Setting Final Cushion...

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During some classroom training the other week, a student asked me the following question...

John
What value should you set the cushion at?

My Response
A good rule of thumb is 10% of the initial shot size. For example, if the overall shot size is 100mm, then the cushion should be about 10mm. This avoids pressure losses from too much material in front of the screw, yet provides enough room in front of the screw for normal variability.

Related Posts:

-Andy

Teaching Tolerances...

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I was asked this question during a recent on-site visit...

QA Manager
What is an easy was to explain tolerances to new employees?

My Response
Focus on the fact that tolerances are commonly expressed in a way which can be easily broken up into simple math equations.

Dimension: 1.00 ± 0.01

Upper Limit: 1.00 + 0.01 = 1.01
Lower Limit: 1.00 - 0.01 = 0.99

Additional Thoughts
When possible break ideas into their simplest form such as an equation or concept. Keep in mind the issue is very often math not tolerances. In this case, focus the attention on basic math and calculator usage first before moving on to part tolerances.

-Andy 
As a trainer, this is one of the more common questions I receive...

Manager
How much training a week should I give my employees?

My Response
We typically recommend between 1 and 2 hours a week. It is always much better to provide your employees a slow, steady, & consistent stream of information over an extended period of time. One hour a week for 40 weeks can be much more effective than one 40-hour week in altering the behavior and improving the skills of your employees.

Additional Thoughts
There is always a place for multi-day training sessions, but they are most effective in teaching a specific skill rather than relaying general knowledge.

-Andy
I was asked this question by a molder who was having trouble balancing a hot runner system...

Bob
We have this new mold which is running 16 cavities in PBT. Usually we can balance the mold using the drop temperatures, but that does not seem to work on this mold. Any thoughts?

My Response
Essentially, semi-crystalline polymers with a high degree of crystallinity such as PBT and nylon are not highly affected by temperature. In such a case, you will have to adjust the gates or the hot runner system itself to balance the shear of the mold.

Additional Thoughts
Cold runner systems are the best for these materials. I know many molders who use a press-side low-RPM grinder to effectively grind up the material and re-introduce PBT back into the process.

-Andy
I was in a discussion recently with a GM and he had this problem...

Manager
My technicians are not willing to take the time to document their changes. They claim it takes too long?

My Response
The issue here is not time, but education. If your employees are not taking time to document, it is likely that they do not fully understand the importance and benefits of good documentation. If they understand the ways it can simplify their job and improve their effectiveness, they would be more interested in compliance. Unfortunately, this is not a simple fix... it require the employees to not only understand the benefits, but also know what to do with the information they are given.

-Andy
I was recently at a company who purchased some training a while back from a different provider under the guise of having a 'resource' for all their employees to use...

My Comments
Training is good, but it is critical that you tie the training to each job function through the use of a training plan. Without a structured training plan focused on job title you will not be able to make a change to your workforce. In general, your employees will not go and train unless there is a structure to show them what they are supposed to do when they train.

-Andy
I was recently at a molding facility during a training implementation was in need of some training due to a lack of fundamentals among the employees...

Company President
What is the best way to process, and why don't we just have everybody process that way starting tomorrow?

My Response
I told her that there were ways that there are many ways to process, and there are a few methods which are far superior to others. Unfortunately without a strong background in processing knowledge your employees will have no reason to understand why this method is better.

Essentially, people who have been making a living molding a particular way do not just change their entire approach to processing because someone tells them it is better. You need to educate them on plastics, machinery, materials, processing, and tooling to ensure that they know why it is a better way.

Additional Thoughts
There are always steps which your employees can take to improve the process. As they see the success they will continue to employ more cost saving, and process improving techniques. This is one of the reasons why it can be easier to teach someone who has never processed that to teach someone who has processed for years.

-Andy
I received this excellent question last week...

Saeed
In one of your videos, you state that higher melt temperatures will increase part weight. To my understanding, a less viscous material is pumped in the cavity with a relative ease thus increasing the part weight. Could you please guide me as to whether or not a decrease in density negates the above?

My Response
You are correct that you will be injecting a less dense material in this scenario… but the higher melt temperature causes many things to occur, but the 2 major factors increasing the part weight and density are listed below:

1) There will be a higher amount of material flow and in-mold pressure during packing resulting in more material entering the mold during both 1st and 2nd stage.

2) A higher melt temperature promotes an increase in part shrinkage resulting in a higher overall part density.

Additional Thoughts
This question points out how complex the interactions between the mold, machine, material, and  injection molding process can become.

-Andy
I received an email from a blog reader about another benefit to increasing injection velocity...

Harry
Another reason we use a higher injection velocity in our facility is to increase the amount of packing that is possible.

My Comments
This is correct because of two reasons. First, the gate begins to freeze the moment the material enters the gate. The shorter time required to fill the mold allows more time for packing. The second reason is because the pressure loss within the mold cavity is decreased, allowing more packing pressure to reach the extremities of the mold during packing.

-Andy
I was at a company recently and the engineer was confused about how to reduce energy consumption during injection...

Engineer
I know higher injection velocities reduce variability, but a lower injection speed uses less pressure and thus reduces the overall energy consumption... right?

My Response
Actually, a higher velocity reduces overall energy consumption during injection even though the injection pressure is increased. Increasing the injection velocity decreases the material viscosity through shear thinning. As a result, the overall energy required to push the final volume of polymer necessary to fill the mold is decreased.

In an actual example performed by one of our trainers, the data from a molding process which was filled at two different times is shown below:

Slow Fill:
Fill time = 3.15sec
Transfer Pressure = 10,460psi

Fast Fill:
Fill time = 0.83sec
Transfer Pressure = 11,910psi

Although the faster fill time has a higher pressure at transfer, the molding machine applied the injection pressure for 27% of the time necessary to fill the mold at the slower speed. When you multiply the fill time by the transfer pressure you get the following effective (or relative) viscosity:

Effective Viscosity = t x psi
Slow Fill = 32,950 psi-s
Fast Fill = 9,890 psi-s

Assuming the pressure profiles are similar in shape, it can be reasonably proposed that the faster fill consumed approximately 30% of the energy necessary to fill the mold at the slower speed.

Additional Thoughts
The additional benefit to filling faster is that the polymer fills the mold and begins to cool faster. In this case the overall cycle time could drop as much as 2 seconds due to the higher injection viscosity.

-Andy






I was discussing the measurement of the polymer temperature with an engineer and he explained a problem he is encountering...

Joe
Each of our technicians are getting different results when we they measure the melt temperature... especially when we measure high temperature materials like polysulfone.

note: I asked one of their techs to demonstrate how they measure the melt temperature and he purged the material, inserted a thin-style probe, and recorded the highest temperature reading. I then asked the technician to repeat the process, but when he inserted the probe I asked him to move is around slowly. The result was a temperature which was 15 degrees higher than his previous measurement.

My Response
When measuring a melt temperature, it is important to move the probe around a little. When the probe is inserted into the melt, a skin of cooled polymer forms around the probe. To ensure you are getting the temperature of the melt, you need to use the surrounding material to soften this skin and get some of the interior polymer melt in contact with the probe.

-Andy
As a follow-up to a previous post, I was asked to expand in the second rule of processing...

The 5 Basic Rules of Processing (from before):
Rule 1 - Make one process change at a time
Rule 2 - Make significant changes
Rule 3 - If a change does not help, change it back
Rule 4 - Document the process
Rule 5 - Document all changes to the process

Rule #2
The idea behind this is that you always want to know you are making a change which is important. Too often people will tweak different parameters without any direct knowledge as to the effectiveness of the change.

When you make a change, you want to ensure it is large enough to make a difference. Remember any change to the process can be reversed either completely or partially.

Additional Thoughts
I have seen many molders who make small adjustments with the belief it will improve the situation. A symptom of this behavior is a control panel with a large amount of numbers which do not end in either 5 or 0. For instance, if the injection profile looks like the following... V1=11.1 mm/s, V2=30.3 mm/s, V3=23.4 mm/s, V4=28.4 mm/s, and V5=12.7 mm/s. It is very unlikely that each of those velocities have been optimized and each speed in the profile can be properly justified. This type of profile is almost always the result of someone tinkering with the process until a good part came out of the machine.

-Andy 

PPE for Purging...

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I have seen many variations on this principle...

Steve
Here we only require our employees to wear safety glasses when purging... is that fine?

My Response
Purged plastics can cause some of the most debilitating injuries because they have a tendency to not only burn, but stick to or inject under your skin as well. When purging goes well, the conditions are relatively safe, but it is not uncommon for a explosive discharge to occur as a result of nozzle blockage or gas buildup.

If you are not wearing a face shield, heat resistant gloves, and long sleeves while purging; you are opening yourself up for serious injury.

Additional Thoughts
In all our training courses, we stress the same PPE recommended by most machine manufacturers which includes the wearing of the following when purging:
  • Face Shield
  • Heat Resistant Gloves
  • Long Sleeves (Cotton)

-Andy


I was asked this question yesterday via email...

Manager
What should I be looking for when my guys process?

My Response
There the 5 things that I always look for:
Rule 1 - Make one process change at a time
Rule 2 - Make significant changes
Rule 3 - If a change does not help, change it back
Rule 4 - Document the process
Rule 5 - Document all changes to the process

These rules apply to injection molding, extrusion, and blow molding alike.

Additional Thoughts
This list seems pretty simple, but I have found that most molders skip at least one or two of these steps whenever they process. 

-Andy
This question came up as a follow-up question to a recent blog about robotics and automation...

GH
Would a part diverter be classified as robotics or automation?

My Response
The general rule I always follow is: If it is programmable, it is a robot... if not, it is automation.

Therefore, if the diverter acted as a sort device where acceptable parts were sent one way, while defective or questionable parts were sent another way based on process or inspection data, then it could be considered robotics. If a sensor was just placed on a conveyor to sense different parts and automatically divert of orient parts in a specific manner, then it might be considered automation.

Additional Thougths
Under such a definition, a simple device such as a sprue picker which needs to be mechanically adjusted to alter the speed, length, and movement of the arm might be considered automation.

-Andy
I was asked the following question by a technician the other day...

Bob
What is the difference between automation and robotics?

My Response
Automation generally refers to any component which performs a basic repetitive task; such as conveying or sorting parts. In general, robotics are more complex devices which are programmed to perform advanced repetitive tasks; such as the removal, stacking, packaging, or assembly of parts.

Additional Thoughts
In the plastics industry, the terms automation and robotics both refer to mechanical pieces of equipment and are often used interchangeably.

-Andy
I recently received a request from a social-networking site to discuss the complications companies encounter in locating well-rounded employees. In this post, I want to address the underlying problem, which is the lack of comprehensive training for production employees.

Initial Concerns
The most effective training systems provide the employees with (1) the information and skills to work and make effective decisions in their job and (2) prepare them for new challenges and advancement opportunities.

Regarding the second goal, it is critical that you prepare your employees for professional growth and advancement. Once you train your employees enough to become competent and capable at their job, additional training should then be made available.  Although some employees are content in their job, do not assume that your workforce is content to remain in the same job doing the same thing until the end of time. The best scenario is to have a cue of overqualified employees waiting for advancement. If a job is not currently available, many employers will offer them the opportunity to fill in (typically with the corresponding pay differential) when a higher job function calls in sick, goes on vacation, or takes an extended leave. 

Additional Thoughts
Change is can be either slow and gradual, or quick and unexpected. Comprehensive employee training combined with effective advancement training will help you prepare your business for change, new markets, growth, and even downsizing.

-Andy 

I recently received a request from a social-networking site to discuss the complications companies encounter in locating well-rounded employees. In this post, I want to address the underlying problem, which is the lack of comprehensive training for production employees.

My Thoughts
The most effective training systems provide the employees with (1) the information and skills to work and make effective decisions in their job and (2) prepare them for new challenges and advancement opportunities.

Regarding the first goal, the employees needs to know more that what is 'necessary' to do their job. For example, teaching the employee the basic steps in a die change is not effective long-term training. An effective die setter should have a fundamental understanding of many aspects including general safety, job-specific safety, tooling, machinery, processing, and the basic economics involved. Without this strong background, they lack the full knowledge and appreciation to bring true value to the company. Such a trained employee may be very helpful in identifying more efficient procedures, evaluating newer technologies, developing new solutions, and troubleshooting complications when they arise.

Additional Thoughts
It has been said that your workforce is your most valuable asset, yet this is only true when your employees are treated as more than simple robots. Robots who perform specific functions can be easily replaced... competent and capable employees, on the other hand, will help your company improve, grow, expand, and take on new challenges.

-Andy

I received this follow-up question regarding the processing of PVC...

MT
I would like to know if it is safe to mold parts in PVC and acetal in presses that are next to each other?

My Response
It should be safe to process, but it is critical that you vent the fumes from both machines to prevent corrosion of your equipment. You should also take the time to educate your employees on the dangers of combining these materials.

Additional Thoughts
It is critical that you create a system to prevent any chance of cross contamination. This may be as simple as a color-coded system so that the color of the container matches a panel next to the machine. Personally, I would create a fool-proof system where the container for VC is not compatible with the acetal material delivery system and vice-versa.

-Andy
I was recently working with a company who had an interesting tale regarding the sale of one of their larger, older, hydraulic molding machines with a very large cylinder clamping unit and corresponding hydraulic reservoir...

Engineer
When we were trying to sell one of these pieces of junk, my recommendation was to drain the oil and sell it for scrap metal or parts. Purchasing then told me they had agreed to sell the machine for a few thousand dollars, hydraulic fluid and all.

note: After a quick calculation, he explained to them that they had just lost money since the value of the hydraulic fluid currently in the machine is worth almost twice the amount they are getting for the machine.

My Thoughts
Although complicated to quantify, most of these older machines are a real drag on the company and their resources. In this case, oil in the machine was more valuable than the machine itself. The machine was being sold because it was slow, unreliable, and wasting resources. It will provide the same drain of resources on the next molder who tries to operate it. Especially when your incorporate the expense of relocating, configuring, and hooking up the machine. In this case, I believe the engineer is right... the fluid should have been reclaimed and  the machine should have been either scrapped or sold for parts rather than be brought back into service.

-Andy

Training as a Resource...

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Recently I was at a customer site and they had many older training materials sitting the the training room unused...

HR
We plan on keeping all these materials here as before so they can be used as a resource while people use your training.

My Response
Training materials are only useful when they are incorporated into the overall training plan. As a rule, employees will not open a book or take training unless they are directed to do so. They are typically too busy to just sit down and read books or take training unless it is requested of them. Believe it or not, if the training is captivating, relevant, and self paced, employees will be very interested in taking training when asked to do so.

Additional Thoughts
It is better to fill your training room with instructional aids such as part prints, sample defects, and work instructions.

-Andy

Guarding Older Machines...

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I was recently at a company with many older (30+ years) home-made molding machines. Although the machines have a large number of moving components and cams, the molder did a great job of adding full guarding around the entire machine. This guarding was not particularly complex, or expensive, but it is a great way to ensure your employees stay safe.

Additional Comments
Make sure all your older machines are well guarded to protect your employees and your company from liability. Even though your machine was legal the day it was purchased does not mean it is not a liability today.

-Andy
I received this question last week...

JIM

Do you have any recommendations on how to capture actual steel temps other than installing thermocouples?  We currently use a surface probe which is time consuming and often difficult to capture the true operating temperature.

My Response
Thermal imaging cameras tend to be inaccurate for mold steel due to the reflectance of the steel. The best bet would be to measure the water temperature going in and out of the tool… since the temperatures along with the difference can give you a good idea of the consistency and adequacy of the cooling. This can be done by surface measurement of the water fittings or in-line sensors.

Additional Thoughts
R is a great technology, but it is most effective at non-reflective textured surfaces. Many times people think they are measuring the temperature of a part or tool, but they are really measuring a nearby wall due to a reflective surface.

-Andy


This question just came in from a medical molder...

 

KH

We are extruding flexible PVC and started injection molding Acetal in the same facility. On the PVC die heads and downstream auxiliary equipment there is a white layer of powdery build up on the metal. What is the cause of this?

 

My Response

The white layer of buildup on the machines is most likely a result of a chemical reaction between the formaldehyde gas and hydrochloric gas byproducts of your two processes. The hydrocholoric gases that result from PVC processing will also attacking any non-treated steal. When processing these two materials in the same facility proper safety measures must be put in place to separate the two materials. To help prevent the white buildup a larger ventilation system with separate exhausts for each process could be put in place.

 

Additional Thoughts

It is dangerous to process PVC and Acetal in the same facility and extreme care should be taken to separate the two materials at all times. A high concentration of formaldehyde and hydrochloric gas may be enough to cause an explosion in the facility. If the PVC or Acetal were accidentally mislabeled, mishandled, and processed together, it would cause an explosion!  

 

-Andy

I got this question via email yesterday...

Technician
I know we should wear safety glasses, but how can I better justify their use?

My Response
I recommend reviewing some of my previous posts on this topic:


-Andy






Spiral Flow Test...

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I received a follow-up question regarding a post earlier this year, The Uses of MFI...

KJ
You mentioned the spiral flow, what is this test?

My Response
The spiral flow test uses a mold with a long spiral flow channel emanating from the center. Notches are etched along the flow path to help identify the length the polymer has flowed within the mold. The mold can be filled using either a constant velocity (constant shear) or constant pressure (constant strain) to determine the polymer behavior.

The behavior of the polymer can be evaluated based on process output data such as flow length, part weight, and pressure at transfer. When using the spiral flow test, it is best to use a mold which has a channel thickness similar to the parts actually being molded.


Additional Thoughts
You might want to consider purchasing a small, inexpensive, molding machine to conduct spiral flow tests on every incoming batch of material.

-Andy
I have read some industry discussion groups lately and have noticed some confusion on the difference between Thermosets and Thermoplastics, so I will use this post to help clarify these points...

Thermosets
Thermosets are polymerized during processing while thermoplastics are polymerized before being processed. During processing, the polymer chains in thermosets fuse together, or cross-link. Once these polymers cross-link, they undergo a chemical change which prevents them from being melted and reprocessed. An egg is an example of a natural polymer which thermosets. Once the egg is heated, it solidifies and cannot be melted again.

Thermoplastics
Thermoplastics are long polymer chains that are fully polymerized when shipped by the resin manufacturer. Thermoplastics can be re-ground, melted and re-processed while retaining most of their original properties. An example of a natural thermoplastic material is wax. It can be melted and formed. Once cooled, the hardened wax can be melted and formed again. Unlike thermosets, most plastics companies prefer thermoplastic materials because they can be reprocessed and recycled.

-Andy
This question came in from a molder overseas...

HM
During process optimization, which is best, keep both the packing pressure and packing time to zero OR only holding pressure?

My Response
This is based on your machine. On most machines, you can turn the pressure down to zero and the pressure will turn off. Before you make this assumption, you should verify this by turning off the time and ensure the part looks the same.

Additional Thoughts
For some related reading, please review some of the following: 

-Andy
I was on a call the other day and was asked this question...

Caller
What type of commitment should I make to training, and why?

My Response
An in-house training initiative gives you a competitive edge in today's fast-paced plastics industry. Well trained employees can better cope and adapt to changing product lines, customer requirements, and production strategies. Today’s customers are sensitive to quality, economy and efficiency. Most customers are impressed with a job delivered on time and on budget, and from a safe plant.

Additional Thoughts
Imagine being able to boast that all of your production workers have gone through a comprehensive in-house training program and that your company has a system in place for continually improving the skills of its workers. Not only does his boost confidence and security among your employees, but it also tells your customers that you’re committed to raising the bar.

-Andy

Retaining Defects...

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I was recently visiting a molder who was having a specific problem...

Supervisor
We are having trouble with our employees properly identifying and naming part defects... any suggestions as to how we can improve this?

note: After a couple questions, it was determined that they do not retain defective parts as they are all discarded, reworked, or reground.

My Response
It is critical that you retain current samples of each part defect your company encounters. These defects should be placed in a visible area to ensure the employees will walk by and see them on a routine basis. This make a great training tool and will help provide a common ground when defect-related questions arise.

Additional Thoughts
Please review your defect board a few times a year to ensure the parts are up to date and still defects. I have seen many parts that are so old that factors such as dust and dimensional creep will make the intended defect invisible.

-Andy

The other week, I received a multiple part question regarding many aspects of materials, this is one part...

Nathan
Although the 1st stage injection time is the same, the virgin PC/ABS (<0.06% moisture) has a 1RMPa higher peak injection pressure than virgin PC/ABS (0.08% moisture). Is this change in pressure common?

My Response
Moisture in the polymer causes hydrolysis to occur. As the water molecule is heated, one of the hydrogen atoms breaks away and both the H+ and OH- ions look for pairs along the polymer chain. In hygroscopic polymers such as PC/ABS these ions break up the long polymer chains resulting in a lower average molecular weight. This drop in molecular weight results in a drop in overall material viscosity.

Additional Thoughts
Because water has a molecular weight of only 18, it alone acts as a plasticizer which reduces the overall viscosity of the material. This is one reason we often recommend molders of non-hygroscopic materials ensure they remove surface moisture from their materials.

-Andy
I was asked this question during an on-site visit earlier this week...

Technician
I know this machine is rated with a maximum injection pressure of 38,000psi, but I am not sure how to convert this to an intensification ratio.

note: The intensification ratio is a factor which is used to convert the hydraulic pressure being applied to the hydraulic injection cylinders into the actual pressure being applied to the polymer melt at the front of the screw.
 
My Response
If you know the maximum plastic pressure (Pp-max) along with the maximum hydraulic pressure (Ph-max) for your machine, you can estimate the intensification ratio (Ri) for your machine. /  = 

Pp-max / Ph-max = Ri

 -Andy
Many processors often experiment in training without a clear-cut goal. One year, they might send some people to a seminar, another year, they might buy some products or try making something themselves. 

Develop a Structured Approach
Although most industry training has some merit, you need to develop a structured approach. For instance, if one form of training turns out to be beneficial for a technician, then it should be evaluated as part of an overall structured training plan for all technicians, both current and future.


-Andy
I have often encounter confusion on these two terms when talking to molders...

Attribute Data
Attribute data has two different outcomes. An example of such an outcome would be a GO / NO-GO gauge which is used when testing parts. This test results in only two different outcomes, Pass or Fail.

Variable Data
Variables are those aspects measured using a scale. An example of this would be a dimension measured using calipers. This device provides a wide variety, or scale, of results based on the accuracy of the instrument and ability of the person taking the measurements.

-Andy

MW vs. MWD...

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I was discussing polymers with a technician and was asked this question:

John
I understand how molecular weight affects the process, but how does molecular weight distribution affect the process?

My Response
Polymer chain mobility is highly dependent on the length, or molecular weight, of the polymer chain. If most of the polymer chains have a similar molecular weight, or smaller distribution, then they are all more likely to soften at similar temperatures typically resulting in a more narrow temperature range at which the polymer can be processed.

Adversely, a broad molecular weight distribution often results in a wider processing window due to the mobility of some polymer chains while other chains remain highly entangled.

Additional Thoughts
Semi-crystalline polymers with a narrow molecular weight distribution can often achieve a higher degree of crystallinity than polymers with a wide distribution. 

-Andy
I have been asked about the proper use of an open-loop molding machines...

Customer
When implementing DECOUPLED MOLDINGsm, how should we best incorporate our open-loop molding machines?

My Response
Basically, open-loop molding machines are not capable of this since open-loop molding machines cannot decouple 1st stage filling from 2nd stage packing. These machines lack closed-loop, injection velocity control and inject using pressure control instead. As a result, the screw speed decreases as the screw moves forward, resulting in an inconsistent shear rate from shot to shot. On these machines, the best approach is to fill and pack the part during 1st stage.

Additional Thoughts
More posts about this topic can be found below:

Mean, Median, and Mode...

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I heard a quality technician make the following comment the other day...

Technician
Mean, Median, Mode... they are all the same.

Mean
The mean is the average of measurements within a particular sampling. This value equals the sum of all the numbers in a sampling divided by the number of values in the sample. For example: the mean of numbers 1.1, 1.1, 1.1, 1.3, 1.4 would be 1.2

Median
The median is the middle measurement within a sampling. This value is determined by lining up all the different measurements and the middle number is the median. For example: the median of numbers 1.1, 1.1, 1.1, 1.3, 1.4 would be 1.3

Mode
The mode is the most commonly occurring number within the measurements. This value is determined by adding up how many times each measurement occurs and choosing the value with the highest frequency. For example: the mode of numbers 1.1, 1.1, 1.1, 1.3, 1.4 would be 1.1

Additional Thoughts
In an ideal distribution, all three values should be the same. For example: For the numbers 1.1, 1.2, 1.2, 1.2, 1.3 the mean, median, and mode all equal 1.2.

-Andy
This question arrived this morning via email...

TA
We are processing polycarbonate and are having problems with short molding as well as silver streaks. The mold design is a hot runner system with three drops.

My Response
For the silver streaks, I suggest you ensure the material is properly dried. A dewpoint meter or moisture analyzer should be incorporated to ensure the material is dry enough for processing. It is also advisable to pull the screw and clan both the screw and barrel to ensure there is no buildup contaminating the material. It is also advisable to use a temperature probe to ensure the material temperature is at the manufacturer's recommended setting.

As for the short shots, you may need to develop a more robust process better capable of handling variation. for more on this, please consider reading the following:

-Andy
I was at an extrusion customer site last week and they were not sure whether the feed system was truly gravimetric or volumetric....

Customer
The system uses a scale to measure the material used when filling the hopper, but has a feed screw to meter the material to the feedthroat. The system can be set to a lbs/hr or RPM of the feed screw.

My Comments
Since the system can adjust the screw speed to maintain a desired lbs/hr setpoint, it can be considered gravimetric. The precision of he setpoint is not high since it has to take intermittent weight measurements as the hopper needs more material. This rate of consumption is then reevaluated each time the hopper is refilled. As a result, the system is a true closed-loop gravimetric system with a relatively long lag time.

-Andy
I was at a customer site last week and we were discussing the use of math on the production floor...

Supervisor
The operators always seem to have trouble counting up how many profiles are on each cart. All they need to do is use a calculator to multiply the number of profiles across by the number high.

note: During this discussion, I asked the supervisor where the operator would get a calculator for this purpose. He searched around and realized they would have to walk all the way across the production floor to locate one.

My Suggestion
Mount a calculator to each profile dump table so the operator can both count the profiles and use the calculator at the same time. Once I made the suggestion, he started to point out other tools they should also make readily accessible to improve the operator's job performance such as pens, job booklets, quality standards, etc.

Additional Thoughts
Keep in mind that many employees will often skip a step, or substitute something rather than go out of their away to locate something crucial to their job. It is your job to ensure your employees have the tools and skills necessary to succeed at their job.

-Andy

Feed Throat Cooling...

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I just received this question via email...

MM
Most of the plastics raw material data sheet do not contain the Feed Zone temp. How can we  keep this temp during production?

My Response
Since this cooling is used to prevent bridging most processor runs this temperature at or near the lowest setting.

The two common reasons a processors will increase this temperature is if 1) the rear heater band cannot maintain the desired setpoint, or 2) condensation is occurring inside the feedthroat.

-Andy
I was in a discussion with a manager the other day. The discussion turned to material driers and the manager said this...

Manager
We don't have any compressed air driers because we process a lot of nylon and we have to dry it centrally as well as at the hopper.

My Comments
Although compressed air driers do not dry the material as quickly as desiccant driers, they can still be implemented as a cost saving alternative in many applications. Hopper-mounted compressed air driers are a great method of keeping previously dried materials from absorbing moisture.

The simplicity, low cost, and reduced maintenance of compressed air material driers make them a great option to consider for hopper-mounted drying.

-Andy

I was asked this question from a company president the other day...

President
Our technicians do everything from changing molds and materials handling to parts testing and troubleshooting  How can we train someone to do this type of job?

My Response
It is true that it is impossible to teach someone all that all at once, but an employee can learn all this over time. The best way to approach this is to break up the instruction by responsibility. Let the person learn a specific aspect of their job sufficiently before moving on to the next function. For example, have then learn how to inspect the parts and become proficient in that role before teaching the job function. If you make each steps in the progression clear and defined, it can give the employee a sense of accomplishment as well as an understanding as to where they are in the development process.

Additional Thoughts
Many companies create interim job functions such as an apprentice or technician level 1, 2, and 3 to differentiate a trainee from a full-fledged technician.

-Andy
I was asked this follow-up question to a previous blog post...

NM
What is the first step in troubleshooting?

My Response
Personally, I believe the first step in good troubleshooting occurs before a defect is made. The first step is to 'Establish a Stable and Reliable Process'.

To further illustrate this point, I recommend reading the following article:

-Andy
A plant manager asked me this question the other day...

John
What is the key to good troubleshooting?

My Response
The most important aspect to successful troubleshooting is good documentation. This starts with the documentation of the process outputs when the mold is creating good parts. With this as a baseline, the troubleshooter can use this documentation to investigate and determine the specific change to the process. Once the change is determined, the process can typically be corrected rather quickly.

There are more articles and links in this blog entry:

-Andy 
I was asked this question the other day...

Bob
What is the difference between a hydraulic machine with a variable-drive pump motor vs. a hydraulic machine with a servo-motor-drive pump motor?

Variable Drive
A variable-drive pump motor adjusts the motor speed to compensate for the demands of the process. These systems typically consume only 70% of the energy consumed by a traditional fixed volume pump. In this system the pump still provides more hydraulic flow than is necessary to mold the actual part and the excess flow which is diverted back to the hydraulic tank. This excess fluid results in an energy loss.

Servo Drive
A servo-drive pump motor uses a precisely-controlled servo-motor to drive the hydraulic pump. Rather than maintaining a line pressure, diverting excessive flow, and adjusting servo valves, the flow from the pump is directly sent to the rotary or linear actuator performing the machine function. Since the pump is precisely controlled, the speeds of actions such as injection and screw rotation are controlled directly by the servo-motor. Pressure limits are easily controlled by limiting the torque of the motor. Since the no un-necessary flow is generated, the efficiency of such machines are about as high as a hydraulic machine can be. In many cases, these machines consume only 30% of the energy consumed by fixed drive pump motors.

-Andy

Why Train...?

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OK, I got this question the other day...

Manager
Why should I bother training my employees?

My Response
The trend in the plastics industry is the following: Companies who are prepared to handle new and more complex challenges are the ones most likely to receive the business these challenges bring... Your potential customers are not going to wait for your employees to catch up when there is a globe of processors waiting to take the business.

Additional Thoughts
If your employees thoroughly understand their job and the fundamentals of processing, they will be more prepared to handle the unique challenges they face in the future.

For more on this, feel free to read:

-Andy

I just received another screw-design related follow-up question...

JP
My supplier is pushing a screw tip with spiral channels cut into it. These are supposed to 'promote better output' and 'improve forward flow'. Is this true?

My Response
Although I have not seen any studies, I have used these myself with no problems and I know many colleagues who believe they help with screw recovery.

Additional Thoughts
Although these tips intuitively make sense, I would like to see a side-by-side study comparing conventional screw tips with spiral tips to quantify the actual benefits.

-Andy
I received this question as a follow-up question from a related blog entry...

GK
If an amorphous polymer requires approximately 8-10 diameters to melt the polymer, how much is needed for semi-crystalline polymers?

My Response
Generally speaking, amorphous polymers require a long transition zone to properly soften and melt the polymer. This provides a more consistent and homogeneous melt.

When processing semi-crystalline polymers, the polymer softens quickly once the polymer reaches it's melting temperature. For this reason the transition zone is typically 5-7 times the diameter for semi-crystalline polymers.

Additional Thoughts
Although the transition zone length is small, it is critical to ensure that a long fee zone is being used for semi-crystalline polymers. This allows the material to heat up using more energy from the heater bands to help melt the polymer with less shear. When processing these materials, it is very common to have a feed zone which is nearly half the overall length of the screw. 

-Andy

What are TPO's...?

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I was asked this question during a classroom training session...

Student
What does TPO stand for?

My Response
Although there is no true standard of nomenclature for blended polymers, TPO typically stands for a category of polymers known as Thermoplastic Polyolefins. Polyolefins are a group of polymers comprised of mainly hydrogen and carbon, mainly polyethylene and polypropylene. TPO's are typically a blend of polyolefins with other additives designed to create a polymer which has a very specific processing and performance characteristic.

In many cases the TPO blend has less semi-crystallinity, less strength, more ductility, higher toughness, more flexibility, and more shrinkage than the base polypropylene and polyethylene constituents.

-Andy