Material Analysis
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Large performance differences between different batches of random copolymer polypropylene raw material
Problem Phenomenon
After changing the raw material batch, products show dimensional deviations, appearance changes or performance fluctuations.
Different batches of raw material differ in melt flow rate, density, molecular weight distribution, etc., requiring process parameters to be readjusted.
Cause Analysis
(1) The melt flow rate (MFR) of different batches of raw material fluctuates
(2) Different batches of raw material differ in molecular weight distribution and crystallinity
(3) Raw material supplier changes or production process adjustments
(4) Raw material storage conditions and time differ, and performance changes
(5) Additive (such as antioxidants, lubricants) content differs
Solution
(1) Test key indicators such as MFR and density for each batch of raw material upon arrival and compare with standard values
(2) Establish a batch management system, using different batches of raw material separately, and mixing batches if necessary
(3) Adjust process parameters when changing batches, conducting mold trial verification before production
(4) Communicate with the supplier, requiring control of the batch-to-batch performance fluctuation range
(5) Use raw materials on a first-in, first-out basis to avoid excessive storage time
Key Takeaway
Batch differences are caused by raw material production fluctuations; a complete incoming material inspection and batch management system needs to be established.
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