|
| |
|
|
-
| This is to inform you that, the QDH 32 (4P Die) along with allied post extrusion equipments supplied by you are commissioned well and the performance was found satisfactory. We are now availing production with following parameters.... |
A Sudhakar, Director
Shudhakar Polymers Limited (Karnataka) |
-
| I wish to convey my deepest appreciation to Windsor’s team for commissioning the 3 layer Co-extrusion Blown film plant, which is the FIRST PLANT IN SRILANKA very successfully. Windsor’s attitude, commitment, dedication, determination and unselfishness to impart your knowledge, was the key factor for this project being a success... |
O.E. Senaratna, CEO
Tuffline Ltd. (Sri Lanka) |
-
It is with pleasure; we would like to appreciate Windsor’s cooperation with our maintenance staff and instructions given by service team were explicit and ideal. We have no hesitation to say that performance of your machine found to be very satisfactory.
Thanking you and looking forward your further assistance. |
Hamed A. Al Khdairi, General Manager
Al-Ahila Plastic Co, W.L.L (Kuwait) |
-
On, behalf of our company, I wish to express our sincere appreciation for the service rendered by your service team in commissioning our 3 layer blown –film plant. We wish to extend our deep and warm appreciation for the work done by your team and their short journey with us has made the installation and commissioning easier and exciting.
We look forward for continued partnership with us. |
Jose A. Castro, Jr. President and CEO
Macondray Plastics, Inc. (Philippines) |
|
| |
|
| GLOBAL PRESENCE |
|
 |
|
| |
|
| |
|
|
| Blown Film Lines - Defects & Suggested Remedies |
|
| Trouble Shooting - Processing |
| Problem |
Cause |
Remedy |
| Gels |
Melt temperature too high (contamination that looks like small specks) |
Lower melt temperature |
| Melt fracture (Rough surface shark skin) |
Melt temperature too low, Die gap too narrow |
Increase melt temp.
Heat die lips, Increase die gap, Use processing aids. |
| Blocking |
- Inadequate cooling
- Excessive winding Tension
- Excessive pressure on Nip roller |
- Use better cooling method
- Adjust tension
- Adjust pressure |
| Port line |
- Melt temperature too low
- Die too cold or too hot |
- Increase melt temperature
- Adjust die temperature |
| Splitting |
- Excessive orientation in machine direction
- Degraded resin |
- Increase blow up ratio
-
Reduce melt temperature |
| Die lines |
- Nick on die lip
- Dirty die
- Inadequate purging |
- Change die
- Clean die
- Increase purging |
| Gauge variation |
- Surging
- Inconsistent take-up speed |
- Check temperature
- Check hopper for bridging, check take up speeds |
Gauge variation
(Transverse direction) |
Non uniform die gap |
Adjust gap, Center air ring |
|
| |
| top |
| Trouble Shooting - Extruder |
| Problem |
Cause |
Remedy |
| Vibration |
- Loose holding
- Improper leveling
- V-belt problem |
- Tighten all bolts of gear box,
motor, rails, barrel, etc.
- Make sure leveling
bolts are
rested on pads
- Tighten nuts
- Tighten foundation bolts
maintaining barrel level
- Level barrel with level bottle taking away barrel heaters
- Check pulley alignment
- Check belt tension
- Make sure all belts are of equal
length |
| Output is fluctuating |
- Change in voltage
- Change in screw speed
- Slipping of material in barrel |
- Check voltage rise or drop
- Check belt tension
- Take out screw & clean Set proper temperature |
| Output is dropping |
- Over-heating of grooved sleeve
- Screw is worn-out |
- Increase water flow. Make sure
that outflow temp. of water is
not above 40 deg C.
- Make sure water flow path is
cleaned with descaling
compound during last 6 months
- Measure OD of screw & ID of
barrel at diff. points. If any
doubt exists, call WML service
engineer for guidance |
| Over-heating motor |
- Insufficient cooling |
- Check blower working
- Check direction of blower
- Clean screen at blower inlet
- Make sure blower sucks fresh
cool air |
|
| |
| top |
| Trouble Shooting - Die |
| Problem |
Cause |
Remedy |
| Melt fracture |
- Die gap too narrow
- Melt temperature too low |
- Increase die gap
- Increase melt temperature
- Heat die lips |
| Port lines on film |
- Melt temperature too low
- Die too cold or too hot |
- Increase melt temperature
- Adjust die temp |
| Die lines on film |
- Dirt in die
- Die lip damage
- Inadequate purging
- Polymer property |
- Clean die lip & also mandrel
- Repair if possible or replace
- Increase purging
- Use processing aids or blend
other polymers |
| Gauge variation (transverse) |
- Non uniform die gap |
- Adjust die gap (use pin gauge)
- Center air ring
- Clean air ring
- Protect bubble from outside air
breeze |
| Winding not in straight line |
- Unstable bubble |
- Center die with center of nip fix
roller with plumb
- Protect bubble from outside air
breeze |
|
| |
| top |
| Trouble Shooting - Take off |
| Problem |
Cause |
Remedy |
| Vibration on tower |
- Improper leveling and support |
- Level properly Fix with foundation |
| Film is shifting on rollers |
- Improper leveling & improper parallelism of
rollers
- Die is not in center of nip |
- Level them and make parallel
- Maintain in center |
| Creases of film |
- Film is over cooled at first nip
- Dirt on rollers tension
- Over or under
- Improper folding & collapsing of bubble |
- Reduce cooling
- Clean all rollers
- Adjust film tension
- Set slats properly |
| Poor open ability of film tube |
- Insufficient cooling of film at first nip
- Nip air pressure too high |
- Increase cooling/reduce output
- Set pressure at 2 to 3 kg/sq.cm |
|
| |
| Pipe Extrusion Lines - Defects & Suggested Remedies |
top |
|
|
| Defects |
Possible Remedies |
Improper wall thickness |
a) Adjust annular gap in the distribution assly.
b) Align take off equipment
c) Adjust rpm of machine and take off equipment
d) Avoid surging of melt in the extruder by balancing temp. profile and rpm of the
screw.
e) Check heaters on the die |
| Inside rough surface |
a) Adjust temp. profile so as to melt polymer completely
b) Avoid melt fracture by increasing die temperatures, lowering shear by reducing
screw rpm
c) Avoid moisture by pre-drying
d) Avoid excessive frictional heat built-up on screw by cooling the screw |
| Outside rough surface |
a) Increase temp. on barrel and die
b) Cool the extrudate near die exit so as to avoid excessive swelling of Pipe before
passing through sizer
c) Avoid melt fracture by increasing die temperature. |
| Lack of gloss on outside |
a) Increase die temperature. surface. |
| Lack of gloss on inside surface |
a) Adjust temp. profile on barrel and die so as to melt the polymer completely |
| Porosity |
a) Avoid moisture by pre-drying
b) Avoid moisture and air entrapment by use of vented extruder or vacuum system
c) Lower temp . of the rear zone so as to melt the polymer only near the head of the
extruder |
| Surface defects |
a) Avoid moisture and air entrapment |
| Indented pock marks |
a) Avoid forced water spraying on the surface of PVC pipe during sizing |
| Discolored material |
a) Lower temp. of barrel and die
b) Avoid running at very high or at very low rpm. High rpm increases shear rate while
low rpm increases residence time of melt in the extruder
c) For larger pipes blow air through spider. |
| Lumpy surface |
a) Extrudate is cold, check barrel temp. and adjust them so as to melt the polymer
completely
b) Increase rpm & temp. so as to give more shear to compound |
| Oval pipe |
a) Cooling arrangement is not adequate, increase the effectiveness of cooling and
sizing
b) Reduce distance between Die exit and sizer
c) Check alignment of the sizer |
| Brittle pipes |
a) If failure is on weld line, avoid weld line by increasing the temperatures,
and adjust rpm of screw (avoiding faster and cold extrusion.)
b) Avoid excessive draw down of the pipe
c) Avoid using excessive regrind material |
| Circumferential waviness |
a) Avoid surging of melt by and ridge slowering rear zone temp. and adjusting rpm
b) Avoid uneven take off speed |
|
| |
| Blow Moulding Machines - Defects & Suggested Remedies |
top |
|
|
| General Faults |
| Problem |
Cause |
Remedy |
| Machine completely dead |
Electrical supply fault |
Check elec. mains supply to starter. SFU fuses etc |
| Pump motor will not run upto speed |
- Faulty motor supply voltage too low. Or single
phasing or loose connections
- Pumps not unloaded |
- Check supply leads to motor for
excess current drawn or low
voltage. Attend connections
- Observe the pressure gauges |
| Pump motor runs but trips out on load |
- Overloads set too low
- Hydraulic circuit pressure too high
- Low voltage. Or single phasing. |
- Check setting of overloads
- Check circuit pressures
- Check the voltage on load and
all phase |
| Barrel over heating in one or more zones |
- Thermocouple incorrectly placed
- Thermocouple circuit broken
- Temp. controller [Fuji / Other]
- Control instrument not cutting out.
Or incorrectly set or incorrectly tuned. |
- Check thermocouple placements
- Repair Thermocouple
- Replace suspect instrument
- Adjust its parameter settings
Retune as per procedure or
otherwise replace |
| NOTE: Overheating of one or more zones may occur if the material has a high viscosity and the screw speed is too high. |
| Temperature indicators erratic |
- Thermocouple insecurely located on barrel
- Type of thermocouple wrong
- Loose connection in thermocouple circuit |
- Tighten thermocouples
- Fit correct type of
Thermocouple
- Check all circuit connection
between thermocouple and
instrument |
| Heater, MCBs trips |
Short or earth in heater circuit |
Trace through circuit concerned |
| Pumps noisy in operation |
- Dirty intake filters
- Dirty or contaminated hydraulic oil
- Insufficient hydraulic oil
- Air being drawn into pumps
- Faulty pumps |
- Remove, clean and replace
filters
- Check and change oil
- Fill oil tank to correct level
- Check suction pipe joints for air
leaks
- Check whether pumps are noisy
when off loaded and if so, strip
and examine |
| Oil overheating |
- Insufficient water supply to cooler
- Contaminated oil
- Pumps continuously loaded due to faulty valve
operation |
- Check water supply
- Change oil
- Place gauges in pumps circuits
and check loading |
|
| |
| top |
| Running Faults (Hand Cycle) |
| Problem |
Cause |
Remedy |
| No machine operation |
- Safe gate not fully closed
- Some MCB tripped in panel |
- Close gate fully. Check limit
switch LS1. Check safety gate
valve
- Check MCB and circuits |
| Platens fail to close when selected |
- Hydraulic pressure not available
- Mould closing four way valves not moving
correctly
- Limit switch LS8 malfunc- tion or released
- Incorrect setting of limit switches or
its dog/cam |
- Check circuit pressure and
delivery through Pump
- Check the components of the
valves [spool,end cap]
- Check LS8 operation.
- Set the cam/limit swtich
properly |
| Platen close but no clamping |
- Decompression valve 18 remain open
- LS4 malfunctioning
- Pilot operated check valve malfunctioning
- System pressure less than required |
- Check 18 with respect to spool
operation, spring, push pin etc
- Check limit switch LS4
- Check components of pilot
operated check valve 20
- Check system pressure
- Direction valve [V7] internal
leakage under high pressure
working |
| Slow down motion not working during closing |
- Limit switch LS3 malfunctioning.
Regenerative circuit not getting cut off
- Lack of pressure |
- Check LS3 limit switch
operation.
- Check operation of valve 22
- Check the pressure on
increase/decrease accordingly |
| Platens fail to open |
- Four way valves not moving correctly
- Lack of circuit pressure
-
Pilot operated check valve malfunctioning
- Limit switch LS8 malfunc- tioning or not
released
- Mould might be jamming |
- Check the directional valves
with respect to spool operation
spring tension and end cap
grooves
- Check circuit pressure
- Check the pilot operated check
valve 20 operation
- Check Limit switch LS8. Adjust
Limit switch cam, so that when
core is out LS8 is released
- Disconnect the mould from the
mould plate and check the
mould opening |
| Core pulling cylinder not moving. |
- 4 way direction control valve not moving
correctly
- Lack of circuit pressure |
- Check the components of the
direction control valve 13 with
respect to spool operation,
spring, end cap. Check circuit
pressure.
- Check Relief valve |
| Material push out not taking place |
- 4 way valve not moving correctly
- Limit switch LS1 malfunc- tioning or
released
- Lack of system pressure
- Throttle valve setting incorrect |
- Check the components of the
direction control valve 13 with
respect to spool operation,
spring, end cap. Check circuit
pressure.
- Check LS1 operation. Adjust
limit switch operation
- Check system pressure
- Adjust setting of throttle valves |
| Blow pin & Stretch pin not moving in/out |
- Solenoid valve V22 not working
- Lack of pressure
- Speed control valve setting incorrect |
- Check valve V22 for solenoid
coils, springs, piping etc.
- Check air pressure and
regulator setting
- Adjust settings of speed control
valve |
| No blow air supply |
- Solenoid valve V20 not working
- Speed control valve setting incorrect |
- Check valve V20 for solenoid
coils, springs, piping etc.
- Adjust settings of speed control
valve |
| Stretching together/apart not taking place |
- Solenoid valve V21 not working
- Speed control valve setting incorrect
- Limit switch LS8/LS9 malfunctioning or
not actuated |
- Check valve V20 for solenoid
coils, springs, piping etc.
- Adjust settings of speed control
valve
- Check Limit switch LS8/LS9.
Adjust Limit switch cam such
that they are operated after full
stroke. |
| Safety gate open/close not taking place |
- Solenoid V24 not working
- Speed control valve setting incorrect |
- Check valve V24 for solenoid
coils, springs, piping etc.
- Adjust setting of speed control
valve |
|
| |
| top |
| Semi or Fully Automatic Cycle |
| Problem |
Cause |
Remedy |
| Material push out not taking place |
- Recycle timer faulty
- Limit switch LS13 malfunction or not
operated
- Problem in parison controller setting and
EOE and EOF signals. |
- Check recycling timer T6
- Check limit switch LS13. Adjust
limit switch position so that it is
operated after push out
cylinder completes reverse
required stroke.
- Check settings of Moog |
| Platens fails to close |
- Closing delay timer faulty
- Limit switch LSB malfunc- tion or not
operated |
- Check closing delay timer T1
- Check Limit switch LSB. Adjust
limit switch cam correctly |
| Parison programme not working |
- Programme timers for lower section and
middle section faulty
- Incorrect profile in Moog / Yuken controller |
- Check operations of T7 and T8
Timers
- Set profile properly in controller |
| Clamping not taking place |
- LS4 malfunction |
- Check LS4 |
| Blow air does not cutout |
- Blow air and exhaust air timers faulty |
- Check operations of T4 and T5
timers. Check valve V20
operations. |
|
| |
| top |
|
|
|