Page

Revision

: 1 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE
Excessive residence time in the barrel
Hang-up of Molten material in the
injection barrel or runner system
Contamination of the injection barrel

BLACK SPECKS
OR
STREAKS

MOULD
Sprue bush nicked, rough or not
seating correctly
Burned material caused by improper
venting
Contamination caused by grease or
lubricants

Degradation due to malfunctioning

heater bands or thermocouples

Mould too small for machine size

Defective nozzle shutoff mechanism

Gates and runners too small

MATERIAL
Contamination of raw material
Wrong material used for particular
mould
Excessive condensate / lubricants on
the material

Inefficient Injection conditions

Cracked injection cylinder or pitted
screw
Oil leaking into injection unit
Inconsistent process cycle
Injection screw rotation (RPM) too high Mould temperature too low

Use of regrind that is too coarse

Screw back pressure too low

Improper gate location

Use of highly volatile materials

Injection speed too high

Insufficient venting

Excessive moisture

BLISTERS

Inadequate or inconsistent cycle time

Page
Revision

: 2 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

MOULD

Injection fill speed too fast

Melt temperature too high or too low
BLUSH

Injection pressure too low

Nozzle diameter too small
Nozzle temperature too low
Clamp opens too quickly

Temperature too low

Ejector System not level or parallel

Inconsistent mould temperature

Cooling time to short

Improper gate location

Parts not packed properly

Parts mishandled after ejection

BOWING

MATERIAL

Page
Revision

: 3 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

MOULD

Improper injection screw design

Gate and/or runner restrictions

Material too cold

Cycle time too short

Condensation

Excessive moisture in material

Excessive packing
BRITTLENESS

MATERIAL

Material is degraded

Excessive back pressure, screw RPM,

or injection speed
Nozzle too hot
Injection pressure too low

BUBBLES

Injection temperature too high

Improper venting

Injection pressure too low

Section thickness too great

Injection forward time too low

Improper runners or gates

Insufficient material feed

Mould temperature too low

Improper injection temperature profile

Excessive injection speed
Insufficient back pressure

Excessive moisture

Page
Revision

: 4 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

MATERIAL

Excessive injection speed or pressure

Improper venting (size or location)

Excessive regrind use

Excessive back pressure

Vents plugged or peened shut

Flow too low

Screw speed too high

Improper gating (size or location)

Excessive lubricant

Improper compression ratio of screw

BURN MARKS

MOULD

Faulty temperature controllers

Nozzle too hot
Excessive barrel temperatures
Nozzle diameter too small
Inadequate or inconsistent cycle time

Use of regrind that is too coarse

Page
Revision

: 5 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

MOULD

MATERIAL

Barrel temperatures too low

Excessive regrind use

Back pressure too low

Use of regrind that is too coarse

Screw speed too low

CLEAR SPOTS
Improper compression ratio of screw
Faulty temperature controllers
Inadequate or inconsistent cycle time

CLOUDY
APPEARANCE

Barrel temperature too low

Uneven packing

Back pressure too low

Dull finish on mould surface

Screw speed too low

Poor mould temperature control

Excessive moisture

Excessive wear between screw and

barrel
Inadequate or inconsistent cycle time
Oil leaks and grease drips

Excessive lubrication

Improper regrind usage

CONTAMINATION
Poor housekeeping

Excessive moisture

Page
Revision

: 6 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

CRACKING

CRAZING

MOULD

MATERIAL

Moulded in stresses

Excessive lubrication

Improper regrind usage

Cooling cycle to short

Insufficient draft allowance

Excessive moisture

Inadequate or inconsistent cycle time

Improper ejection

Moulded in stresses

Excessive gate size

Contaminated material

Cycle time too short

Mould temperature too low

Excessive moisture

Inadequate injection speed and/or

time

Contaminated mould surfaces

Injection barrel temperatures too high

Improper ejection

Injection speed too low

Mould temperature too low

Contaminated regrind

Inadequate injection cushion

Sharp gate and runner corners

Use of regrind that is too coarse

njection hold time too short

Excessive mould release

Foreign materials and/or additives

DELAMINATION

Barrel temperatures too low

Excessive moisture

Page
Revision

: 7 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

DISCOLOURATION

MOULD

Excessive shot size ratio

Improper mould temperature

Excessive residence time

Inefficient cooling

Barrel temperatures too high

Inadequate venting

MATERIAL
Contaminated material

Nozzle temperature too high

Excessive cycle time
Improper screw design
Excessive or inconsistent cycle time

FLASH

Excessive injection pressure

Improper split line seal

Excessive residence time

Inadequate mould supports

Barrel temperatures too high

Inadequate venting

Excessive cycle time

Sprue bushing too long

Inadequate clamp pressure

Excessive mould lubricant

Page
Revision

: 8 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

MOULD

MATERIAL

Inadequate injection pressure

Inadequate residence time
FLOW LINES

Barrel temperature too low

Nozzle temperature too low
Inconsistent cycle time
Inadequate injection pressure

Mould temperature too low

Improper flow rate

Inadequate residence time

Gates or runners too small

Inadequate lubrication

Barrel temperatures too low

Improper gate location

Excessive moisture content

Nozzle temperature too low

Inadequate venting

Excessive feed cushion

Inadequate polishing of mould surfaces

Injection Speed too low

Contaminated moulding surfaces

GLOSS (LOW)

Nozzle bore too small

Inadequate or inconsistent cycle time

Page
Revision

: 9 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

MOULD

Excessive injection speed

Mould temperature too low

Barrel temperature too high or too low

Gates or runners too small

Nozzle opening too small

Improper gate location

nadequate nozzle temperature

Excessive gate land length

Barrel temperatures too low

Mould temperature to low

Inadequate back pressure

Gates or runners too small

Injection pressure or speed too low

Improper gate location

MATERIAL
Improper flow rate

JETTING

mproper flow rate

KNIT LINES

Excessive gate land length

SHRINKAGE

Barrel temperatures too high

Mould temperature too high

Insufficient injection pressure or time

Gates or runners too small

Inadequate cooling time

Improper gate location

Insufficient cushion and/or hold time

Excessive gate land length

Faulty check valve

Improper flow rate

Page
Revision

: 10 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

NON-FILL (SHORT
SHOTS)

MOULD

MATERIAL

Insufficient material feed

Mould temperature too low

Improper flow rate

Barrel temperatures too low

Gates or runners too small

Excessive regrind

Faulty check ring

Improper gate location

Use of regrind that is too coarse

nadequate back pressure

Insufficient venting

Excessive moisture content

Nozzle too small

Wall section too thin

Non-uniform granule size

Injection pressure or speed too low

Sprue bushing too long

Insufficient injection time

Runner diameter too small

Excessive feed cushion

Sprue diameter too small

Excessive non-return valve clearance

Bridging in feed throat
Insufficient press capacity

Page
Revision

: 11 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

SINK MARKS

MOULD

MATERIAL

Barrel temperatures too high

Mould temperature too high opposite

ribs

Improper flow rate

Insufficient injection pressure or time

Gates or runners too small

Excessive regrind use

Inadequate cooling time

Improper gate location

Use of regrind that is too coarse

nsufficient cushion and/or hold time

Excessive gate land length

Faulty check valve

Excessive rib thickness

Trapped air or gases
Unbalanced flow pattern

SPLAY / SPLASH
MARKS

Barrel temperatures too high

Gate too small

Excessive moisture

Excessive screw rotation speed (RPM)

Obstruction in gate or runner

Contaminated material

Nozzle too small, too hot, or

obstructed

Cracks in mould

Excessive shot size

Trapped air or gases
Improper purging

Page
Revision

: 12 / 12
: 001

Rev. Date

: Sept 2014

INJECTION MOULDING TROUBLESHOOTING GUIDE

CAUSE
PROBLEM
MACHINE

WARPAGE

MOULD

Inadequate injection pressure or time

Mould temperature too low

Inadequate residence time

Gates or runners too small

Barrel temperature too low

Improper gate location

Nozzle temperature too low

Uneven mould temperatures

nadequate cycle time

Non-uniform ejection

MATERIAL
Improper flow rate

Lack of cushion under packing

Excessive stress buildup

This information and our technical advice - whether verbal, in writing or by way of trials - is given in good faith but without warranty, and this also applies where
proprietary rights of third parties are involved. Our advice does not release you from the obligation to verify the information currently provided - especially that
contained in our safety data and technical information sheets - and to test our products as to their suitability for the intended processes and uses. The
application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and,
therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery.
Test Values: Unless specified to the contrary, the values given have been established on standardized test specimens at room temperature. The figures should
be regarded as guide values only and not as binding minimum values. Kindly note that, under certain conditions, the properties can be affected to a considerable
extent by the design of the mould/ die, the processing conditions and the colouring.