temperature
o High barrel temperature
o Clamping pressure low
POSSIBLE SOLUTIONS
o Decrease Injection pressure
o Decrease injection speed
o Clean cores
o Clean splits
o Clean cavity
o Decrease mould temperature
o Decrease barrel temperature
o Increase clamp pressure
POSSIBLE SOLUTIONS
o Check hoses on mould for damage
o Check mould for leaks
o Check that dehumidifier is working properly
o Check that the machine enclosures has no major gaps
POSSIBLE SOLUTIONS
o Check for resin cleanliness
o Clean the resin hopper
o Purge the barrel thoroughly on restart
o Reduce melt temperature
o Reduce back pressure
POSSIBLE SOLUTIONS
o Check temperature of mould cavity heater sand Manifold
o Check barrel temperature
o Check that no foreign material is in gate area
POSSIBLE SOLUTIONS
o Check barrel temperature
o Check mould temperature
o Increase back pressure
o Check that the mixing head of the screw or the screw is not broken. Of Inspect the check valve
on thescrew (not Husky Machine)
9 Problem: CONCENTRICITY
POSSIBLE CAUSES
o Injection speed high
o Injection core bent
POSSIBLE SOLUTIONS
o Decrease injection speed
o Check that the injection core is not bentand straighten it.
POSSIBLE SOLUTIONS
o Check that the cavity heater is working
o Increase the cavity temperature
o Increase the manifold temperature
o Check that the drier is working
o Decrease injection hold pressure
o Check that no foreign object obstructs the cavity gate
o Increase cooling time
o Check water flow through the injectioncore and cavity
o Check that the fountain in the injectioncore is not bent
11 Problem: LONG GATE
POSSIBLE CAUSES
o Cavity heater malfunction
o Cavity heater low
o Gate valve malfunction
o Shut-off nozzle malfunction
o Short decompression time
POSSIBLE SOLUTIONS
o Check cavity heater
o Increase cavity temperature
o Check that the gate valve is working
o Check that the barrel shut-off nozzle is working
o Increase decompression time
POSSIBLE SOLUTIONS
o Check barrel temperature
o Check drier temperature
o Increase back pressure
o Lower temperature at last extruder zone
o Check extruder mixing head
POSSIBLE SOLUTIONS
o Decrease injection pressure
o Reduce shot size
o Decrease injection hold time
14 Problem: STRINGING
POSSIBLE CAUSES
o High cavity temperature
o Low cooling time
o Low hold time
o Inadequate coolant to cavity
o Gate valve malfunction
POSSIBLE SOLUTIONS
o Reduce cavity temperature
o Increase cooling time
o Increase injection hold time
o Check water flow to cavities
o Check that gate valves are working
15 Problem: CLOUDY PREFORMS
POSSIBLE CAUSES
o Inefficient Drying
o Blocked drier filters
o Air leaks on the drier
o Air leaks on machine hoppers
o Low air flow to drying hopper
o Low process air temperature
o Barrel temperature low
o Insufficient drying
o Back pressure low
POSSIBLE SOLUTIONS
o Check drier temperature and dew point
o Clean drier air filters
o Check for air leaks on drier
o Check for air leaks on machine hopper
o Check air flow to hopper
o Increase drier process temperature
o Increase barrel temperature
o Shut machine down for 1 hour and dry material
o Increase back pressure
POSSIBLE SOLUTIONS
o Increase packing pressure
o Increase holding time
o Increase cooling time
o Lower cavity temperature
o Check for foreign material in gate area.
POSSIBLE SOLUTIONS
o Reduce cavity temperature
POSSIBLE SOLUTIONS
o High core and cavity temperatures
o Increase cooling time
o Increase injection hold time
o Check water temperature and water flow to injection Mould
o Check temperature of injection cores and cavities
POSSIBLE SOLUTIONS
o Check for resin AA levels
o Reduce the barrel temperature
o Reduce back pressure
o Reduce screw RPM
o Reduce injection speed
o Reduce mold manifold temperature
o Reduce cycle time
o Reduce cushion
o Increase inlet resin temperature
TROUBLESHOOTING GUIDE
POSSIBLE SOLUTIONS
o Move shield away from finish into a thicker part of the preforms taper
o Bring shield close to perform
o Increase oven exhaust
o Reduce neck element heat
POSSIBLE SOLUTIONS
o Realign transfer arm
o Realign blow mould or nozzle if necessary
POSSIBLE SOLUTIONS
o Reduce air delay time
o Reduce stretch rod pressure
o Move shield into a thicker part of the taper o Increase heat in the body or base
o Increase low blow pressure
o Reduce heat in the neck
POSSIBLE SOLUTIONS
o Reduce heat in the body and/ or base until pearlescence occurs then increase neck temperature.
o Increase stretch rod pressure
o Increase air delay time
o Reduce low blow pressure
o Move shield into the thinner part of the taper o Check height of preform though oven.
o Check for air leak through nose
POSSIBLE SOLUTIONS
o Move shield into a thicker part of the preforms taper.
o Reduce air delay time
o Reduce stretch rod pressure
o Increase low blow pressure
o Reduce heat in the neck. If thickening occurs below desired area Increase heat below the neck
element.
POSSIBLE SOLUTIONS
o Reduce heat adjacent to the haze untilpearlescence is evident somewhere onthe bottle
o Reduce heat over all until pearlescenceis evident.
o Increase air circulation through oven,increase blower speed, clean blowers.
8 Problem: EXCESSIVE FILL POINT DROP
POSSIBLE CAUSES
o Low levels of orientation results in the material not having enough strength to resist the
pressure applied.
POSSIBLE SOLUTIONS
o Reduce over all perform temperature allowing the bottle to be blown closer to its natural
stretch limit. Under this condition slight pearlescence may be evident
9 Problem: PEARLESCENCE
POSSIBLE CAUSES
o Pearlescence results from stretching of molecules faster than they can respond past it's natural
stretch limit. Small tears appear on the material's surface.
POSSIBLE SOLUTIONS
o Material to thin - Increase heat other than where pearl is evident.
o Where the pearlescent area may be allowed to stretch further increase heat at pearl.
o Increase overall preform temperature
o Pearlescence opposite a swung gate (Refer Swung Gate)
o Pearlescence on the bottle shoulder may be the result of a blow air leak through nose from
either the low valve, high blow valve or stretch rod
oReduce low blow volume, increase low blow timeand reduce low blow pressure.
o Ensure low blow bottle is not to large. Excessive petal formation in low blow will cause pearl
in the petal area.
o Pearlescence in the body in the form of a ring is the result of insufficient low blow.
POSSIBLE SOLUTIONS
o Ensure excessive mould parting does not occur o Increase low blow pressure ensuring bottle
diameter is close to blow mould size
o Low blow bottle too small. In this case the volume of air trying to escape during high blow is
more than the venting can allow.
o Low blow bottle blown to fast.
o Excessive high blow pressure at the end of low blow to minimize air that remains in the blow
mould before high blow starts.
o Reduce low blow pressure and extend low blow time if the body of the bottle has
reached the mould
o Reduce high blow pressure
POSSIBLE SOLUTIONS
o Increase low blow pressure
o Increase heat in the body
o Reduce heat in the base and/ or neck.
o Reduce air delay time
o Reduce stretch rod pressure
POSSIBLE CAUSES
o Poor heating profile resulting in poor distribution of material, insufficient stretching of the
body or shoulder.
POSSIBLE SOLUTIONS
o Reduce heat near the base of the perform until pearlescence occurs then increase heat to the
shoulder and/or body. Repeat until base weight is correct
o Increase air delay time
o Increase stretch rod pressure
o Reduce low blow pressure
o Reduce oven shielding of the taper
POSSIBLE SOLUTIONS
o Check high pressure. If possible. If station related check for high blow leaks from nozzle or
stretch rod
o Increase high blow time
o Reduce base weight by reducing
POSSIBLE SOLUTIONS
o Check the preform for a drag marl. Ensure oven shields are not touching the preform. Check
collect, spindle or mandrel rotation
o Increase air flow onto the surface of the preform
POSSIBLE SOLUTIONS
o Reduce over all preform temperature
o Reduce heat beside failure point
o Where failures occur between neck and shoulder adjust shield into a thicker part of the taper
18 Problem: LOW BURST PRESSURE (BODY)
POSSIBLE CAUSES
o Insufficient orientation (Too hot)
o Material to thin
o Confirmationo Low IV
POSSIBLE SOLUTIONS
o Reduce preform temperatureo Reduce body heat
POSSIBLE SOLUTIONS
o Increase heat below the perform
o Reset stretch rod clearance
o Reduce stretch rod pressure
POSSIBLE SOLUTIONS
o Base weight correct or light, reduce heat beside and/or below the gate
o Endcap temperature too high
o Aged performs
o Insufficient mould cooling
o Excessive inherent preform stress
o Base weight to heavy, reduce perform temperature
o Increase high blow time.
POSSIBLE SOLUTIONS
o Reduce heat in the areas other than the base. If the fold remains after pearlescence has formed.
Heat may be applied to the preform end cap area.
o Increase low blow pressure
o Reduce air delay time
o Reduce stretch rod pressure
POSSIBLE SOLUTIONS
o Reduce heat or below the end cap area
o Increase low blow pressure
o Reduce stretch rod pressure
POSSIBLE SOLUTIONS
o Increase heat beside or below the gate
o Reduce stretch rod pressure
o Check preform for excessive crystallinity, if so change preforms.
o Increase stretch rod, mould base gap
POSSIBLE CAUSES
o Misalignment of the preform to the mould, nozzle or stretch rod.
o Inadequate mould cooling, one half only If the gate is centered to the stretch rod impact mark
and yet not centered to the mould base at the end of blow the stretch rod has lost control during
blow.
o Lower half of preform too hot
o Low blow pressure too high
o Air delay time too short
o Stretch rod length too short
o Excessive stretch rod cushioning
o Worn stretch rod guides
o Excessive preform eccentricity
o Thick crystallinity near gate
POSSIBLE SOLUTIONS
o Fix swung gate.
o Reduce preform temperature to pearlescence, reduce base weight if necessary. Increase high
blow time
o Reduce heat in the preform's lower body
o Line lubricants generally cause severe stress cracking in all feet.
o Increase base weight
26Problem: EXPLOSIONS
POSSIBLE CAUSES
o Hot bottles (Refer Hot Bottles)o Folds in the base
o Light base weight
o Excessive post mould growth
o Low I.V.
o Chemical Reaction (Refer stress Cracking)
o Contamination
o Air bubbles above the gate
POSSIBLE SOLUTIONS
o Refer Causes
o Stress Cracking
o Cracked bases
o Excessive crystallinity