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Questions and Answers
What is the primary reason for operators not to have music in their ears when running a blown film extrusion machine?
What is the fastest way to stop a line in a safety condition?
Why should the emergency stop not be used as the standard method for stopping the line?
Who is responsible for slowing down the downstream equipment in a manually controlled system when stopping the line?
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What is the recommended approach for stopping the extruders under non-emergency conditions?
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Why is it important to clear any unwanted film or excess polymer from the outside of the machine before restarting?
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In a fully automated system, what happens when the extrusion rate is slowed down to zero?
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What should operators do if they need to stop a line under non-emergency conditions?
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What is one potential consequence of using an emergency stop as a standard method for stopping the line?
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What should be done after slowing down all components of a blown film extrusion machine?
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Study Notes
Pre-Startup Preparations
- Avoid overheating the material inside the extruders or die, which can cause partial decomposition and produce carbons that can take a long time to clear.
- Warm up the gearbox oil by slowly running the nip rollers, winders, and oscillating nips for 30 minutes before starting production.
- Use this time to test the open/close functions of the primary and secondary nips, and ensure the web handling motors are warm.
Equipment Preparation
- Ensure cooling systems are up and running, with water temperature between 40 and 50°F (4-10°C).
- Check that blenders are ready to operate, with all electro-mechanical devices functioning properly.
- Prepare the air ring by allowing time for the heating die to soften any solid material, then clean the air ring and IBC cooling openings of leftover resin and silicone grease.
Startup Procedures
- Don't start the oscillating die until the line is running stable, which can take 30-60 minutes after startup.
- Listen to the line and pay attention to the sounds of the motors, as sudden changes can indicate potential problems.
- Avoid using music with earbuds while running the line, and instead use hearing protection to allow for awareness of changes in the machine's sound.
Stopping the Line
- Use the emergency stop only in safety-critical conditions, and instead slow down the extrusion rate to zero over a minute or two under normal conditions.
- Slow down the downstream equipment, including the nips, winders, air ring, and IBC, before stopping the line.
- Clear any unwanted film or excess polymer from the outside of the machine before restarting.
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Description
Learn about the importance of cleaning air ring and IBC cooling openings from left-over resin and silicone grease. Understand the significance of proper positioning and adjustment of air ring and IBC for production efficiency.
