Rauwendaal Extrusion engineering, Inc.
Rauwendaal Extrusion Engineering, Inc. 530.269.1082

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Troubleshooting Extrusion Seminar
by Chris Rauwendaal

November 15-16, 2017
Sheraton Sand Key Resort
Clearwater Beach, FL
Phone: 727-595-1611


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About the Seminar
This seminar is designed to enhance troubleshooting skills of extrusion personnel.  Extrusion problems can be very costly and it is important to troubleshoot these problems quickly, efficiently, and systematically.  The first part of the seminar covers the basic requirements for efficient troubleshooting followed by a description of useful troubleshooting tools.  The next session teaches various techniques such as brainstorming sessions, flow charts, fishbone diagrams that encourage systematic troubleshooting.  Various machine related problems are discussed in this session.

The following session deals with polymer degradation.  First the basic types of degradation are explained followed by specific measures one can take to reduce degradation in the extrusion process.  The remainder of the seminar deals with actual extrusion problems.  Extrusion instabilities are broken down in specific categories based on frequency.  By identifying the specific category the list of possible causes can be reduced significantly.  Each instability is discussed in detail with various possible solutions.  Die flow problems are discussed in depth with solutions to each type of die flow problem.

In the end several case studies of actual extrusion problems will be covered.  Attendees are encouraged to bring actual problems to the seminar so that real problems can be addressed in the seminar.  Attendees will be asked to submit actual extrusion problems to the instructor before the seminar so that these problems can be incorporated in the presentation and the handout material.  Finally, there will be a demonstration of computer software to aid in troubleshooting extrusion problems.

Testimonials from previous seminars

Seminar Hours, Cancellation Policy, Location and Accomodation

Course Description

1. Requirements for efficient troubleshooting
• Instrumentation
• Understanding the process
• Collection of historical data.
• Condition of the equipment
• Information on the feedstock 

2. Tools for troubleshooting

• Temperature measurement devices
• Data acquisition systems
• Microscopy
• Thermochromic materials
• Thermal analysis
       * DTA and DSC
       * TGA
       * FTIR
       * TMA
       * Torque rheometer
       * Other thermal characterization

3. Systematic troubleshooting
• Upsets versus development problems
• Troubleshooting techniques
       * Brainstorming sessions
       * Flow charts
       * Fishbone diagrams
• Machine related problems
       * The drive system
       * The feed system
       * The heating and cooling system
       * Wear problems
• Screw binding
       * Mechanism of screw binding
       * Solving screw binding problems

4. Polymer degradation
• Thermal degradation
• Mechanical degradation
• Chemical degradation
• Effect temperature and residence time
• Melt temperatures in extrusion
• Residence times in extrusion
• Solving degradation problems 

Books authored by Chris Rauwendaal:

  • Understanding Extrusion
  • Polymer Extrusion
  • Troubleshooting the Extrusion Process
  • SPC in Injection Molding and Extrusion
  • Polymer Mixing
  • Mixing in Polymer Processing

When ordering books from Hanser Publications use the code RAU2014 for a 25% discount.


Course Description (continued)

5. Extrusion instabilities
• Frequency of instability
       * High frequency instabilities
       *  Screw frequency instabilities
       * Low frequency instabilities
       * Very slow fluctuations
       * Random fluctuations
• Functional instabilities
       * Solids conveying problems
       * Melting related problems
       * Melt conveying problems
       * Mixing related instabilities
• Solving extrusion instabilities 

6. Air entrapment
• Mechanism of air entrapment 
• Avoiding air entrapment
• Removing entrapped air 

7. Gel problems
• How and where gels can be produced
• Gels created in polymerization
• Gels created in the extrusion process
• How to measure gels
• Solving gel problems 

8. Die flow problems
• Melt fracture
• Die lip buildup
• V- or W-patterns
• Specks and discoloration
• Die lines and weld lines
• Solving die flow problem

9. Various Extrusion Operations
• Troubleshooting blown film extrusion
• Troubleshooting sheet extrusion
• Troubleshooting tubing & pipe extrusion
• Troubleshooting profile extrusion

10. Case studies
Attendees are encourage d to bring actual extrusion problems to the seminar for a hands-on application of the material presented 

The book “Troubleshooting the Extrusion Process” will be available from Hanser Publication website search for rauwendaal.

When ordering books from Hanser Publications use the code RAU2014 for a 25% discount.