Material Analysis
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Large Performance Differences Between Different Batches of High-Density Polyethylene Raw Material
Problem Phenomenon
After changing the raw material batch number, the product shows dimensional deviations, appearance changes, or performance fluctuations.
Different batches of raw materials differ in melt flow rate, density, molecular weight distribution, etc., causing the process parameters to be readjusted.
Cause Analysis
(1) The melt flow rate (MFR) of different batches of raw materials fluctuates
(2) Different batches of raw materials differ in molecular weight distribution and crystallinity
(3) The raw material supplier changes or the production process is adjusted
(4) The storage conditions and time of the raw materials are different, and the performance changes
(5) The content of additives (such as antioxidants, lubricants) differs
Solution
(1) After each batch of raw material arrives, test key indicators such as MFR and density, and compare them with standard values
(2) Establish a batch management system; use different batches of raw materials separately, and mix batches when necessary
(3) When changing the batch number, adjust the process parameters, and conduct mold trial verification before production
(4) Communicate with the supplier and require controlling the performance fluctuation range between batches
(5) Use raw materials first in first out to avoid storing them for too long
Key Takeaway
Batch differences are caused by raw material production fluctuations, and a sound incoming inspection and batch management system needs to be established.
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