1、 Problem: Poor puffiness (the product is too soft or too hard, not fluffy)
Phenomenon: The product density is too high and it becomes hard; Or it may be too soft and have poor structural support.
Possible reasons and solutions:
Improper moisture content in raw materials
Inspection: Check whether the initial moisture content of the raw materials is within the required range of the process.
Solution: If it is too high, reduce the amount of water/steam added; If it is too low, increase it appropriately. When using a pre conditioner, it is necessary to ensure stable addition of steam and water.
Insufficient temperature and pressure
Inspection: Check if the expansion chamber temperature and mold head temperature have reached the set values.
Solution: Appropriately increase the amount of steam added, raise the heater temperature, or adjust the screw combination to increase the pressure and temperature inside the chamber.
Screw wear
Inspection: Check whether the screw components, especially the conveying sleeve and kneading block, are severely worn. Wear and tear can lead to insufficient pushing force, as well as inability to increase pressure and temperature.
Solution: Replace worn screw components.
Mold head issue
Check whether the mold hole is blocked or excessively worn.
Solution: Clean the mold holes or replace the template with a new one. The opening area of the new template will affect the back pressure.
2、 Problem: The product has irregular shape, roughness, and broken strips
Phenomenon: After the product is molded, it is not a smooth cylinder/block, with a rough surface, cracks, and easy breakage.
Possible reasons and solutions:
Low moisture content in raw materials
Inspection: The material is too dry.
Solution: Increase the moisture content in the raw materials or conditioner appropriately to make the material more plastic.
Uneven temperature of the mold head
Inspection: The local temperature of the mold head is too high or too low.
Solution: Check if the heating ring of the mold head is working properly to ensure that the overall temperature of the mold head is uniform.
Blockage or wear of the mold head
Inspection: Some mold holes are blocked, resulting in inconsistent discharge speeds; Or the inner wall of the mold hole is worn and rough.
Solution: Stop the machine to clean the mold head and use a special tool to pass through the hole. The template needs to be replaced due to severe wear and tear.
Cutter issue
Inspection: The cutting blade is worn, loose, or has improper rotation speed.
Solution: Tighten or replace the blade, adjust the cutting speed to match the discharge speed.
3、 Problem: The host current is too high (overload)
Phenomenon: If the displayed value of the main motor ammeter continues to approach or exceed the rated value, it may cause tripping.
Possible reasons and solutions:
Excessive feeding amount
Check if the feeder is set too fast.
Solution: Reduce the feeding frequency appropriately and follow the starting principle of "less first, more later".
Raw material moisture too low/too high
Inspection: If the material is too dry, it will cause a significant increase in friction; Being too wet can form a "sticking cylinder" and increase resistance.
Solution: Adjust the moisture content of the raw materials to the process standard range.
Excessive oil/fiber content in the formula
Inspection: Reviewing the formula, high fat or high fiber will significantly increase the load.
Solution: Optimize the formula or try adding some liquid raw materials during the post conditioning stage.
Mold blockage
Inspection: The mold hole is blocked by foreign objects or carbonized materials, resulting in excessive back pressure.
Solution: Stop the machine immediately and clean the mold head.
Transmission component malfunction
Inspection: Check if the bearings or gearbox are damaged.
Solution: Contact professional maintenance personnel for inspection.
4、 Problem: The host current is too low
Phenomenon: The current of the main motor is much lower than the normal value, and the discharge is weak.
Possible reasons and solutions:
Interruption or insufficient feeding
Check whether the feeder is blocked, empty or set incorrectly.
Solution: Check the silo to ensure smooth feeding and adjust the feeding amount.
Excessive moisture content in raw materials
Inspection: The material is too wet and slippery, slipping in the screw and unable to establish pressure.
Solution: Reduce the moisture content of raw materials.
The screw is severely worn
Inspection: Screw wear leads to a decrease in pushing efficiency.
Solution: Check and replace worn screws.
5、 Problem: Abnormal vibration or noise of the equipment
Phenomenon: During operation, there is a sound of impact, friction, or severe overall vibration.
Possible reasons and solutions:
Foreign objects enter the cavity
Inspection: Hard objects such as metals and stones may be mixed into the raw materials.
Solution: Immediately stop the machine, reverse turn and clean the cavity. Strengthen the cleaning and magnetic separation of raw materials.
Damage to bearings or transmission components
Check: Listen to the source of the sound. If it comes from the gearbox or spindle connection, it may be a bearing or gear problem.
Solution: Stop the machine immediately and contact the manufacturer or professional personnel for maintenance.
Improper assembly or breakage of screws
Inspection: The screw is not installed correctly and there is a gap; Or cracks may appear on the screw shaft.
Solution: Reinstall or replace the damaged screw.
Loose base bolts
Inspection: Check the fixing bolts of the host and its motor.
Solution: Re tighten all anchor bolts.