Moulding Troubleshooting

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MOULDING PROBLEMS AND THEIR POSSIBLE REMEDIES
THERMOPLASTICS
SHORT SHOTS
MOULDING REMEDIES MOULD RELATED REMEDIES MACHINE / MATERIAL REMEDIES
1) INJECTION PRESSURE MUST NOT BE LOW. 1) RUNNER AND GATE SIZE MUST NOT BE SMALL. 1) CHECK THE MATERIAL IN THE HOPPER
2) THERE SHOULD NOT BE LOSS OF INJECTION PRES- 2) NOZZLE OPENING SHOULD NOT BE SMALL. 2) ENSURE THAT THE HOPPER'S THROAT IS NOT
SURE DURING CYCLE. 3) GATE POSITION SHOULD BE CORRECT. BLOCKED
3) INJECTION TIME MUST NOT BE SHORT. 4) INCRESE THE NUMBER OF GATES IF NEEDED. 3) OPTIMIZE THE FEED CONTROL IN THE MACHINE.
4) INJECTION SPEED SHOULD BE SUFFICIENT. 5) INCREASE THE SIZE OF COLD SLUG WELL. 4) ENSURE FEED SYSTEM OPERATING CORRECTLY.
5) CAVITIES MUST BE FILLED EQUALLY. 6) PROVIDE SUFFICIENT VENTING. 5) PLASTICIZING CAPACITY OF THE MACHINE MUST NOT
6) THERE SHOULD BE MINIMUM INTERRUPTION IN THE BE SMALL FOR THE SHOT.
FEED SYSTEM. 6) THERE SHOULD NOT BE INCONSISTENT CYCLES -
7) RAISE CYLINDER TEMPERATURE. MACHINE CAUSED / OPERATOR CAUSED.
8) RAISE NOZZLE TEMPERATURE. 7) CHECK THE RETURN VALVE WORKING CORRECTLY
9) RAISE MOULD TEMPERATURE. AT THE TIP OF THE SCREW.
FLASHES
1) INJECTION PRESSURE SHOULD BE OPTIMUM. 1) PROPER CORE AND CAVITIES SEALING 1) THE CLAMPING TONNAGE OF THE MACHINE SHOULD
2) INJECTION TIME SHOULD BE OPTIMUM. 2) CORE AND CAVITIES MUST NOT BE MISMATCHED. BE SUFFICIENT TO PROVIDE THE REQUIRED TONNAGE .
3) INJECTION SPEED SHOULD NOT BE TOO FAST. 3) MOULD PLATES MUST BE PARALLEL. 2) MOULD AND MACHINE SHOULD BE SET CORRECTLY.
4) EQUALIZED FILLING SHOULD BE THERE IN CAVITIES. 4) SUFFICIENT SUPPORT FOR CORE AND CAVITY. 3) CLAMPING PRESSURE SHOULD BE MAINTAINED.
5) INJECTION FEED SHOULD BE OPTIMUM. 5) ALL THE PINS MUST BE WELL MATCHED AT THE 4) MACHINE PLATENS SHOULD BE PARALLEL.
6) CYLINDER TEMPERATURE SHOULD NOT BE TOO HIGH BUTTING SURFACE OF THE TWO HALVES OF MOULD. 5) TIE BARS SHOULD BE EQUALLY STRAINED.
7) NOZZLE TEMPERATURE SHOULD NOT BE TOO HIGH. 6) VENTS MUST NOT BE TOO LARGE.
8) MOULD TEMPERATURE SHOULD NOT BE HIGH. 7) LAND AREA ROUND THE CAVITIES MUST NOT BE TOO
LARGE , REDUCING THE SEALING PRESSURE.
SINK MARKS
1) THERE SHOULD NOT BE INSUFFICIENT FEED. 1) INCREASE THE GATE SIZE. 1) INCREASE PLASTICIZING CAPACITY OF THE MACHINE
2) INCREASE THE INJECTION PRESSURE. 2) INSREASE THE RUNNER SIZE. 2) MAKE CYCLE CONSISTENT.
3) INCREASE THE INJECTION FORWARD TIME. 3) INCREASE THE SPRUE AND NOZZLE SIZE. 3) TRY TO COOL THE PART IN HOT WATER.
4) INCREASE THE BOOST TIME. 4) PROPER VENTING IN THE MOULD. 4) DRY THE MATERIAL BY PREHEATING.
5) INCREASE THE INJECTION SPEED. 5) EQUALIZE FILLING RATE OF THE CAVITIES.
6) INCREASE THE OVERALL CYCLE. 6) PREVENT INTERRUPTED FLOW IN THE CAVITIES.
7) MATERIAL SHOULD NOT BE TOO HOT CAUSING 7) GATE IN THICK SECTIONS.
EXCESSIVE SHRINKAGE. 8) REDUCE UNEVEN WALL THICKNESS WHERE POSSIBLE
8) MATERIAL SHOULD NOT BE TOO COLD CAUSING
INCOMPLETE FILLING AND PACKING.
9) MOULD TEMPERATURE SHOULD NOT BE TOO HIGH AS
THE MATERIAL WILL NOT SETUP QUICKLY ENOUGH.
10) LOCAL HOT SPOTS SHOULD NOT BE THERE IN MOULD
11) CHECK THE MOULD TEMPERATURE CONTROL
SYSTEM.
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POOR WELD LINES

1) CYLINDER TEMPERATURE SHOULD NOT BE LOW. 1) SUFFICIENT VENTING AT THE WELD. 1) PLASTICIZING CAPACITY SHOULD BE SUFFICIENT.
2) NOZZLE TEMPERATURE SHOULD NOT BE LOW. 2) RUNNER AND GATE SYSTEM SHOULD NOT BE TOO 2) THERE SHOULD NOT BE EXCESSIVE LOSS OF PRE-
3) MOULD TEMPERATURE SHOULD BE OPTIMUM. SMALL. SSURE IN THE CYLINDER.
4) MELT TEMPERATURE SHOULD BE EVEN. 3) SPRUE OPENING SHOULD NOT BE TOO SMALL. 3) MATERIAL SHOULD NOT BE CONTAMINATED.
5) INJECTION PRESSURE SHOULD BE SUFFICIENT. 4) SUFFICIENT NOZZLE OPENING SHOULD BE THERE 4) LUBRICATE MATERIAL FOR BETTER FLOW IF NEEDED.
6) INJECTION FEED SHOULD NOT BE SLOW. 5) ADD ADITIONAL GATES IF POSSIBLE ( THIS MIGHT ADD
ADDITIONAL WELDS BUT IT WOULD BE STRONGER AND
SHOULD BE AT LESS OBJECTIONABLE POSITION ).
6) WALL SECTION SHOULD NOT BE TOO THIN CAUSING
PREMATURE FREEZING.
7) CORE MUST NOT BE SHIFTING CAUSING THE OPPOS-
ITE WALL TO BE TOO THIN.
8) EQUALIZE FILLING RATE
9) AVOID INTERRUPTED FILLING.
BRITTLENESS
1) INCREASE CYLINDER TEMPERATURE. 1) PART DESIGN MUST NOT BE TOO THIN. 1) MACHINE PLASTICIZING CAPACITY SHOULD BE SUF-
2) INCREASE NOZZLE TEMPERATURE. 2) GATE MUST NOT BE TOO SMALL. FICIENT.
3) IF MATERIAL IS THERMALLY DEGRADING, LOWER 3) SUFFICIENT RUNNER SIZE. 2) THERE SHOULD BE NO OBSTRUCTION IN THE CYLIN-
CYLINDER AND NOZZLE TEMPERATURE. 4) ADD REINFORCEMENT ( RIBS, FILLETS ). DER WHICH DEGRADES THE MATERIAL.
4) INCREASE INJECTION SPEED. 3) THERE SHOULD BE NO CONTAMINATED MATERIAL.
5) INCREASE INJECTION PRESSURE. 4) ENSURE NO WET MATERIAL.
6) INCREASE INJECTION FORWARD TIME. 5) USE MATERIAL WITH LOWER VOLATILE CONTENT.
7) INCREASE INJECTION BOOST. 6) REDUCE THE AMOUNT OF REGROUND MATERIAL.
8) INCREASE MOULD TEMPERATURE. 7) INCREASE THE STRENGTH OF MATERIAL ( I.e ADD
9) PART SHOULD HAVE STRONG WELD LINES. MORE RUBBER TO HIGH IMPACT POLYSTYRENE ).
10) SCREW SPEED MUST NOT BE TOO HIGH, SO THAT
IT MAY NOT DEGRADE THE MATERIAL.
MATERIAL
DISCOLORATION
1) OPTIMIZE THE TEMPERATURE OF THE CYLINDER. 1) PROPER VENTING IN THE MOULD. 1) CLEAN THE MACHINE.
2) LOWER THE NOZZLE TEMPERATURE. 2) INCREASE THE GATE SIZE. 2) CLEAN THE HOPPER DRYER.
3) DECREASE THE SCREW SPEED. 3) INCREASE THE RUNNER-SPRUE-NOZZLE SYSTEM. 3) PREVENT DIRTY ATMOSPHERE:
4) DECREASE THE BACK PRESSURE. 4) CHANGE GATING PATTERN. a) CLEAN NOZZLE
5) DECREASE THE INJECTION PRESSURE. 5) REMOVE LUBRICANT AND OIL FROM MOULD. b) INSPECT NOZLLE AND SPRUE BUSH FOR BURRS.
6) DECREASE THE INJECTION FORWARD TIME. 6) INVESTIGATE MOULD LUBRICANT. c) PURGE CYLINDER.
7) DECREASE INJECTION BOOST TIME. d) CLEAN CYLINDER AND CHECK FOR BURRS.
8) SLOW DOWN INJECTION RATE. e) CHECK CYLINDER FOR CRACK.
9) DECREASE THE CYCLE. 4) CHECK THE FUNCTIONING OF THE THERMOCOUPLE.
5) CYLINDER OBSTRUCTION SHOULD BE DEGRAING THE
MATERIAL.
6) CHECK CONTAMINATION IN MATERIAL.
7) PREHEAT THE MATERIAL PROPERLY.
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8) THERE SHOULD NOT BE TOO MANY VOLATILES IN THE
MATERIAL.
9) THE MATERIAL, ADDITIVES AND COLORANTS SHOULD
NOT BE DEGRADING.
SPLAY, MICA OR FLOW

MARKS
1) REDUCE SCREW SPEED. 1) INCREASE COLD SLUG WELL. 1) CHECK NOZZLE FOR PARTIAL OBSTRUCTION
2) REDUCE BACK PRESSURE. 2) INCREASE RUNNER AND RUNNER EXTENSION. 2) CHECK SPRUE-NOZZLE-CYLINDER FOR BURRS.
3) REDUCE INJECTION SPEED IF JETTING IS THE CAUSE. 3) POLISH SPRUE RUNNER AND GATE. 3) USE POSITIVE SHUT-OFF TO PREVENT DROOL.
4) INCREASE INJECTION PRESSURE. 4) OPEN GATE OR CHANGE GATE TO TAB. 4) INSUFICIENT MACHINE CAPACITY.
5) INCREASE INJECTION FORWARD TIME. 5) CHANGE GATE LOCATION.
6) INCREASE BOOSTER TIME. 6) INCREASE VENTING.
7) INCREASE CYCLE. 7) IMPROVE MOULD SURFACE.
8) OPTIMIZE THE CYLINDER T6EMPERATURE. 8) USE MINIMUM LUBRICANT AND CHANGE THE TYPE OF
9) RAISE THE MOULD TEMPERATURE IF IT IS TOO LOW. LUBRICANT.
10) THE MOULD TEMPERATURE SHOULD BE UNIFORM. 9) REMOVE WATER CAUSED BY LEAKS AND CONDE-
11) OPTIMIZE THE NOZZLE TEMPERATURE. NSATION.
10) TRY LOCALISED GATE HEATING.
SURFACE BLEMISH AT
THE GATE
1) INCREASE THE BARREL TEMPERATURE. 1) RAISE MOULD TEMPERATURE. 1) USE DRY MATERIAL.
2) INCREASE NOZZLE TEMPERATURE. 2) INCREASE GATE SIZE. 2) REMOVE CONTAMINANTS FROM THE MATERIAL.
3) SLOW DOWN INJECTION RATE. 3) CHANGE GATE SHAPE ( TAB OR FLARE GATE ).
4) INCREASE INJECTION PRESSURE. 4) INCREASE COLD SLUG WELL.
5) USE MINIMUM LUBRICANT. 5) INCREASE RUNNER SIZE.
6) CHANGE LUBRICANT. 6) CHANGE GATE LOCATION.
7) INCREASE VENTING.
8) PROVIDE RADIUS AT THE GATE POSITION AT CAVITY.
WARPAGE AND
SHRINKAGE
1) INCREASE CYCLE TIME. 1) CHANGE GATE SIZE AND LOCATION.
2) INCREASE INJECTION PRESSURE WITHOUT EXCESS- 2) ADD ADDITIONAL GATES.
IVE PACKING. 3) INCREASE KNOCKOUT AREA.
WARPED WALLS 3) INCREASE INJECTION FORWARD TIME WITHOUT 4) KEEP KNOCKOUTS EVEN.
EXCESSIVE PACKING. 5) HAVE SUFFICIENT VENTING SPECIALLY FOR DEEP
4) INCREASE INJECTION BOOST TIME WITHOUT EXCES- PARTS.
SIVE PACKING. 6) STRENGTHEN PART BY INCREASING WALL THICKNESS.
5) INCREASE THE FEED WITHOUT EXCESSIVE PACKING. 7) STRENGTHEN PART BY ADDING RIBS AND FILLETS.
6) LOWER THE MATERIAL TEMPERATURE. 8) TO REDUCE WARPAGE REDUCE MOULD TEMPERA-
7) KEEP PACKING AT THE MINIMUM. TURE TO STIFFEN THE OUTER SURFACE.
8) TO REDUCE SHRINKAGE RAISE THE MATERIAL TEMP- 9) TO DECREASE SHRINKAGE RAISE MOULD TEMPERAT-
ERATURE TO PERMIT MORE PACKING. URE TO INCREASE PACKING
9) KEEP PACKING AT A MAXIMUM.
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10) INCREASE INJECTION SPEED.
11) SLOW DOWN EJECTION MECHANISM.
12) ANNEALING PARTS AFTER MOULDING MAY REDUCE
WARPING.
13) COOL IN A SHRINK FIXTURE.
14) COOL IN WATER.
DIMENSIONAL
CONTROL
1) MOULD TYEMPERATURE SHOULD BE EVEN. 1) CHECK MOULD DIMENSIONS. 1) CHECK THE INCONSISTENT SCREW STOP ACTION.
2) SUFFICIENT INJECTION PRESSURE. 2) THERE SHOULD BE NO DISTORTION DURING EJECTION 2) CHECK THE INCONSISTENT SCREW SPEED.
3) INCREASE INJECTION FORWARD AND BOOST TIME. 3) ENSURE EVEN FILLING OF THE MOULD. 3) ENSURE THE RETURN VALVE IS FUNCTIONING PRO-
4) OPTIMIZE BARREL AND NOZZLE TEMPERATURE. 4) OPTIMIZE GATE DIMENSIONS. PERLY.
5) CHECK THE RUNNER DIMENSIONS. 4) CHECK UNEVEN BACK PRESSURE.
5) CHECK MALFUNCTIONING OF THERMOCOUPLE.
6) CHECK THE MALFUNCTIONING OF THE BAND HEATER.
7) SUFFICIENT PLASTICIZING CAPACITY OF MACHINE.
8) THERE CAN BE BATCH TO BATCH VARIATION, SO
CHECK THE MATERIAL WITH TEST REPORT.
9) ENSURE DRY MATERIAL IS USED.
STICKING IN MOULD
1) USE MORE MOULD RELEASING AGENT. 1) SEE IF STICKING IS CAUSED BY SHORT SHOTS NOT 1) REPAIR ANY MALFUNCTIONING OF THE KNOCKOUT
2) REDUCE MATERIAL FEED. ENGAGING KNOCKOUT SYSTEM. SYSTEM.
3) REDUCE INJECTION PRESSURE 2) REMOVE UNDERCUTS. 2) LENGTHEN INSUFFICIENT INSUFFICIENT KNOCKOUT
4) REDUCE INJECTION FORWARD TIME AND BOOST TIME 3) REMOVE BURRS, NICKS AND SIMILAR IRREGULARITIES. TRAVEL DISTANCE.
5) REDUCE MOULD TEMPERATURE. 4) REMOVE SCRATCHES AND PITS. 3) CHECK TO SEE IF THE PLATENS ARE PARALLEL.
6) INCREASE OVERALL CYCLES. 5) IMPROVE THE MOULD SURFACE. 4) CHECK THE TIE ROD BUSHINGS.
6) RESTONE OR POLISH IN THE DIRECTION OF EJECTION. 5) REMOVE THE CONTAMINATION IN THE MATERIAL.
7) ENSURE THE DRAFT ANGLE IS PROVIDED. 6) ADD LUBRICANT TO THE MATERIAL.
8) INCREASE THE EFFECTIVE KNOCKOUT AREA. 7) DRY THE MATERIAL.
9) CHANGE THE KNOCKOUT LOCATION.
10) CHECK THE MOVEMENT OF THE PLATES AND LOOSE
CAMS ETC.
11) SEE IF CAMS ARE CLEARING BEFORE PART IS
EJECTED.
12) ADD AIR EJECTION IN DEEP DRAWN COMPONENTS.
13) CHECK IF THE CORE IS SHIFTING DURING MOULDING.
14) SEE IF THE MOULD BASE IS DEFORMING DURING
MOULDING.
15) DECREASE THE GATE SIZE AND ADD ADDITIONAL
GATES
16) EQUALIZE THE MOULD FILLING RATE.
17) PREVENT INTERRUPTED FILLING.
18) RADIUS AND REINFORCED PARTS GIVING GREATER
RIGIDITY.
19) ADD ADITIONAL KNOCKOUT SYSTEM SUCH AS AIR
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EJECTION.
20) IF THE PART REMAINS ON THE WRONG SIDE YOU CAN
UNDERCUT THE OTHER SIDE.
STICKING IN SPRUE
1) USE SPRUE BREAK ( MACHINE MOVES BACK SLIGH- 1) INCREASE THE PULL OUT FORCE OF THE PULL-OUT 1) CHECK THE MATERIAL CONTAMINATION.
TLY, BREAKING CONTACT BETWEEN NOZZLEAND SPRUE) SYSTEM. 2) DRY MATERIAL.
2) INCREASE SUCKBACK. 2) REDUCE MOULD TEMPERATURE.
3) REDUCE FEED.
4) REDUCE INJECTION PRESSURE.
5) REDUCE RAM FORWARD TIME.
6) REDUCE INJECTION BOOST TIME.
7) REDUCE MATERIAL TEMPERATURE.
8) REDUCE CYLINDER TEMPERATURE.
9) REDUCE NOZZLE TEMPERATURE.
NOOZLE DROOLING
1) REDUCE NOZZLE TEMPERATURE. 1) INCREASE COLD SLUG WELL. 1) USE POSITIVE SEAL TYPE NOZZLE
2) INCREASE SUCKBACK. 2) INCREASE RUN-OFF. 2) USE REVERSE TAPER NOZZLE.
3) USE SPRUE BREAK. 3) CHECK FOR CONTAMINATION.
4) DECREASE MATERIAL TEMPERATURE. 4) DRY THE MATERIAL.
6) REDUCE INJECTION FORWARD TIME.
7) REDUCE INJECTION BOOST TIME
THERMOSET PLASTICS
BLISTERING ON
MATERIAL
1) INCREASE BACK PRESSURE 1) INCREASE GATE SIZE.
2) INCREASE INJECTION PRESSURE 2) INCREASE RUNNER SIZE.
3) INCREASE FEED. 3) INCREASE CAVITY VENTS.
4) INCREASE CYCLE TIME.
5) INCREASE MOULD TEMPERATURE.
SETUP PROBLEMS OF
MATERIAL
2) REDUCE SCREW SPEED.
3) REDUCE BACK PRESSURE.
5) INCREASE NOZZLE OPENING.
6) CLEAN ( FLUSH ) SCREW.
7) LOWER NOZZLE TEMPERATURE.
MOULDING PROBLEMS AND THEIR POSSIBLE REMEDIES
SHORT SHOTS
MACHINE REMEDIES
1) CHECK THE MATERIAL IN THE HOPPER
2) ENSURE THAT THE HOPPER'S THROAT IS NOT
BLOCKED
3) OPTIMIZE THE FEED CONTROL IN THE MACHINE.
4) ENSURE FEED SYSTEM OPERATING CORRECTLY.
5) PLASTICIZING CAPACITY OF THE MACHINE MUST NOT
BE SMALL FOR THE SHOT.
6) THERE SHOULD NOT BE INCONSISTENT CYCLES -
MACHINE CAUSED / OPERATOR CAUSED.
7) CHECK THE RETURN VALVE WORKING CORRECTLY
AT THE TIP OF THE SCREW.
FLASHES
MACHINE REMEDIES
1) THE CLAMPING TONNAGE OF THE MACHINE SHOULD
BE SUFFICIENT TO PROVIDE THE REQUIRED TONNAGE .
2) MOULD AND MACHINE SHOULD BE SET CORRECTLY.
3) CLAMPING PRESSURE SHOULD BE MAINTAINED.
4) MACHINE PLATENS SHOULD BE PARALLEL.
5) TIE BARS SHOULD BE EQUALLY STRAINED.
SINK MARKS
MACHINE REMEDIES
1) INCREASE PLASTICIZING CAPACITY OF THE MACHINE
2) MAKE CYCLE CONSISTENT.
3) TRY TO COOL THE PART IN HOT WATER.
4) DRY THE MATERIAL BY PREHEATING.
POOR WELD LINES

MACHINE REMEDIES
1) PLASTICIZING CAPACITY SHOULD BE SUFFICIENT.
2) THERE SHOULD NOT BE EXCESSIVE LOSS OF PRE-
SSURE IN THE CYLINDER.
3) MATERIAL SHOULD NOT BE CONTAMINATED.
4) LUBRICATE MATERIAL FOR BETTER FLOW IF NEEDED.
BRITTLENESS
MACHINE REMEDIES
1) MACHINE PLASTICIZING CAPACITY SHOULD BE SUF-
FICIENT.
2) THERE SHOULD BE NO OBSTRUCTION IN THE CYLIN-
DER WHICH DEGRADES THE MATERIAL.
3) THERE SHOULD BE NO CONTAMINATED MATERIAL.
4) ENSURE NO WET MATERIAL.
5) USE MATERIAL WITH LOWER VOLATILE CONTENT.
6) REDUCE THE AMOUNT OF REGROUND MATERIAL.
7) INCREASE THE STRENGTH OF MATERIAL ( I.e ADD
MORE RUBBER TO HIGH IMPACT POLYSTYRENE ).
MATERIAL DISCOLORATION
MACHINE REMEDIES
1) CLEAN THE MACHINE.
2) CLEAN THE HOPPER DRYER.
3) PREVENT DIRTY ATMOSPHERE:
a) CLEAN NOZZLE
b) INSPECT NOZLLE AND SPRUE BUSH FOR BURRS.
c) PURGE CYLINDER.
d) CLEAN CYLINDER AND CHECK FOR BURRS.
e) CHECK CYLINDER FOR CRACK.
4) CHECK THE FUNCTIONING OF THE THERMOCOUPLE.
5) CYLINDER OBSTRUCTION SHOULD BE DEGRAING THE
MATERIAL.
6) CHECK CONTAMINATION IN MATERIAL.
7) PREHEAT THE MATERIAL PROPERLY.
8) THERE SHOULD NOT BE TOO MANY VOLATILES IN THE
MATERIAL.
9) THE MATERIAL, ADDITIVES AND COLORANTS SHOULD
NOT BE DEGRADING.
SPLAY, MICA OR FLOW MARKS

MACHINE REMEDIES
1) CHECK NOZZLE FOR PARTIAL OBSTRUCTION
2) CHECK SPRUE-NOZZLE-CYLINDER FOR BURRS.
3) USE POSITIVE SHUT-OFF TO PREVENT DROOL.
4) INSUFICIENT MACHINE CAPACITY.
SURFACE BLEMISH AT THE GATE

MACHINE REMEDIES
1) USE DRY MATERIAL.
2) REMOVE CONTAMINANTS FROM THE MATERIAL.
WARPAGE AND SHRINKAGE

MACHINE REMEDIES
DIMENSIONAL CONTROL
MACHINE REMEDIES
1) CHECK THE INCONSISTENT SCREW STOP ACTION.
2) CHECK THE INCONSISTENT SCREW SPEED.
3) ENSURE THE RETURN VALVE IS FUNCTIONING PRO-
PERLY.
4) CHECK UNEVEN BACK PRESSURE.
5) CHECK MALFUNCTIONING OF THERMOCOUPLE.
6) CHECK THE MALFUNCTIONING OF THE BAND HEATER.
7) SUFFICIENT PLASTICIZING CAPACITY OF MACHINE.
8) THERE CAN BE BATCH TO BATCH VARIATION, SO
CHECK THE MATERIAL WITH TEST REPORT.
9) ENSURE DRY MATERIAL IS USED.
STICKING IN MOULD
MACHINE REMEDIES
1) REPAIR ANY MALFUNCTIONING OF THE KNOCKOUT
SYSTEM.
2) LENGTHEN INSUFFICIENT INSUFFICIENT KNOCKOUT
TRAVEL DISTANCE.
3) CHECK TO SEE IF THE PLATENS ARE PARALLEL.
4) CHECK THE TIE ROD BUSHINGS.
5) REMOVE THE CONTAMINATION IN THE MATERIAL.
6) ADD LUBRICANT TO THE MATERIAL.
7) DRY THE MATERIAL.
STICKING IN THE SPRUE

MACHINE REMEDIES
1) CHECK THE MATERIAL CONTAMINATION.
2) DRY MATERIAL.
NOOZLE DROOLING
MACHINE REMEDIES
1) USE POSITIVE SEAL TYPE NOZZLE
2) USE REVERSE TAPER NOZZLE.
3) CHECK FOR CONTAMINATION.
4) DRY THE MATERIAL.
MOULDING REMEDIES
1) INJECTION PRESSURE MUST NOT BE LOW.
2) THERE SHOULD NOT BE LOSS OF INJECTION PRES-
SURE DURING CYCLE.
3) INJECTION TIME MUST NOT BE SHORT.
4) INJECTION SPEED SHOULD BE SUFFICIENT.
5) CAVITIES MUST BE FILLED EQUALLY.
6) THERE SHOULD BE MINIMUM INTERRUPTION IN THE
FEED SYSTEM.
7) RAISE CYLINDER TEMPERATURE.
8) RAISE NOZZLE TEMPERATURE.
9) RAISE MOULD TEMPERATURE.
MOULDING REMEDIES
1) INJECTION PRESSURE SHOULD BE OPTIMUM.
2) INJECTION TIME SHOULD BE OPTIMUM.
3) INJECTION SPEED SHOULD NOT BE TOO FAST.
4) EQUALIZED FILLING SHOULD BE THERE IN CAVITIES.
5) INJECTION FEED SHOULD BE OPTIMUM.
6) CYLINDER TEMPERATURE SHOULD NOT BE TOO HIGH
7) NOZZLE TEMPERATURE SHOULD NOT BE TOO HIGH.
8) MOULD TEMPERATURE SHOULD NOT BE HIGH.
MOULDING REMEDIES
1) THERE SHOULD NOT BE INSUFFICIENT FEED.
2) INCREASE THE INJECTION PRESSURE.
3) INCREASE THE INJECTION FORWARD TIME.
4) INCREASE THE BOOST TIME.
5) INCREASE THE INJECTION SPEED.
6) INCREASE THE OVERALL CYCLE.
7) MATERIAL SHOULD NOT BE TOO HOT CAUSING
EXCESSIVE SHRINKAGE.
8) MATERIAL SHOULD NOT BE TOO COLD CAUSING
INCOMPLETE FILLING AND PACKING.
9) MOULD TEMPERATURE SHOULD NOT BE TOO HIGH AS
THE MATERIAL WILL NOT SETUP QUICKLY ENOUGH.
10) LOCAL HOT SPOTS SHOULD NOT BE THERE IN MOULD
11) CHECK THE MOULD TEMPERATURE CONTROL
SYSTEM.
MOULDING REMEDIES
1) CYLINDER TEMPERATURE SHOULD NOT BE LOW.
2) NOZZLE TEMPERATURE SHOULD NOT BE LOW.
3) MOULD TEMPERATURE SHOULD BE OPTIMUM.
4) MELT TEMPERATURE SHOULD BE EVEN.
5) INJECTION PRESSURE SHOULD BE SUFFICIENT.
6) INJECTION FEED SHOULD NOT BE SLOW.
MOULDING REMEDIES
1) INCREASE CYLINDER TEMPERATURE.
2) INCREASE NOZZLE TEMPERATURE.
3) IF MATERIAL IS THERMALLY DEGRADING, LOWER
CYLINDER AND NOZZLE TEMPERATURE.
5) INCREASE INJECTION PRESSURE.
6) INCREASE INJECTION FORWARD TIME.
7) INCREASE INJECTION BOOST.
8) INCREASE MOULD TEMPERATURE.
9) PART SHOULD HAVE STRONG WELD LINES.
10) SCREW SPEED MUST NOT BE TOO HIGH, SO THAT
IT MAY NOT DEGRADE THE MATERIAL.
MOULDING REMEDIES
1) OPTIMIZE THE TEMPERATURE OF THE CYLINDER.
2) LOWER THE NOZZLE TEMPERATURE.
3) DECREASE THE SCREW SPEED.
4) DECREASE THE BACK PRESSURE.
5) DECREASE THE INJECTION PRESSURE.
6) DECREASE THE INJECTION FORWARD TIME.
7) DECREASE INJECTION BOOST TIME.
8) SLOW DOWN INJECTION RATE.
9) DECREASE THE CYCLE.
RAING THE
LES IN THE
MOULDING REMEDIES
1) REDUCE SCREW SPEED.
2) REDUCE BACK PRESSURE.
3) REDUCE INJECTION SPEED IF JETTING IS THE CAUSE.
5) INCREASE INJECTION FORWARD TIME.
6) INCREASE BOOSTER TIME.
7) INCREASE CYCLE.
8) OPTIMIZE THE CYLINDER T6EMPERATURE.
9) RAISE THE MOULD TEMPERATURE IF IT IS TOO LOW.
10) THE MOULD TEMPERATURE SHOULD BE UNIFORM.
11) OPTIMIZE THE NOZZLE TEMPERATURE.
MOULDING REMEDIES
1) INCREASE THE BARREL TEMPERATURE.
2) INCREASE NOZZLE TEMPERATURE.
3) SLOW DOWN INJECTION RATE.
5) USE MINIMUM LUBRICANT.
6) CHANGE LUBRICANT.
MOULDING REMEDIES
1) INCREASE CYCLE TIME.
2) INCREASE INJECTION PRESSURE WITHOUT EXCESS-
IVE PACKING.
3) INCREASE INJECTION FORWARD TIME WITHOUT
EXCESSIVE PACKING.
4) INCREASE INJECTION BOOST TIME WITHOUT EXCES-
SIVE PACKING.
5) INCREASE THE FEED WITHOUT EXCESSIVE PACKING.
6) LOWER THE MATERIAL TEMPERATURE.
7) KEEP PACKING AT THE MINIMUM.
8) TO REDUCE SHRINKAGE RAISE THE MATERIAL TEMP-
ERATURE TO PERMIT MORE PACKING.
9) KEEP PACKING AT A MAXIMUM.
11) SLOW DOWN EJECTION MECHANISM.
12) ANNEALING PARTS AFTER MOULDING MAY REDUCE
WARPING.
13) COOL IN A SHRINK FIXTURE.
14) COOL IN WATER.
MOULDING REMEDIES
1) MOULD TYEMPERATURE SHOULD BE EVEN.
2) SUFFICIENT INJECTION PRESSURE.
3) INCREASE INJECTION FORWARD AND BOOST TIME.
4) OPTIMIZE BARREL AND NOZZLE TEMPERATURE.
MOULDING REMEDIES
1) USE MORE MOULD RELEASING AGENT.
2) REDUCE MATERIAL FEED.
3) REDUCE INJECTION PRESSURE
4) REDUCE INJECTION FORWARD TIME AND BOOST TIME
5) REDUCE MOULD TEMPERATURE.
6) INCREASE OVERALL CYCLES.
MOULDING REMEDIES
1) USE SPRUE BREAK ( MACHINE MOVES BACK SLIGH-
TLY, BREAKING CONTACT BETWEEN NOZZLEAND SPRUE)
2) INCREASE SUCKBACK.
3) REDUCE FEED.
5) REDUCE RAM FORWARD TIME.
6) REDUCE INJECTION BOOST TIME.
7) REDUCE MATERIAL TEMPERATURE.
MOULDING REMEDIES
2) INCREASE SUCKBACK.
3) USE SPRUE BREAK.
4) DECREASE MATERIAL TEMPERATURE.
6) REDUCE INJECTION FORWARD TIME.
7) REDUCE INJECTION BOOST TIME
MOULD RELATED REMEDIES
1) RUNNER AND GATE SIZE MUST NOT BE SMALL.
2) NOZZLE OPENING SHOULD NOT BE SMALL.
3) GATE POSITION SHOULD BE CORRECT.
4) INCRESE THE NUMBER OF GATES IF NEEDED.
5) INCREASE THE SIZE OF COLD SLUG WELL.
6) PROVIDE SUFFICIENT VENTING.

1) PROPER CORE AND CAVITIES SEALING
2) CORE AND CAVITIES MUST NOT BE MISMATCHED.
3) MOULD PLATES MUST BE PARALLEL.
4) SUFFICIENT SUPPORT FOR CORE AND CAVITY.
5) ALL THE PINS MUST BE WELL MATCHED AT THE
BUTTING SURFACE OF THE TWO HALVES OF MOULD.
6) VENTS MUST NOT BE TOO LARGE.
7) LAND AREA ROUND THE CAVITIES MUST NOT BE TOO
LARGE , REDUCING THE SEALING PRESSURE.

1) INCREASE THE GATE SIZE.
2) INSREASE THE RUNNER SIZE.
3) INCREASE THE SPRUE AND NOZZLE SIZE.
4) PROPER VENTING IN THE MOULD.
5) EQUALIZE FILLING RATE OF THE CAVITIES.
6) PREVENT INTERRUPTED FLOW IN THE CAVITIES.
7) GATE IN THICK SECTIONS.
8) REDUCE UNEVEN WALL THICKNESS WHERE POSSIBLE
OO HIGH AS
E IN MOULD

1) SUFFICIENT VENTING AT THE WELD.
2) RUNNER AND GATE SYSTEM SHOULD NOT BE TOO
SMALL.
3) SPRUE OPENING SHOULD NOT BE TOO SMALL.
4) SUFFICIENT NOZZLE OPENING SHOULD BE THERE
5) ADD ADITIONAL GATES IF POSSIBLE ( THIS MIGHT ADD
ADDITIONAL WELDS BUT IT WOULD BE STRONGER AND
SHOULD BE AT LESS OBJECTIONABLE POSITION ).
6) WALL SECTION SHOULD NOT BE TOO THIN CAUSING
PREMATURE FREEZING.
7) CORE MUST NOT BE SHIFTING CAUSING THE OPPOS-
ITE WALL TO BE TOO THIN.
8) EQUALIZE FILLING RATE
9) AVOID INTERRUPTED FILLING.

1) PART DESIGN MUST NOT BE TOO THIN.
2) GATE MUST NOT BE TOO SMALL.
3) SUFFICIENT RUNNER SIZE.
4) ADD REINFORCEMENT ( RIBS, FILLETS ).

1) PROPER VENTING IN THE MOULD.
2) INCREASE THE GATE SIZE.
3) INCREASE THE RUNNER-SPRUE-NOZZLE SYSTEM.
4) CHANGE GATING PATTERN.
5) REMOVE LUBRICANT AND OIL FROM MOULD.
6) INVESTIGATE MOULD LUBRICANT.
1) INCREASE COLD SLUG WELL.
2) INCREASE RUNNER AND RUNNER EXTENSION.
3) POLISH SPRUE RUNNER AND GATE.
4) OPEN GATE OR CHANGE GATE TO TAB.
5) CHANGE GATE LOCATION.
7) IMPROVE MOULD SURFACE.
8) USE MINIMUM LUBRICANT AND CHANGE THE TYPE OF
LUBRICANT.
9) REMOVE WATER CAUSED BY LEAKS AND CONDE-
NSATION.
10) TRY LOCALISED GATE HEATING.

1) RAISE MOULD TEMPERATURE.
2) INCREASE GATE SIZE.
3) CHANGE GATE SHAPE ( TAB OR FLARE GATE ).
5) INCREASE RUNNER SIZE.
6) CHANGE GATE LOCATION.
8) PROVIDE RADIUS AT THE GATE POSITION AT CAVITY.

1) CHANGE GATE SIZE AND LOCATION.
2) ADD ADDITIONAL GATES.
3) INCREASE KNOCKOUT AREA.
4) KEEP KNOCKOUTS EVEN.
5) HAVE SUFFICIENT VENTING SPECIALLY FOR DEEP
PARTS.
6) STRENGTHEN PART BY INCREASING WALL THICKNESS.
7) STRENGTHEN PART BY ADDING RIBS AND FILLETS.
8) TO REDUCE WARPAGE REDUCE MOULD TEMPERA-
TURE TO STIFFEN THE OUTER SURFACE.
9) TO DECREASE SHRINKAGE RAISE MOULD TEMPERAT-
URE TO INCREASE PACKING

1) CHECK MOULD DIMENSIONS.
2) THERE SHOULD BE NO DISTORTION DURING EJECTION
3) ENSURE EVEN FILLING OF THE MOULD.
4) OPTIMIZE GATE DIMENSIONS.
5) CHECK THE RUNNER DIMENSIONS.

1) SEE IF STICKING IS CAUSED BY SHORT SHOTS NOT
ENGAGING KNOCKOUT SYSTEM.
2) REMOVE UNDERCUTS.
3) REMOVE BURRS, NICKS AND SIMILAR IRREGULARITIES.
4) REMOVE SCRATCHES AND PITS.
5) IMPROVE THE MOULD SURFACE.
6) RESTONE OR POLISH IN THE DIRECTION OF EJECTION.
7) ENSURE THE DRAFT ANGLE IS PROVIDED.
8) INCREASE THE EFFECTIVE KNOCKOUT AREA.
9) CHANGE THE KNOCKOUT LOCATION.
10) CHECK THE MOVEMENT OF THE PLATES AND LOOSE
CAMS ETC.
11) SEE IF CAMS ARE CLEARING BEFORE PART IS
EJECTED.
12) ADD AIR EJECTION IN DEEP DRAWN COMPONENTS.
13) CHECK IF THE CORE IS SHIFTING DURING MOULDING.
14) SEE IF THE MOULD BASE IS DEFORMING DURING
MOULDING.
15) DECREASE THE GATE SIZE AND ADD ADDITIONAL
GATES
16) EQUALIZE THE MOULD FILLING RATE.
17) PREVENT INTERRUPTED FILLING.
18) RADIUS AND REINFORCED PARTS GIVING GREATER
RIGIDITY.
19) ADD ADITIONAL KNOCKOUT SYSTEM SUCH AS AIR
EJECTION.
20) IF THE PART REMAINS ON THE WRONG SIDE YOU CAN
UNDERCUT THE OTHER SIDE.

1) INCREASE THE PULL OUT FORCE OF THE PULL-OUT
SYSTEM.
2) REDUCE MOULD TEMPERATURE.
2) INCREASE RUN-OFF.
Shrinkage% of Plastic & Rubber
Material in Moulds
Material Name Shinkage %
ABS 0.4 – 0.7
CA 0.3 – 0.7
CAB 0.2 – 0.5
CP 0.2 – 0.5
EVA 0.7 – 2.0
FEP 3.0 – 6.0
GPPS 0.2 – 0.8
HDPE 1.5 – 4.0
HIPS 0.2 – 0.8
LDPE 1.5 – 4.0
PA6 1.0 – 1.5
PA66 1.0 – 2.0
PBT 1.5- 2.0
PC 0.6 – 0.8
PES 0.6 – 0.8
PET 1.8 – 2.1
PMMA 0.2 – 1.0
POM 2.0 – 3.5
PP 1.0 – 3.0
PPO 0.5 – 0.7
PSU 0.6 – 0.8
PTFE 5.0 – 0.9
PVDF 2.0 – 3.0
SAN 0.2 – 0.6
PP/EPDM 1.0 – 2.0

PUR/TRU 0.5 – 2.0
SBS 0.4 – 1.0
SEBS 1.0 – 5.5
DMC 0.5 – 0.2
MF 0.6 – 1.0
PF 0.7 – 1.2
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Moulding Troubleshooting

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Moulding Troubleshooting

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PAGE 0 OF 05

MOULDING PROBLEMS AND THEIR POSSIBLE REMEDIES

POOR WELD LINES

SPLAY, MICA OR FLOW

POOR WELD LINES

SPLAY, MICA OR FLOW MARKS

SURFACE BLEMISH AT THE GATE

WARPAGE AND SHRINKAGE

STICKING IN THE SPRUE

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

MOULD RELATED REMEDIES

PP/EPDM 1.0 – 2.0

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