https://www.avient.com/sites/default/files/2022-06/Maxxam FR Injection Molding Processing Guide.pdf
• Vents should be placed at the intersection of each 90° bend in the runner system off of the cold slug well and vented to atmosphere PROBLEM CAUSE SOLUTION Black Specks Contamination • Purge barrel with general purpose PP • Verify correct nozzle is being used • Pull screw for cleaning Degraded/overheated material • Decrease melt temperature • Decrease back pressure • Decrease injection speed • Use appropriately sized barrel Brittleness Degraded/overheated material • Decrease melt temperature • Decrease back pressure • Decrease injection speed • Use appropriately sized barrel Gate location and/or size • Relocate gate to nonstress area • Increase gate size to allow higher flow rate and lower molded-in stress Burning Process related • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease injection rate Mold design • Clean, widen and increase number of vents • Increase gate size to reduce shear Fibers/Minerals on Surface or Uneven Surface Appearance Melt temperature too low • Increase melt temperature • Increase mold temperature • Increase injection speed Insufficient packing • Increase hold pressure and time • Increase shot size Flash Injection pressure too high • Decrease injection pressure • Increase clamp pressure • Decrease injection rate • Increase transfer position Excess material volume • Adjust transfer position • Decrease pack pressure • Decrease shot size • Decrease injection rate Melt and/or mold too hot • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease screw speed Loose clamp • Reset mold height • Increase clamp tonnage Troubleshooting Recommendations PROBLEM CAUSE SOLUTION Incomplete Fill Melt and/or mold too cold • Increase nozzle and barrel temperatures • Increase mold temperature • Increase injection rate Mold design • Enlarge or widen vents and increase number of vents • Check that vents are unplugged • Check that gates are unplugged • Enlarge gates and/or runners • Perform short shots to determine fill pattern and verify proper vent location • Increase wall thickness to move gas trap to parting line Shot size • Adjust transfer position to 98% full • Increase shot size Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature • Decrease back pressure • Increase screw decompression Shrink Too much shrink • Increase cooling time • Decrease mold temperature Too little shrink • Decrease cooling time • Increase mold temperature Sink Marks Part geometry too thick • Reduce wall thickness • Reduce rib thickness Melt too hot • Decrease nozzle and barrel temperatures • Decrease mold temperature Insufficient material volume • Adjust transfer position • Increase shot size • Increase injection rate • Increase packing pressure Troubleshooting Recommendations (continued) PROBLEM CAUSE SOLUTION Sticking in Mold Overfilled cavity • Decrease injection rate and pressure • Decrease hold pressure • Adjust transfer position • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease cooling time Mold design • Increase draft angle • Polish cores in direction of ejection Part is too hot • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase cooling time Warp Process related • Increase cooling time • Increase melt temperature • Increase pack pressure • Increase pack time • Decrease mold temperature Mold design • Inspect for non-uniform mold cooling Part design • Inspect for non-uniform wall thickness Temperature control unit incorrect temperature • Check settings • Inspect thermocouple Weld Lines Melt front temperatures are too low • Increase pack and hold pressure • Increase melt temperature • Increase injection rate • Increase mold temperature Mold design • Increase gate size • Perform short shots to determine fill pattern and verify proper vent location • Add vents and/or false ejector pin • Move gate location 1.844.4AVIENT www.avient.com Copyright © 2022, Avient Corporation.
https://www.avient.com/sites/default/files/2020-09/stat-tech-tri-fold-processing-guide.pdf
PROBLEM CAUSE SOLUTION Incomplete Fill Melt and/or mold temperature too cold Mold design Shot Size • Increase nozzle and barrel temperatures • Increase mold temperature • Increase injection speed • Increase pack and hold pressure • Increase nozzle tip diameter • Check thermocouples and heater bands • Enlarge or widen vents and increase number of vents • Check that vents are unplugged • Check that gates are unplugged • Enlarge gates and/or runners • Perform short shots to determine fill pattern and verify proper vent location • Increase wall thickness to move gas trap to parting line • Increase shot size • Increase cushion Brittleness Melt temperature too low Degraded/Overheated material Gate location and/or size • Increase melt temperature • Increase injection speed • Measure melt temperature with pyrometer • Decrease melt temperature • Decrease back pressure • Use smaller barrel/excessive residence time • Relocate gate to nonstress area • Increase gate size to allow higher flow speed and lower molded-in stress Fibers on Surface (Splay) Melt temperature too low Insufficient packing • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase pack and hold pressure, and time • Increase shot size • Increase gate size Sink Marks Part geometry too thick Melt temperature too hot Insufficient material volume • Reduce wall thickness • Reduce rib thickness • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase shot size • Increase injection rate • Increase packing pressure • Increase gate size Flash Injection pressure too high Excess material volume Melt and/or mold temperature too hot • Decrease injection pressure • Increase clamp pressure • Decrease injection speed • Increase transfer position • Decrease pack pressure • Decrease shot size • Decrease injection speed • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease screw speed TROUBLESHOOTING RECOMMENDATIONS PROBLEM CAUSE SOLUTION Excessive Shrink Too much orientation • Increase packing time and pressure • Increase hold pressure • Decrease melt temperature • Decrease mold temperature • Decrease injection speed • Decrease screw rpm • Increase venting • Increase cooling time Not Enough Shrink Too little orientation • Decrease packing pressure and time • Decrease hold pressure • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase screw rpm • Decrease cooling time Burning Melt and/or mold temperature too hot Mold design Moisture • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease injection speed • Clean, widen and increase number of vents • Increase gate size or number of gates • Verify material is dried at proper conditions Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature • Decrease back pressure • Increase screw decompression • Verify material has been dried at proper conditions Weld Lines Melt front temperatures too low Mold design • Increase pack and hold pressure • Increase melt temperature • Increase vent width and locations • Increase injection speed • Increase mold temperature • Decrease injection speed • Increase gate size • Perform short shots to determine fill pattern and verify proper vent location • Add vents and/or false ejector pin • Move gate location Warp Excessive orientation Mold design • Increase cooling time • Increase melt temperature • Decrease injection pressure and injection speed • Increase number of gates Sticking in Mold Cavities are overpacked Mold design Part is too hot • Decrease injection speed and pressure • Decrease pack and hold pressure • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase cooling time • Increase draft angle • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase cooling time TROUBLESHOOTING RECOMMENDATIONS www.avient.com Copyright © 2020, Avient Corporation.
https://www.avient.com/sites/default/files/2022-06/Nymax BIO Bio-based Polyamide Solutions Processing Guide.pdf
Decrease mold temperature Insufficient material volume 1.
Increase transfer position Excess material volume 1.
https://www.avient.com/sites/default/files/2020-12/therma-tech-processing-guide.pdf
Maintain a minimum draft angle of 1° per side. 4 Therma-Tech Troubleshooting Recommendations Problem Cause Solution Incomplete Fill Melt and/or mold too cold • Increase nozzle and barrel temperatures • Increase mold temperature • Increase injection rate • Increase pack and hold pressure • Increase nozzle tip diameter • Check thermocouples and heater bands Mold design • Enlarge or widen vents and increase number of vents • Check that vents are unplugged • Check that gates are unplugged • Enlarge gates and/or runners • Perform short shots to determine fill pattern and verify proper vent location • Increase wall thickness to move gas trap to parting line Shot size • Increase shot size • Increase cushion • Decrease transfer position Brittleness Low melt temperature • Increase melt temperature • Increase injection rate • Measure melt temperature with pyrometer Degraded/ overheated material • Decrease melt temperature • Decrease back pressure • Use smaller barrel/excessive residence time • Decrease screw rpm Gate location and/or size • Relocate gate to nonstress area • Increase gate size to allow higher flow rate and lower molded in stress Fibers on Surface (Splay) Melt temperature too low • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase screw rpm Insufficient packing • Increase pack and hold pressure, and time • Increase shot size • Increase gate size Processing Guide 5 Problem Cause Solution Sink Marks Part geometry too thick • Reduce wall thickness • Reduce rib thickness • Maintain nominal wall thickness Melt too hot • Decrease nozzle and barrel temperatures • Decrease mold temperature Insufficient material volume • Increase shot size • Increase injection rate • Increase pack pressure/time • Increase gate size Flash Injection pressure too high • Decrease injection pressure • Increase clamp pressure • Decrease injection rate • Increase transfer position Excess material volume • Decrease pack pressure • Decrease shot size • Decrease injection rate Melt and/or mold too hot • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease screw speed Excessive Shrink Too much orientation • Increase packing time and pressure • Increase hold pressure • Decrease melt temperature • Decrease mold temperature • Decrease injection speed • Decrease screw rpm • Increase venting • Increase cooling time Not Enough Shrink Too little orientation • Decrease packing pressure and time • Decrease hold pressure • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase screw rpm • Decrease cooling time Troubleshooting Recommendations 6 Therma-Tech Troubleshooting Recommendations Problem Cause Solution Burning Melt and/or mold too cold • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease injection rate Mold design • Clean, widen and increase number of vents • Increase gate size or number of gates Moisture • Verify material is dried at proper conditions Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature • Decrease back pressure • Increase screw decompression • Verify material has been dried at proper conditions Weld Lines Melt front temperatures are too low • Increase pack and hold pressure • Increase melt temperature • Increase vent width and locations • Increase injection rate • Increase mold temperature Mold design • Decrease injection rate • Increase gate size • Perform short shots to determine fill pattern and verify proper vent location • Add vents and/or false ejector pin • Move gate location Warp Excessive orientation • Increase cooling time • Increase melt temperature • Decrease injection pressure and injection rate Mold design • Increase number of gates Sticking in Mold Cavities are overpacked • Decrease injection rate and pressure • Decrease pack and hold pressure • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase cooling time Mold design • Increase draft angle Part is too hot • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase cooling time 1.844.4AVIENT www.avient.com Copyright © 2020, Avient Corporation.
https://www.avient.com/sites/default/files/2023-04/Fiber Colorants and Additives Brochure.pdf
Product range • Flame retardants to reduce flammability of fibers and fabrics especially in building and construction applications • Light stabilizers to protect fibers used outdoors or exposed to sunlight against UV light • Antimicrobials to protect hygienic fiber products from bacteria proliferation • Antistatics to reduce electrostatic charges • Antioxidants to reduce polymer oxidation during spinning and protect fabrics during service life • Optical brighteners to provide a brilliant white effect and blueish hue • Electrets to retain electrostatic charge on the polymer surface for a longer period of time in filtration applications • Hydrophobics to impart durable water repellency • Chain extenders for recycled polyester fibers • Others on request Product characteristics • Good spinnability • Fiber-specific QC and protocols • Lot-to-lot consistency • Carriers: PET, PBT, PA 6, PP, and others • Possibility to combine colors and additives into a combination concentrate for convenience • Product guidance from our fiber expert team • Focus on safe and sustainable formulations Applications • Continuous filaments (POY, FDY, HOY, BCF) • Long and short spinning staple fiber • Nonwoven processes (spunbond and meltblown) Cesa™ Fiber Additives MagIQ™ Liquid Fiber Colorants & Additives Multiple color production • Depending on the manufacturing set-up, several injection points can be added to enable multiple color production at the same time on a single extruder Batch size flexibility • Fiber producers can manufacture anything from a few kilograms to hundreds of tons using the same simple process Rapid color changes • No extruder contamination and easy color-on, color-off operation increases color change speed Waste reduction • Rapid color changes, precise metering and the ability to adjust color in-line reduces waste during color changeovers Continuous metering & long spin pack life • High pigment and dye concentrations mean fewer pack changes are required • Where color is running low for larger volume runs, low level metering sensors alert operators and packs can be changed without disrupting production In-line IV adjustment • Specialist additives are available to adjust Intrinsic Viscosity (IV) in-line for rPET applications • These additives are available as single products, or can be combined with color to create a multi- functional formulation Color design service • Avient offers a dedicated color design service to help shorten product development cycles and enhance market agility Liquid color processing • Formulations are stable at temperatures up to 60°C and retain good flow properties at temperatures as low as 10°C • These formulations can help lower yarn friction and abrasion, and there is no fuming or evaporation during production Avient’s liquid fiber colorant technology combines advanced liquid color formulations with state-of-the-art, high-pressure metering equipment to enable late-stage injection of liquid color for spun-dyed polymer melt.
The extruder is never contaminated with color which translates into faster, more efficient color changeovers that make low volume and custom color production a reality.
https://www.avient.com/sites/default/files/resources/POL%2520IR%2520Presentation%2520-%2520Investor%2520Day%25205-18-15.pdf
Van Hulle President, Global Color, Additives & Inks PolyOne Corporation Page 16 Appliances 2% Building & Construction 12% Consumer 7% Electrical & Electronics 1% Healthcare 6% Industrial 14% Packaging 31% Textiles 7% Transportation 8% Wire & Cable 12% 2014 Revenue by Industry Segment 2014 Revenues: $0.9 Billion At a Glance Global Color, Additives & Inks United States 44% Europe 36% Canada 2% Asia 12% Latin America 6% PolyOne Corporation Page 17 A Case Study for Transformational Success 1.7% 4.6% 5.1% 5.5% 7.2% 8.1% 9.7% 12.2% 14.7% 2006 2007 2008 2009 2010 2011 2012 2013 2014 Operating Margin $9 $26 $28 $25 $43 $50 $75 $104 $125 2006 2007 2008 2009 2010 2011 2012 2013 2014 Operating Income ($M) •Cultural mindset shift from volume to value •Customer centric focus and training •Differentiation with innovation and service •Acquisitions expand portfolio of technology Global Color, Additives & Inks PolyOne Corporation Page 18 395 262 2006 2014 From Volume… (lbs in millions) -34% $94 $293 2006 2014 To Value Gross Margin ($ in millions) +210% Global Color, Additives & Inks PolyOne Corporation Page 19 Accelerating Growth Global Color, Additives & Inks Innovation Market Growth/ Megatrends Geographic Expansion Collaboration PolyOne Corporation Page 20 Who We Are Growing With Global Color, Additives & Inks PolyOne Corporation Page 21 Innovation Pipeline Potential Global Color, Additives & Inks Addressable Market ($ millions) $300 $500 $400 Prototype Frame Opportunity Scale-up & Test Market Build Business Case Commercial Launch Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 3 3 5 0 1 8 3 1 1 5 1 1 1 1 0 Breakthrough Platform Derivative PolyOne Corporation Page 22 Megatrends Aligned with Key End Markets Increasing Energy Efficiency Protecting the Environment Improving Health and Wellness Megatrend End Markets Globalizing and Localizing Health & Wellness Transportation Packaging Consumer Global Color, Additives & Inks PolyOne Corporation Page 23 $150M Revenue Potential $500M Revenue Potential Additive Technologies InVisiOSM Color & Design Services Key Initiatives Global Color, Additives & Inks PolyOne Corporation Page 24 Innovation Market Growth / Megatrends Geographic Expansion Collaboration Platinum Vision 1.7% 7.2% 14.7% 20%+ 2006 2010 2014 2020 Platinum Vision World Class Operating Margin Accelerating Growth Global Color, Additives & Inks PolyOne Corporation Page 25 Summary • Global Capabilities • Innovation Leader • Collaboration – One PolyOne Global Color, Additives & Inks Color Matters PolyOne Corporation Page 26 Global Specialty Engineered Materials Craig M.
Nikrant President, Global Specialty Engineered Materials PolyOne Corporation Page 27 What We Do Concept to Design Specialty Formulations Global Specialty Engineered Materials PolyOne Corporation Page 28 Appliances 4% Building & Construction 3% Consumer 18% Electrical & Electronics 16% Healthcare 12% Industrial 8% Packaging 5% Transportation 20% Wire & Cable 12% 2014 Revenue by Industry Segment 2014 Revenues: $0.6 Billion At a Glance Global Specialty Engineered Materials United States 44% Europe 33% Canada 2% Asia 19% Latin America 2% PolyOne Corporation Page 29 A Case Study for Transformational Success 1.1% 1.3% 3.4% 5.1% 9.6% 8.0% 8.6% 9.3% 12.1% 2006 2007 2008 2009 2010 2011 2012 2013 2014 Operating Margin $4 $5 $18 $21 $50 $46 $47 $57 $72 2006 2007 2008 2009 2010 2011 2012 2013 2014 Operating Income ($M) Global Specialty Engineered Materials •Globally harmonized specialty strategy and culture •Value proposition and customer centric selling •Differentiation with innovation and service •Expand technology portfolio with select acquisitions PolyOne Corporation Page 30 2006 2014 From Volume… (lbs in millions) 269 286 +6% $42 $163 2006 2014 To Value Gross Margin ($ in millions) +292% Global Specialty Engineered Materials PolyOne Corporation Page 31 Accelerating Growth Innovation Market Growth Geographic Expansion Collaboration Global Specialty Engineered Materials PolyOne Corporation Page 32 Who We Are Growing With Global Specialty Engineered Materials http://www.google.com/url?
Garratt President, Performance Products and Solutions PolyOne Corporation Page 48 2014 Revenue by Industry Segment 2014 Revenues: $0.8 Billion At a Glance Performance Products & Solutions United States 80% Canada 14% Asia 2% Latin America 4% Appliances 8% Building & Construction 33% Consumer 5% Electrical & Electronics 3% Healthcare 1% Industrial 11% Packaging 5% Transportation 18% Wire & Cable 16% PolyOne Corporation Page 49 What We Have Delivered 4.3% 6.3% 7.2% 7.7% 2011 2012 2013 2014 Operating Margin $28 $39 $56 $63 2011 2012 2013 2014 Operating Income ($M) •Relentless focus on portfolio mix optimization •Lean Six Sigma drives operational excellence • Innovating in new markets such as healthcare •Expanding presence in Mexico and China Performance Products & Solutions PolyOne Corporation Page 50 $96 $109 2006* 2014 To Value Gross Margin ($ in millions) +13% 1,431 1,124 2006* 2014 From Volume… (lbs in millions) -21% Performance Products & Solutions *2006 = Near peak housing PolyOne Corporation Page 51 Accelerating Growth Market Growth/ Megatrends Innovation Collaboration Geographic Expansion Performance Products & Solutions PolyOne Corporation Page 52 Who We Are Growing With Performance Products & Solutions http://www.google.com/url?
https://www.avient.com/sites/default/files/2023-08/Fiber-Line Winding Product Bulletin.pdf
Fiber-Line™ Precision Winding PRODUCT BULLETIN Precision winding is a process in which successive coils of fiber are laid parallel or nearly parallel with each other to hold the maximum amount of fiber in a given volume.
https://www.avient.com/sites/default/files/2023-09/Cesa Fiber Additives for Heat Preservation Technical Bulletin.pdf
TEMPERATURE DISTRIBUTION DIAGRAM • Test Method: FTTS-FA-010-2007 4.2 • Equipment: Thermovision • Heat Source: 500W Halogen Lamp • Heat Distance: 100 cm Surface temperature before exposure: 20.22°C Surface temperature after 10 min exposure: 33.85°C Temperature change: +13.6°C Added Cesa Fiber Additives for heat preservation TEST METHOD STANDARD REQUEST TEST RESULT GB/T30127 Far infrared radiation properties Far infrared emissivity ≥0.88 (5-14um) (Test temperature: 34°C) 0.9 Far infrared radiation temperature rise ≥ 1.4°C 9°C GB/T 18319-2019 Thermal retention with accumulated by infrared ray Maximum temperature rise ≥ 6°C 8.9°C Mean temperature rise ≥ 4.4°C (20 minutes) 5.6°C FTTS-FA-010 Infrared radiation properties & thermal retention temperature rise Average emissivity ≥ 0.8 (2-22um) (Test temperature: 25°C) 0.8 Specified heating ΔT ≥ 0.5°C (relative to the standard) +5.34°C (ΔT) GB/T 11048-2008 Method A Thermal transmittance Unit: clo Naked body: 0 Underwear: 0.04 T-shirt: 0.09 Thick sweater: 0.35 Winter coat: 0.7 All the data above are the reference value 0.625 Human Physiological Experiment Blood flow volume +12.9% Blood flow velocity +13.6% Blood oxygenation(%SpO2) +1.7% www.avient.com Copyright © 2023, Avient Corporation.
https://www.avient.com/sites/default/files/2023-04/Impress High Gloss Metallic Effect Colorants Product Bulletin.pdf
They want their products to win share in high-volume consumer markets by standing out at point-of-sale.
https://www.avient.com/resource-center/knowledge-base/article/injection-molding-mold-design
For high volume production, the initial expense of quality tooling is a sound investment.
Since TPEs are slightly compressible in the molten state, larger runner volumes can cause hot tip gates to drool after the mold is opened.