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| Problem |
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Possible Cause |
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Possible Solution |
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| Orange Peel |
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Melt temperature too low |
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Increase barrel/die/screw temperature |
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Check heater bands for proper functioning | ||
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Lubricant level too low / wrong lubricant for the temperature range |
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Check and start with high-melting external | |
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| Dull finish |
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Melt temperature too low |
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Increase barrel/die/screw temperature Increase speed |
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| Poor fusion |
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Melt temperature too low |
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Increase barrel/die/screw temperature |
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Powder/Granules too cold (stored outside?!) | ||
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| Gloss streaks |
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Exessive panel thickness (dragging on calibrators) |
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Check calibrator |
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Incorrect tank height |
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Align tank | |
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| Dull streaks |
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Excessive plate out in die or first calibrator |
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Check your compound (see "Plate out") |
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Foreign matter in calibrator |
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Check and clean calibrator | |
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| Scratchy Panel |
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Excessive plate out in die or first calibrator |
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Check your compound (see "Plate out") |
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Foreign matter in calibrator or die |
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Check and clean | |
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Pull die for polish / run purge through the die (only purge without big chunks of filler) | ||
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| Excessive gloss |
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Melt temperature too high |
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Decrease barrel/die temperature |
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| Gaseous Finish |
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Overfusion at vent |
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lower temperature profile |
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Vent not working properly |
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Check whether water temperature of the vacuum pump is not too high (should be below 17 C) | |
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Melt temperature too high |
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Decrease barrel/die temperature | |
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Flow restriction |
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Check size of orifice | |
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Change the filter | ||
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Check for burn | ||
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| Chattering |
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Sticking somewhere in downstream |
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Check for excessive vacuum or water |
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Check punch speed | ||
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Check embosser rollers for plate out, sticking to rolls | ||
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Check calibrators for plate out | ||
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Check whether panel is wet when going into puller | ||
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Check for excessive heat in the panel | ||
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Puller clamp force too low |
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Change gear ratio or puller | |
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| Bends |
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Misalignment |
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Raise or lower position of tank |
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Check product flow through calibrators | ||
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Excessive or insufficient cooling (air or water) |
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Increase/Decrease cooling | |
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| Bow |
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Uneven gauge |
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Adjust die accordingly to balance panel, check for excessive clip or butt flow |
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Double check alignment of all equipment (preformer must be squared to calibrators) | ||
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Move bow adjustment block accordingly | ||
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Ensure embosser is applying level pressure on each side and is squared to die. Check hydraulic pressure or air pressure | ||
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Ensure all calibrator blocks are squared to each other | ||
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Uneven cooling to calibrators |
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Check water flow to calibrator blocks | |
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Inconstinent vacuum |
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Check for blocked line, poor water supply to liquid ring pump, full filter canister | |
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Calibrators are blocked |
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Ensure calibrators are free of debris | |
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Uneven water temperature in the tank |
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Check for even water temperature on each side of tank | |
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| Twist |
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Misalignment |
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Level tank |
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Low water level | ||
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Embosser squareness | ||
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Tank and calibrator squareness | ||
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| Oilcanning |
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Panel too thin |
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Open bottom adjustment bolts on die, if necessary (or top bolts) |
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Check amperage. If running below specification, increase | ||
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Slow down haul off and embosser | ||
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Decrease extruder RPM (should be last resort) | ||
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Ensure panel is installed properly on oil can board | ||
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Reset die (final option) | ||
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