Reliance Industries Limited

TROUBLE SHOOTING GUIDE

PREFORM MAKING IN TWO STAGE TECHNOLOGY

# PROBLEM CAUSE REASON ACTION SIDE EFFECTS

1 Material A. Tip / manifold temperature A --- Increase temperatures Poor gate quality, Shrinking, Hot pre-
temperature too too low B --- Decrease hold pressure / forms and hence bending, short shots.
low B. Hold pressure/time too high time
C. Mould cooling time too high C ---- Decrease mould cooling
D. Decompression time too low time
E. Injection speed too high D --- Increase decompression
time
E --- Decrease injection speed

2 A. Tip / manifold temperature A --- Increase temperatures Poor gate quality, Shrinking, Hot pre-
too low B --- Decrease hold pressure / forms and hence bending, short shots.
B. Hold pressure/time too high time
C. Mould cooling time too high C --- Decrease mould cooling
time
3 Gate crystallinity Material A. Tip temperature too low A Increase tip temperatures Poor gate quality
temperature too B. Hold pressure/time too high B Decrease hold pressure/time
low C. Mould cooling time too high C Decrease mould cooling time
D. Decompression time too low D Increase decompression time
4 A. Tip / manifold temperature A Decrease temperatures A,B,C --- Poor gate quality
too high D --- Poor gate quality , shrinking
B. Decompression time too low B Increase decompression hot pre-forms & bending
C. Hold pressure too high time
D. Mould cooling time too low C Decrease hold pressure
D Increase mould cooling time

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# PROBLEM CAUSE REASON ACTION SIDE EFFECTS

5 A. Incorrect shot capacity A. Increase shot capacity A -- Poor gate quality

B. Injection speed/pressure too B. Increase injection B,D - Poor gate quality, sinking, hot
low speed/pressure preforms and hence bending
C. Hold pressure/time too low C. Increase hold pressure/time C --- Poor gate quality
D. Manifold temperature too low D. Increase manifold
temperature

6 Air or gas inside A. Material contains moisture not A Check drier operation
barrel entrapped in properly dired. B Decrease decompression time
the produce. B. Decompression time too high C Decrease temperature
(hot material being pulled D Clean mould venting
from the gate area)
C. Tip/manifold temperature too
high
D. Poor mould venting

7 Un-melts Improper shear / A. Poor drier operation A. Check drier operation C --- Poor gate quality, shrinking, hot
melting of material B. Poor PET melt mixing B. Check screw back pressure, preforms & bending
increase if required

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# PROBLEM CAUSE REASON ACTION SIDE EFFECTS

8 A Hold pressure/time too low A. Increase hold pressure/time A -- poor gate quality
B Poor gate pad/core cooling B. Check mould cooling/core
temperature

9 A. Injection speed too high C. Decrease injection speed A -- Poor gate quality, short shots
B. Hold pressure/time too low D. Increase hold pressure/time B,C -- Poor gate quality, sinking, hot
C. Decompression time too high E. Decrease decompression time preforms and bending
D. Mould cooling time too low F. Increase mould cooling time D --- Poor gate quality
E. Poor mould cooling G. Check mould/core cooling

10 Hot material A. Manifold tip temperature too A. Decrease manifold tip temp. Poor gate quality, sinking, bending,
spraying into the high B. Decrease hold pressure/time short shots
mould and B. Hold pressure/time too high C. Vary decompression time
subsequently C. Improper decompression time D. Decrease injection speed
material flown D. Injection speed too high (Minimise resident time of resin)

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# PROBLEM CAUSE REASON ACTION SIDE EFFECTS

11 A. Poor drier operation A. Check drier operation C --- Poor gate quality
B. Poor mould cooling B. Check mould cooling/core
C. Inability to cool preform cooling
quickly (post crystallinity) C. Define crystallinity type
D. Post crystallinity decrease
melt temperature

12 Thermal imbalance A Poor mould cooling A. Check mould cooling B,C -- Poor gate quality
or excessive B Hold pressure/time too low B. Increase hold pressure
residual stress. C Mould cooling time too low C. Increase mould cooling time

13 Scratches A. Damage to the mould A. Check mould condition

B. Damage to the robot tube A. Check robot condition
( if applicable ) B. Check robot alignment
A. Poor robot alignment C. Check discharge area for
B. Damage occurring from sharp obstructions
edges with in discharge area

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# PROBLEM CAUSE REASON ACTION SIDE EFFECTS

14 Wall thickness A Poor mould condition A. Check mould condition

variation. B Poor machine condition B. Check machine condition
(machine level, tie bar
alignment )

15 Water marks C. Condensation on the mould A. Raise mould cooling water A -- Poor gate quality, shrinking, hot
(groove ring) surface temperature preforms and hence bending
D. Water leak B. Check for water leak

16 Narrow lines poor re-weld A Blocked mould venting A Clean mould venting
( Hair-line )
17 Thread damage A Damaged mould splits A Check mould condition
B Injecting degraded material B Check the causes of
degradation

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# PROBLEM CAUSE REASON ACTION SIDE EFFECTS

18 Split line flash E. Injection pressure/speed too A. Decrease injection Note:- these adjustments may cause:-
high pressure/speed A,B poor gate quality
F. Hold pressure too high B. Decrease hold pressure sinking
G. Clamp tonnage too low C. C increase clamp tonnage hot preforms
H. Mould dirty (obstruction D. D clean mould (remove bending
present) obstruction) C increase in tool wear
I. Poor mould condition E. E check mould condition F poor gate quality
J. Material temperature too high F. F decrease material
temperature
19 Split gate A. Tip temperature too high A -- Decrease temperature
( Holes in the gate ) B. Hold pressure/time too low B -- Increase hold Pressure / Poor gate quality
C. Mould cooling time too low time
D. Misalignment of HR nozzle C -- Increase mould cooling
and cavity gate time

20 Strings A. Tip/Manifold temperature too A. Decrease temperatures Poor gate quality, sinking, preforms
high B. Check valve bending.
B. Poor valve gate operation if operation/timing
applicable C. Increase decompression time
C. Decompression time too high D. Decrease holding pressure
D. Holding pressure too high E. Increase mould cooling time
E. Mould cooling time too low

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