Shop-Floor Defect Atlas & Troubleshooting Matrix

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.

Extrusion

Visual Symptoms Periodic thickness variation along the length of the extruded rubber strip or tube.

Root Causes Inconsistent feed stock feeding into the screw throat, pressure fluctuation in the gear pump, or screw slippage.

Corrective Actions Ensure uniform strip feeding via belt conveyors, inspect feed roller pressure, and calibrate extruder drive motor controllers.

Extrusion

Visual Symptoms Wavy, distorted edges or micro-cracks along the profile width during extrusion run.

Root Causes Die temperature unevenly controlled, excessive extrusion speed, or low Mooney viscosity batch stock.

Corrective Actions Calibrate zone heating elements on the extruder head, adjust screw speed, and check compound scorch safety.

Curing

Visual Symptoms Deep indentations, rubber-filled vent holes, or gas pockets trapped on the outer tread pattern surface.

Root Causes Vents clogged with release agent or rubber debris, or excessive moisture/volatiles in the green compound.

Corrective Actions Establish a routine mold cleaning and vent wire-cleaning schedule, and check green stock storage humidity.

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