Cause:
PEX tends to get stuck on the equipment and is difficult to remove.
Solution:
Washing with EKO WARM according to the regular Injection Procedure.
EKO WARM doesn’t foam and does not need to be settled during the washing process. It maintains a low flow even during the PEX’s processing heat and pushes it out with ease.
Cause:
Layers of resin (some of which was chemically changed and is no longer transparent) coat the screw, nozzle and mold and cause the clouding effect in the product, that may also lead to burning and black spots.
Solution:
Washing with EKO CLEAR NEW according to the regular injection procedure.
EKO CLEAR NEW is a transparent PC based product. It does not foam and does not require settling. During the settling it clings to the equipment’s polymer layers and pulls them out with it.
Cause:
Resin and pigment get caught up and accumulated in the narrow runners. They are released by surprise into the product and cover it with black spots and/or strips of color.
Solution:
Using an EKO SAVE™ cleaning material (EKO WARM RICH usually) designated to hot runners, which does not contain glass fibers and consists of suitable tiny particles.
Working before the injection procedure. For ideal cleaning results, we recommend injecting the EKO SAVE™ cleaning material in half batch through the sealed mold.
In the event of delicate and narrow passages, we recommended injecting through an open mold, at a changing injection speed, while performing short and quick shots.
Cause:
Old paint gets caught up on the edge of the injection point, as a result of their design which opens slightly towards the mold. These areas do not experience sheer forces and are difficult to reach and clean. Pigment gets caught and is released during the injection.
Solution:
Fixing the mold and improving the surface area and heating at the injection point.
Using a designated EKO SAVE™ cleaning product, and following the Injection Cleaning Procedure.
Cleaning tip – we recommend cleaning the screw prior to cleaning the mold. Next, clean the mold and injection point after heating by an additional 15-20 degrees.
Cause:
The resin and pigment tend to stick to the equipment, accumulate and burn. The burnt material is released into the final product randomly and will damage it, causing undesired waste.
Solution:
Preventative use, preferably weekly or after operating with a single color/resin for a few days, using a designated EKO SAVE™ cleaning product, while following the Injection Cleaning Procedure.
Cleaning tips
Cause:
Fault due to an under-reading of the thermal cable or due to work that was not performed according to the work procedures.
Solution:
Periodic external examination of the thermal cables.
Preventative cleaning using an EKO SAVE™ cleaning product (usually very abrasive, according to the severity of the issue). Determining the final EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cleaning tips
Cause:
Equipment malfunction – screw, nozzle, mold – resulting from ongoing or wrong use in which resin and pigment accumulate and burn.
Solution:
Performing preventative maintenance on the equipment and often even breakdown maintenance is necessary due to the significant product waste and resin, and loss of machine operation time.
Old/worn equipment requires more time/cleaning when changing materials and paints.
Using the appropriate EKO SAVE™ cleaning solution at a frequency that will prevent the issues (e.g. weekly).
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
The screw becomes contaminated over time due to burnt polymer in the raw material, mostly in areas of stagnation, sub-pressure and reverse flow.
Solution:
Cleaning with EKO SAVE™ materials prior to removing the screw, as it is more efficient that external cleaning.
The cleaning procedure most be performed using a filler rich, polyolefinic based material, such as EKO GGX NEW.
Cleaning tips: Raise the operation profile by 30-50 degrees (according to the equipment’s and row material limitation) and remove the screw at this temperature, slowly and carefully.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Problematic areas – the screw, no-return, nozzle, filter, mold injection points, inserts and mold hot runners.
Cause:
Lack of sheer forces in these areas and relative heat drop.
Sometime, the resin moves in the opposite direction due to the design of the screw and type of operation.
Resin and pigment accumulate, burn and later on contaminate, usually by surprise.
Solution:
Performing the cleaning procedure, using an EKO SAVE™ product, according to the Injection Cleaning Procedure.
Feeding another half a dose of cleaning product (half the cylinder’s volume) and removing it in partial injections (through the mold) and quick shots.
The raw material is not uniform and it contains contaminated or heat sensitive components.
A raw material that is too moist will sabotage the working conditions and damage the surface area of the product.
Raw materials that have already started the degradation processes (waste and deterioration) due to age or storage conditions tend to burn and contaminate the equipment.
Solution:
Using materials that are suitable for the job and eliminating products that may causes problems in advance, as they may damage the equipment and cause significant waste and delay manufacturing.
Using an abrasive EKO SAVE™ product suitable for this serious problem and “fire extinguishing”. Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts
Cause:
EKO SAVE™ products usually have a low flow rate and high complexity levels (containing fillers) which make it difficult to remove them from the machine using the following resin.
Solution:
Cause:
Usually an under-reading that leads to overheating of the heating element, burning of resin and pigment and their accumulation in the equipment, resulting in black spots in the product and significant waste.
Solution:
Periodic external examination of the thermal cables and replacement of faulty cables.
To clean existing black spots, use the suitable EKO SAVE™ cleaning material (usually relatively abrasive).
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
The wrong type of screw creates excessive shear stress and heat, mostly to the middle and front parts of the screw, which hurts the quality of the product and difficulties in manufacturing a proper and uniform product.
The resin and pigment burn and are accumulated on the product, while black spots appear on the product, usually by surprise.
Solution:
Designing a suitable screw in advance, and replacing a faulty screw when necessary.
We recommend switching any sensitive mold/product that suffer from significant waste, to operation in a machine with a suitable screw.
Using the appropriate EKO SAVE™ cleaning solution at a frequency that will prevent the issues (e.g. weekly). Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
The following areas of the equipment may suffer from wear and tear: Screw, cylinder, layer combiner, nozzle, vent openings (outlets for gas and liquids), melt pump, mold, head, non-return at the screw’s edge, the mold’s injection points, hot channels.
The materials accumulate in the wear and tear areas, burn up and are released over time.
Solution:
Performing preventative maintenance on the equipment and often even breakdown maintenance is necessary due to the significant product waste and resin, and loss of machine operation time.
Using the appropriate EKO SAVE™ cleaning solution at a frequency that will prevent the issues (e.g. weekly). Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts
Resin and pigment accumulate in these areas at a higher than usual rate and burn over time.
The following areas of the equipment may suffer from wear and tear: The vent, front part of the screw, the back part of the screw’s covers, parts of the melt pump, edges of the flat nozzle, spiral mandrill, sheet inflation and more.
Solution:
Performing preventative maintenance on the equipment and often even breakdown maintenance is necessary due to the significant product waste and resin, and loss of machine operation time.
Using the appropriate EKO SAVE™ cleaning solution at a frequency that will prevent the issues (e.g. weekly). Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Working at a heat that is above the allowed maximum rate for the raw materials and/or a prolonged stop of the resin in an area that is too hot for it.
Solution:
Training the team to work according to the manufacturer’s guidelines and planning the work in order to prevent these situations, such as planning ahead to avoid any prolonged pauses.
During long stops (a shift or more) we recommend turning the machine off to room temperature on a suitable stopping material or to reduce the heat profile during the stop.
We recommend stopping using an EKO SAVE™ designated for stopping and for work according to the shutdown and stop procedure.
The raw material is not uniform and it contains contaminated or heat sensitive components.
A raw material that is too moist will sabotage the working conditions and damage the surface area of the product.
Raw materials that have already started the degradation processes (waste and deterioration) due to age or storage conditions tend to burn and contaminate the equipment.
Solution:
Using materials that are suitable for the job and eliminating products that may causes problems in advance, as they may damage the equipment and cause significant waste and delay manufacturing.
Using an abrasive EKO SAVE™ product suitable for this serious problem and “fire extinguishing”. Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts
Cause:
EKO SAVE™ products usually have a low flow rate and high complexity levels (containing fillers) which make it difficult to remove them from the machine using the following resin.
Solution:
Cause:
The passages become narrow in the small nozzles (according to the thickness of the piping, which is thinner here). As a result, the pigment gets caught up here more than usual and paints the system. The gas release is not as efficient in narrow passages, which over time causes a layer of paint on the metal.
Solution:
A feed of EKO SAVE™ cleaning material (usually EKO GGX NEW) at a low speed of about 5 rpm, until the cleaning material is used up or until the cleaning is completed, and then move on to the next paint.
This problem is usually solved during the removal (usually after about 30 kilograms).
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Resins and pigments stick and accumulate on the screw over time and it is very difficult to clean them using mechanical means after the screw has been dismantled (hard brushes and dismantling materials).
Solution:
remove the profile temperature by minus 20-40 degrees.
wash using the EKO GGX NEW usually.
Note: Lowering the temperature while controlling the engine load, and raising it if necessary. .
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts .
Cause:
Leftovers of heat sensitive resin burn in the machine before it cools down, as well as during reheat. Regular resin that remains in the machine during the stop tends to burn up as well.
Solution:
Stop/turn off the machine with EKO SAVE™ cleaning material means for stopping and working according the Shutdown and stopping procedure. The process includes removing the resin that is being used and inserting the cleaning material in its place. The cleaning material prevents oxidization, freezes in the equipment’s “holes”, corners and passages.
During startup, the cleaning material absorbs the leftovers and removes them out.
Resins such as PVC HDPE PS LDPE PP and others.
Cause:
The heat sensitivity of the different resins.
For example, PVC is an extremely sensitive resin, so it is usually processed at a heat of less than 190 degrees, using a screw with a low L/D (usually 20) in order to reduce the heat delay time to a minimum, while achieving a satisfactory process within a short amount of time.
Solution:
We recommend processing PVC and similar sensitive materials in a dual screw system, in order to get a low process/delay ratio that will prevent its burning.
Prevent stops during the PVC processing. If forced to stop, start by removing it and cleaning with a suitable EKO SAVE™ product.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Frequent changes between paints on the extruder (the small one) line lead to its contamination overtime and to difficulties in the passage between different paints.
Solution:
Ongoing preventative cleaning (weekly or after each series of a certain paint, or when switching from a problematic paint) using a suitable EKO SAVE™ product, that will prevent accumulation and burning of old paints.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts .
Cause:
During a long series in the black HDPE, the paint coats the heat and it becomes difficult to clean.
Solution:
Ongoing preventative cleaning (weekly or after each long series) using a suitable EKO SAVE™ product will prevent accumulation and coating of the black material.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
The problem is common in MFI flow paths in various HDPE, which results in the remaining materials in the MFI low inside the machine and their fire over time.
Solution:
Systemically preventing cleaning (once a week or after any particular color series or problematic material transition) using appropriate EKO SAVE™ material, which will prevent accumulation and burning of old colors.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts .
Cause:
The frequency of work in this field, using a wide range of pigments and switching between different pigments and resins without performing a thorough preliminary cleaning leads to their burning.
Solution:
Thorough cleaning after problematic paints, after a long series of a specific paint and transferring between different resins with a suitable EKO SAVE™ material and according to the relevant extrusion procedure.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Resin or pigment accumulated in the equipment and burnt due to excessive heat.
The accumulation of resin in the equipment is caused due to a “reverse flow”” (in the extrusion line), “sub-pressure areas”, “dead areas” and wear and tear sections of the equipment. All of these causes make the raw material to delay in wrong places.
Excessive heat to the resin is caused due to malfunctioning equipment (overheating of the heating element), work that isn’t according to procedure (delaying the resin in heat beyond its ability) or due to faulty resin resulting in early degradation, quick burn and causing visible black spots on the product.
Solution:
Preventing these issues from recurring by identifying the cause of the problem and eliminating it.
For example, maintenance to the equipment’s wear and tear areas, external examination to ensure the reliability of the heat sensors (thermocouples), heating element, improved control over storage of the raw materials (good cover and ventilation conditions) and regular operator training regarding following procedures.
Preventing the problem by using EKO SAVE™ materials regularly, since resin sticks and burns anyway, and is difficult to fully prevent.
Using EKO SAVE™ materials that are relatively abrasive to “turn out the fire” in order to postpone the dismantling the equipment and manually cleaning it.
Cause:
When using a raw material that emits gases (VOC) or water vapor (hydroscopic), the cylinder must have a vent hole. This opening is sensitive to contamination and dirt due to its physical structure and the fact that shear stresses that apply on other areas of the screw.
This is why it is important to create the cleaning and shear stresses required for cleaning.
Solution:
We recommend sealing the vent during the general cleaning process using a suitable cover, in order to maintain the cleaning pressures that are required in the cylinder. In the even that it is not possible to seal the vent opening, expect a pressure drop in the cylinder volume during the cleaning process, due to the material foaming through the ventilation opening.
To clean the ventilation opening, fill it with cleaning material by manually inserting a number of grains. The vent will clean during the extruder cleaning process.
Cause:
This is an area that contains mixers and pins. The raw materials stick to them, oxidize, burn up and are randomly released into the product.
Solution:
Working according to the relevant extrusion procedure while using the relevant EKO SAVE™ material.
This issue is usually treated with and abrasive material such as EKO GGX NEW or EKO S.
Cause:
Integrating the layers/extrudes in the layer integrator is performed in relatively narrow passages, which cause the resin to stick and burn, making it difficult to clean.
Solution:
Working according to the relevant extrusion procedure, maintaining high and changing pressures in the layer integrator, while using the relevant EKO SAVE™ material.
This issue is usually treated with and abrasive material such as EKO GGX NEW or EKO S.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts, and while take the layers and resins into consideration.
Cause:
There are no shear pressure in these areas (push and heat) as there is no mechanical movement of the screw.
Most problems occur in the torque/angle areas, and the dirt can be seen in the internal side of the product.
Solution:
Working according to the relevant extrusion procedure while using the relevant EKO SAVE™ material.
Most of the time, we will use an abrasive material such as the EKO GGX NEW or EKO S for this problem, together with changing the flow speed (and pressures) in the adapter and throughout the extruder.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
The main problem is in the chock bar area, which is used to direct the internal flow within the flat nozzle. The chock bar becomes dirty, and small lumps are formed on it, which cause scratches to the final product.
The edges of the nozzle collect a significant amount of dirt and are the most difficult to clean.
Solution:
Open and close the chock bar screws in the scratched area during the cleaning process, using the proper EKO SAVE™ product, in order to clear and remove and stuck materials.
Raise the temperature at the nozzle edges by another 35° and lower the temperature in the center of the nozzle to 20°. The temperature lapse will improve the flow of the cleaning material towards the edges of the nozzle which are difficult to clean.
This issue is usually treated with and abrasive material such as EKO GGX NEW or EKO S. Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Different materials have a different MFI flow, different processing temperature and they are not necessarily compatible to each other. As a result, it is difficult to remove one material from the machine using another material. This may happen during the passage from a low flow HDPE to the ABS, making it difficult to push the HDPE out.
Solution:
Selecting a suitable EKO SAVE™ cleaning material that will manage to mediate between the different materials regarding the process temperature and flow rates.
Adjusting the EKO SAVE™ flow rate is crucial, as the cleaning material must know how to push the “past” but also to easily make way for the “future”.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Paints are chemically inclined to stick to equipment, as a result of covalent balance.
Certain paints, such as blue, yellow, green and black are known to be difficult to remove and replace. Paints that were not removed will burn over time and create black spots on the product.
Solution:
Preventing the problem by using a better suited pigment, according to the supplier’s recommendation.
Performing ongoing preventative maintenance using EKO SAVE™ products during operation with a problematic pigment to avoid accumulation in the equipment. Do not allow layers of coating on top of each other, and keeping a distance from the equipment’s metal layer by performing preventative cleaning using EKO SAVE™ products.
Using EKO SAVE™ products during color changes, as an intermediate material between the different paints. Determining the correct solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Raw material is caught behind the deckling (a sub-pressure area) where it accumulates and is released in the passage between materials and colors.
Solution:
Washing with a suitable EKO SAVE, according to the relevant adapter extrusion procedure while maintaining overheat of +35° of the deckling, while using the relevant EKO SAVE™ product.
This issue is usually treated with and abrasive material such as EKO GGX NEW or EKO S.
Cleaning with EKO SAVE™ should only be performed after the deckling have been disassembled
Cause:
Use of heat sensitive materials during the manufacturing of multi-layer sheets.
The problem will appear in the extrudes were different raw materials are used alternately, meaning that it is impossible to assign a single extruder to each type of raw material due the different methods of use.
Solution:
Preventing the problem by working with an extruder designated for the problematic material (when possible).
Using the appropriate EKO SAVE™ cleaning solution at a frequency that will prevent the issues (e.g. when switching to a different raw material). Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts
Cause:
Switching from resin A to resin B which has a higher processing temperature.
Residue of Resin A that were not cleared out will burn during the switch to Resin B.
This problem is worse when switching to a resin type such as PEEK, which is processed at a temperature of about 400 degrees, and switching over to it requires full removal of Resin A.
Solution:
Use an EKO SAVE™ cleaning material that can mediate between material A and B that can be processed at the temperature range of the two.
Once you are done working with material A, clean it at its processing temperature with a suitable EKO SAVE™ material and then switch to working with Resin B at its processing temperature.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Frequently used HDPE and MDPE accumulate in the cylinder, screw and spiral mandrill, where they burn and contaminate.
Solution:
This may call for a manual disassembly of the equipment – at least once a year – for proper cleaning.
Using suitable abrasive EKO SAVE™ materials according to the recommended Cleaning Procedure will prolong the amount of time between each disassembly.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cleaning tips
Cause:
The different types of PE tend to intersect and oxidize. Black and yellow spots are released, disrupting the unity of the resin, creating holes in the sheet.
Stopping the line on the PE, even for a short period of time, may cause a fire.
Solution:
Stop/turn off the machine with EKO SAVE™ cleaning material means for stopping and working according the Shutdown and stopping procedure. The process includes removing the resin that is being used and inserting the cleaning material in its place. The cleaning material prevents oxidization, freezes in the equipment’s “holes”, corners and passages.
During startup, the cleaning material absorbs the leftovers and removes them out.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Polymer is trapped and accumulated, creating a coating layer on the metal in the spiral mandrill.
Solution:
Using preventative treatment while stopping the line, by using EKO SAVE™ products, which include shutting the machine off on stopping material (usually EKO WARM RICH) and using the Shutdown and stopping procedure.
You can wash the line using EKO SAVE™ product, according to need, without stopping the line.
The contamination is released from the equipment during the heating-cooling process. The cleaning material absorbs them and helps them out of the system.
Cause:
Pigments tend to coat the nozzle and other parts of the equipment overtime, which prevent a smooth transfer to the following color, as well as to the clear sheet.
Solution:
This may call for a manual disassembly of the equipment – at least once a year – for proper cleaning.
EKO SAVE™ materials according to the recommended Cleaning Procedure will prolong the amount of time between each cleaning disassembly.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
During multi-layer manufacturing with multiple extruders, it is usually impossible to set a designated extruder for each type of raw material. As a result, materials that are partially sensitive to heat that are not compatible to each other are processed alternately in the same place.
This leads to different materials getting caught up in the equipment, accumulating and burning.
Solution:
This may call for a manual disassembly of the equipment – at least once a year – for proper cleaning.
EKO SAVE™ materials according to the recommended Cleaning Procedure will prolong the amount of time between each cleaning disassembly.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Setback and stopping for long periods of time in heat conditions or operating at a high temperature.
Solution:
Preventative cleaning with an EKO SAVE™ product that is suitable for working with the above mentioned materials. It can mediate between them and the other materials in the extruder.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Difficult colors, such as blue, yellow, green and black tend to cling and form layers on the equipment.
Solution:
Preventative cleaning with an EKO SAVE™ suitable for work with difficult pigments.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Old pigment that accumulates in the extruder and head is released, appearing mostly in the parting line.
Solution:
Using EKO SAVE™ cleaning material (EKO LIL or EKO GGX NEW usually) as part of ongoing periodical treatments or after each use of paint, in order to clean out the old pigment.
Be sure to carefully follow the work procedure, while putting an emphasis on delaying the cleaning material for at least 10-20 minutes, and working slowly enough so that the machine can process it well.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts.
Cause:
Resin and paint that get caught up in the screw, head, adapters and wear and tear areas, get stuck and burn.
Solution:
Washing the machine with the suitable EKO SAVE™ material according to the blow molding work procedure.
In addition, and as a step before performing a manual dismantling and cleaning, we recommend cleaning by initiating a shutdown using an EKO SAVE™ product as part of the Stop-Shutdown procedure. We recommend using EKO LIL, which specializes in getting into all of the “holes” and pushing the leftover HDPE out.
Determining the correct EKO SAVE™ solution will be performed by completing the TEG questionnaire or through a Chat conversation with the EKO experts .
Cause:
The edges of the no-return piston, areas without shear-forces/screw (passages and accumulator) and wear and tear areas of the equipment may collect resin and pigment that accumulate on them, and burn in layers over time.
Solution:
Performing a periodic cleaning procedure using a suitable EKO SAVE™ material (with above average abrasiveness) while performing the following guidelines in the work procedure:
A proper clean requires three doses of EKO SAVE, but the financial savings resulting the saving resign and machine operational time are usually much higher.