Shop-Floor Defect Atlas & Troubleshooting Matrix

Calendering

Visual Symptoms Small, hard cured rubber particles embedded into the continuous calendered sheet surface.

Root Causes Stagnant material trapping in roll nips or dead zones, leading to localized curing over time.

Corrective Actions Clean roll nips regularly, eliminate material stagnation pockets, and optimize compound scorch safety.

Extrusion

Visual Symptoms Rough, matte, or alligator-skin surface texture on high-speed extruded profiles.

Root Causes Excessive shear stress at the die exit, low extrusion temperature, or poor die land lubrication/design.

Corrective Actions Increase die temperature, streamline die entry angle, and apply approved processing aids or external lubricants.

Tyre Building

Visual Symptoms Sidewall rubber component overlaps too high on the tread or leaves the carcass exposed near the lower bead.

Root Causes Misaligned sidewall applicators, incorrect drum width settings, or operator positioning error.

Corrective Actions Calibrate automated sidewall application guides and establish strict visual alignment marks on drums.

Extrusion

Visual Symptoms Sponge-like texture or tiny pinholes visible along the surface of the extruded profile cross-section.

Root Causes Moisture trapped in fillers or synthetic polymers, inadequate compound warm-up, or vacuum hopper failure.

Corrective Actions Dry hygroscopic compounding ingredients, pre-heat/dry masterbatches, and check vacuum pump efficiency on the extruder.

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