How to troubleshoot inaccurate proportioning in the mixing system

In the extrusion production process of PVC, PE, and PP plastics, the accuracy of the mixing ratio directly determines the color, toughness, hardness, and stability of the finished product. Many factories often encounter problems such as color difference in finished product batches, brittle products, and numerous surface defects. Repeated adjustments to extrusion parameters have not improved, ultimately resulting in early hidden dangers caused by inaccurate mixing system ratios. As the first process of extrusion production, once the ratio is imbalanced, the subsequent pipe extrusion line and profile production line cannot recover the quality deviation of the finished product even if they are precise. Based on years of equipment debugging and after-sales experience, Beisu Machinery has compiled a set of troubleshooting steps that can be directly implemented in the workshop to help enterprises quickly solve problems with abnormal proportioning.

The main troubleshooting dimensions for inaccurate proportioning in the mixing system

Check the accuracy of the weightlessness measurement feeding system

The vast majority of inaccurate proportioning problems arise in the measurement and feeding process. After long-term continuous production, the weight loss metering and batching system is prone to sensor zero drift, material accumulation and agglomeration at the discharge port, and loose closure of pneumatic valves, resulting in fluctuating amounts of main materials, additives, and calcium powder feeding. During daily inspections in the workshop, it is necessary to regularly calibrate weighing data, clean up clumped materials in the discharge channel, check valve opening and closing sensitivity, and ensure accurate feeding data from the source.

Check the operating status of the high-speed mixer

Accurate measurement does not necessarily mean uniform mixing. Many production lines have normal proportioning data, but the finished products are still unstable, and the problem mostly lies in the mixer. Long term wear of the stirring blade, residual material on the inner wall of the kettle, and unstable rotation speed can all cause uneven local mixing of materials, resulting in the phenomenon of “false ratio”. It is recommended to thoroughly clean the machine at the end of each production shift, regularly check the wear of the mixing blades, and ensure that each batch of materials can be thoroughly mixed to avoid residual materials interfering with the new formula ratio. The high-speed mixing unit equipped with Beisu Machinery adopts anti sticking and wear-resistant design, which can effectively reduce uneven mixing faults.

Verify the production process parameter settings

Artificially changing parameters and mixing formula parameters are high-frequency problems in small and medium-sized workshops. Different materials and formulas of raw materials have different mixing times, heating temperatures, and feeding sequences. Randomly changing parameters and mixing old and new formula parameters can easily lead to insufficient dispersion of additives, significant differences in material plasticization, and ultimately result in unstable product quality. It is recommended to fix the exclusive process formula during production, reset the parameters in a timely manner after material replacement, and avoid human operation errors that may cause mixing deviation.

Investigate the impact of raw materials and workshop environment

Moisture absorption, uneven particle size, and large fluctuations in workshop temperature and humidity can indirectly cause abnormal proportioning of raw materials. Damp materials are prone to clumping and blockage, resulting in insufficient actual feeding amount; Fine powder additives are prone to wall hanging and floating, resulting in high actual losses. Before production, it is necessary to dry and screen the raw materials to maintain a dry and stable workshop environment and reduce the interference of external factors on the accuracy of the mixing system.

Summary of troubleshooting

The proportioning of the mixing system is not accurate. Following the troubleshooting logic of “checking equipment first, then parameters, and finally materials” can quickly locate the fault. Daily equipment calibration, body cleaning, and parameter standardization management can significantly reduce the probability of ratio imbalance and stabilize the product quality of the entire extrusion production line. As a professional manufacturer of extrusion equipment, Beisu Machinery can provide a complete set of technical services such as mixing system calibration, troubleshooting, and process optimization.

FAQ

Q1: What is the most common reason for inaccurate mixing ratio?

A: The main reasons are drift of the weight loss measurement sensor, blockage of material discharge, and uneven mixing of the mixer and improper setting of process parameters.

Q2: How to quickly distinguish between measurement problems or mixed problems?

A: A large deviation in the overall weight of the batch is a measurement malfunction; The weight is normal, but the color difference and physical properties of the finished product are inconsistent, mostly due to uneven mixing.

Q3: Will humid weather affect the accuracy of mixing ratio?

A: Yes, moisture and clumping of raw materials can lead to poor feeding and insufficient feeding, directly causing an imbalance in the ratio and defects in the finished product.

Q4: Does the mixing system need regular calibration?

A: Yes, it is recommended to calibrate the mass production line once a month, and for production lines that frequently change formulas, the calibration frequency should be increased as needed.

Q5: Can Beisu Machinery provide on-site debugging services?

A: Yes, it supports one-stop technical support such as troubleshooting, parameter calibration, and process optimization for the mixing system.

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