Troubleshooting Guide: Common Issues and Solutions in Screw and Barrel Performance

As a manufacturer or factory involved in the production and sales of screw and barrel products, ensuring optimal performance is crucial for the success of your clients' operations. However, even the most advanced screw and barrel systems can encounter issues that affect productivity and efficiency.

1. Issue: Poor Melting or Mixing Efficiency Solution: Evaluate screw design and material selection for compatibility with the processed materials. Consider specialized screw profiles or coatings to enhance melting and mixing capabilities.

Example: For processing high-viscosity materials like PVC, choosing a screw with a deep flight depth and a larger pitch can improve melting efficiency. Additionally, incorporating mixing elements, such as kneading blocks or distributive mixing sections, can ensure better homogeneity in the melt.

2. Issue: Inconsistent Melt Temperature Solution: Inspect the barrel for hotspots and clean or repair them as necessary. Verify temperature settings and ensure they match the specific processing requirements.

Example: Hotspots can result from residue buildup or material degradation. Regularly cleaning the barrel with purging compounds and using barrel insulation can help maintain uniform temperature distribution, reducing the risk of inconsistent melt temperatures.

3. Issue: Excessive Wear or Corrosion Solution: Regularly inspect the screw and barrel surfaces for wear and implement proper maintenance practices. Consider using wear-resistant coatings or materials to prolong the lifespan of components.

Example: When processing abrasive materials like glass-filled plastics, using screws with abrasion-resistant coatings, such as tungsten carbide, can significantly extend the screw's life and prevent excessive wear.

4. Issue: Surging or Starvation Solution: Review the screw design and feed throat geometry to optimize material flow. Adjust processing parameters to maintain a consistent and steady material supply.

Example: Surging can occur when the screw design does not provide sufficient compression, leading to inconsistent material feeding. By incorporating a barrier or mixing section, surging can be minimized, ensuring a continuous material flow and preventing production interruptions.

5. Issue: Screw Slippage Solution: Check the torque and speed settings to ensure they match the processing demands. Inspect the drive system and replace any worn-out or damaged parts.

Example: Screw slippage can result from worn-out drive belts or inadequate torque settings. Regularly inspecting and maintaining the drive system can prevent such issues, keeping the screw rotation stable and avoiding production delays.

6. Issue: Overheating of Screw and Barrel Solution: Verify cooling systems and ensure they are functioning correctly. Optimize processing conditions to prevent excessive heat generation.

Example: Improper cooling can lead to elevated temperatures in the barrel, affecting material properties and causing degradation. Regularly check cooling channels for blockages and ensure an adequate cooling rate to maintain optimal processing temperatures.

7. Issue: Degraded Product Quality Solution: Analyze the screw and barrel wear patterns and replace components as necessary. Ensure proper material handling and storage to avoid contamination.

Example: Poor material handling practices, such as exposing plastics to moisture, can lead to degraded product quality. Implementing proper material handling procedures and using moisture-resistant materials can safeguard the integrity of the processed materials and the final product.

8. Issue: Screw Jamming or Blocking Solution: Investigate the material characteristics and processing conditions that may lead to jamming. Modify the screw design or employ additives to mitigate this problem.

Example: Certain materials with poor flow properties, like regrind or recycled plastics, can be prone to jamming. Adding flow-enhancing additives or using barrier screws can alleviate this issue, ensuring smooth material flow through the screw and barrel.

9. Issue: Melt Fracturing Solution: Adjust temperature and pressure settings to prevent excessive shear. Consider using compression screws to reduce the risk of melt fracturing.

Example: Melt fracturing can occur in materials with high melt viscosity. Lowering the processing temperature or reducing shear rates can help prevent fracturing. Alternatively, using compression screws with increased compression ratios can compress the melt and reduce the risk of fractures.

10. Issue: Noisy Operation Solution: Inspect the screw and barrel for signs of damage or misalignment. Lubricate components as required and optimize processing parameters for quieter operation.

Example: Noisy operation can be caused by worn-out components or misaligned elements within the screw and barrel. Regularly lubricating moving parts and conducting routine maintenance can significantly reduce noise levels, ensuring a quieter and more efficient operation.

Still not find that you want? Feel free to contact us, Barrelize is professional manufacturer and over 30 years in screw and barrel industry.