UNIPOL®

Polypropylene
Technology

Extrusion Issues
May 2017

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Extrusion Issues
Agenda
− Review of Common Pelleting Problems
− Peroxide Cracking: Extruder Variables
− Good Pellet Cutting

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 Extrusion Issues
Common Pelleting Problems
− Surging, indicated by power spikes, poor pellet cut. Caused by:
• Uneven feed
• Melt pump control loop tuning
• Harmonic surges
• Return gas from mixing zone
− Incomplete melting, indicated by high die plate pressure, unmelted resin
in pellets. Caused by:
• Screw configuration not intensive enough
− Vent port plugging, indicated by vent system purge gas low flow or high
pressure. Caused by:
• Improper startup technique
• Worn screw
• Screw speed too low for feed rate
• High residual peroxide when cracking, indicated by odor. (later in
this presentation)
− Pellet cutting problems. (later in this presentation)
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 Extrusion Issues
Peroxide Cracking: Requires Complete Cracking
– Incomplete cracking, indicated by odor, more peroxide added than
required
– For full cracking:
• Lupersol 101: melt temperature 210° C
• Trigonox 301: melt temperature 230° C and longer residence
time
– Higher temperatures make pellet cutting more difficult

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 Extrusion Issues
Peroxide Cracking: Controlling the Variables on an Extruder
– Screw Speed:
• High speed for high rate
– Gate/Throttle/Slot Valve Control:
• Close for higher temperature and increased residence time
– Melt Pump Suction Pressure:
• Raise for higher temperature and increased residence time
– Feed Rate:
• Reduce feed rate for higher temperature and increased
residence time
– Barrel Temperature:
• Lower barrel temperature has small effect on melt
temperature, some effect on residence time
– Screw Configuration:
• Optimize for product mix

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 Extrusion Issues
Good Pellet Cutting Practices
(Taken from Pelletizer Knives Inc. (PKI) presentation in 2015)
− Knife Mounting Procedure
− Alignment of Knives to Die Face
− Effects of Excessive Forward Pressure
− Worn Die Face
− Consistent Polymer Flow
− Typical Solutions for Polymer Defects

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Extrusion Issues

KNIFE
MOUNTING

KNIFE
KNIFE ADVANCING PELLET DESIGNS
PROCEDURES
QUALITY

KNIFE
MATERIALS

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 Extrusion Issues
Knife Mounting Procedure
− Knives will mount up
uniformly
− Allows for knives to seat
more quickly to die face
on startup

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Extrusion Issues
Alignment of Knives to Die
Face
− Results of poor alignment:
• Poor pellet quality (fines,
tails, chains)
• Knife breakage
• Excessive knife wear

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Extrusion Issues

Effects of Excessive Forward

Pressure

− Knife tip raising off die plate

− Results:
• Fines
• Tails
• Knife Breakage
− Lower Forward Pressure after
start-up

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Extrusion Issues

Consistent Polymer Flow

− Polymer surges can push
back knives
− Results:
• Knife breakage
• Trashout

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Extrusion Issues
Worn Die Face

Results in
excessive
knife wear

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Extrusion Issues
Typical Solutions for Pellet Defects
Internal Voids- Moisture = Dry polymer
Entrained gas = Degas polymer
Quench rate too fast = Increase quench water temperature
Longs or Elbows- Extrusion rate too high = Reduce extrusion rates
Frozen die holes = Increase die temperature
Low melt temperature = Increase water temperature
Too few of knives = Increase number of knives
Dog Bones - Low viscosity product = Make knife clearance adjustments
Elastic stretchy product = Lower quench water
Tails - Cracked orifice tips = Plug hole
Knife to die gap too large = Make knife adjustment or die alignment
Die surface irregular = Regrind die face
Shaft not aligned = Check ID/OD knife sweep coverage on die
Twin or Chains- Product too hot = Lower product temperature
Quench water too hot = Lower water temperature
Knife speed too high = Lower knife speed(add more knives)
Die holes too close
Clusters - Product too hot = Lower water temperature
Quench water too hot = Lower water temperature
Low quench water flow = Check flow rate
Fines - Cracked orifice tips = Plug hole or make knife adjustment
Die holes partially blocked = Purge die and check product flow uniformity
Shaft not aligned = Realign pelletizer
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Extrusion Issues
Any Questions?

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