Extrusion & Post
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Unstable output/surging in general-purpose polyethylene extrusion process
Problem Phenomenon
The extruder output is sometimes more and sometimes less, the extrudate is uneven in thickness, and periodic surging occurs.
Unstable output directly affects the dimensional accuracy and quality consistency of the product.
Cause Analysis
（1）The conveying of the screw feeding section is unstable, and the solid bed breaks
（2）The hopper feeding is not smooth, and the raw material bridges
（3）The barrel temperature is improperly set, and the feeding section temperature is too high or too low
（4）The screw speed fluctuates
（5）The raw material particle size is uneven or contains too much powder
Solution
（1）Optimize the barrel temperature distribution, and appropriately lower the feeding section temperature to prevent premature melting
（2）Install a vibrator on the hopper to prevent bridging and ensure continuous feeding
（3）Reasonably set the temperature of each section of the barrel to ensure it is within the range of 160-260°C
（4）Check the extruder drive system and stabilize the screw speed
（5）Control the uniformity of the raw material particles, and the powder ratio should not exceed 5%
Key Takeaway
Unstable output is caused by unstable solids conveying, and the barrel temperature and feeding system need to be optimized.
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