Shop-Floor Defect Atlas & Troubleshooting Matrix

Oil Bleed / Syneresis in Compound Stock

Mixing

Visual Symptoms Free oil pooling on the surface of mixed slabs or sheets during storage prior to processing.

Root Causes Exceeded liquid plasticizer loading limits, poor absorption by carbon black/fillers, or low structural oil-absorption values.

Corrective Actions Review formula plasticizer-to-filler ratios, switch to higher absorption carbon black grades, and check mixing temperature.

Over-mastication / Low Polymer Molecular Weight

Mixing

Visual Symptoms Extremely soft, tacky compound with reduced tensile strength and elasticity post-mixing.

Root Causes Excessive mixing cycle time, high shear rates, or overheating during the breakdown stage.

Corrective Actions Reduce rotor speed during masterbatch breakdown, monitor energy input (kWh/kg) limits, and optimize dump timing.

Plied-Up Splice Separation / Lifting

Tyre Building

Visual Symptoms Cymbal, innerliner, or sidewall splice lifting or failing to bond securely on the building drum.

Root Causes Contaminated or dusty splice surfaces, low green tack of the rubber compound, or insufficient overlap pressure.

Corrective Actions Enforce clean-room protocols to prevent dust contamination, check tackifier levels in compound, and increase stitcher roller force.

Plied-Up Splice Separation / Lifting

Tyre Building

Visual Symptoms Cymbal, innerliner, or sidewall splice lifting or failing to bond securely on the building drum.

Root Causes Contaminated or dusty splice surfaces, low green tack of the rubber compound, or insufficient overlap pressure.

Corrective Actions Enforce clean-room protocols to prevent dust contamination, check tackifier levels in compound, and increase stitcher roller force.

Shop-Floor Defect Atlas & Troubleshooting Matrix

Oil Bleed / Syneresis in Compound Stock

Over-mastication / Low Polymer Molecular Weight

Plied-Up Splice Separation / Lifting

Plied-Up Splice Separation / Lifting

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