Plastic products processing is widely used in today's society, and the scrap rate directly affects the economic benefits and resource utilization of enterprises. Reducing the scrap rate can not only improve product quality, but also reduce material waste and production costs.
Impurity content: The presence of impurities in raw materials will affect the performance of plastics. For example, impurities may cause the fluidity of plastic melts to deteriorate, and local defects such as bubbles and cracks may appear during the injection molding process.
Moisture content: Moisture will cause hydrolysis reaction during plastic processing, reducing the strength and stability of plastics. For example, during the extrusion process, excessive moisture content will cause problems such as roughness and deformation on the surface of plastic extrudates.
Temperature control: Too high or too low temperature will affect the molding of plastics. For example, too high temperature during injection molding will cause the plastic to decompose and carbonize, resulting in problems such as scorch spots and deformation on the product.
Pressure control: Insufficient pressure will lead to incomplete product molding, while excessive pressure may cause flash and deformation of the product. For example, during the injection molding process, excessive pressure will cause the plastic melt to overfill the mold cavity, resulting in a decrease in product dimensional accuracy.
Mold design: The structure, dimensional accuracy and surface quality of the mold have an important impact on the quality of the product. For example, unreasonable design of the mold demoulding slope will make it difficult to demould the product, or even cause demoulding damage; unreasonable design of the mold runner will cause the plastic melt to be unevenly distributed in the mold cavity, resulting in defects.
Equipment wear: Equipment wear will affect the accuracy and quality of the product. For example, the wear of the screw of the injection molding machine will cause uneven plasticization of the plastic melt, thus affecting the molding quality of the product.
Equipment failure: Equipment failure will cause production interruption and increase the scrap rate. For example, failure of the electrical system of the equipment will prevent the equipment from operating normally, affecting the processing of the product.
Select high-quality raw materials: Select raw materials with good performance and stability to ensure that the quality of the raw materials meets the production requirements. For example, select plastic raw materials with high purity and low impurity content.
Inspect the quality of raw materials: Conduct strict inspections on raw materials to ensure that the quality of raw materials meets the standards. For example, test the moisture content and impurity content of raw materials.
Reasonable storage of raw materials: Raw materials should be stored in a dry and well-ventilated environment to avoid moisture and deterioration. For example, store the raw materials in a dry warehouse to prevent them from absorbing moisture.
Formulate reasonable process parameters: Formulate reasonable processing parameters according to the characteristics and requirements of the product. For example, during injection molding, determine the appropriate temperature, pressure and injection speed according to factors such as the type of plastic, the shape and size of the product.
Control temperature: During the processing, strictly control the temperature to ensure the temperature of the plastic melt is stable. For example, the temperature of the plastic melt is controlled by a heating device and a cooling system.
Control pressure: Reasonably control the pressure to ensure the quality of product molding. For example, during the injection molding process, adjust the pressure according to the requirements of the product and the structure of the mold.
Optimize mold design: The mold design should meet the requirements of the product and the characteristics of the production process. For example, the mold demoulding slope and flow channel design should be reasonable to avoid problems such as demoulding difficulties and poor product molding.
Strengthen process management: Strengthen the management of the processing technology to ensure the stability and consistency of the process. For example, regularly check and adjust the process parameters to promptly discover and solve process problems.
Regularly maintain equipment: Regularly maintain the equipment to ensure the normal operation of the equipment. For example, regularly maintain, clean and lubricate the equipment, and replace worn parts in time.
Timely repair equipment failure: When the equipment fails, it should be repaired in time to avoid affecting production. For example, inspect and repair the electrical system and mechanical parts of the equipment to ensure the normal operation of the equipment.
Strengthen equipment management: Strengthen the management of equipment and improve the utilization rate and maintenance level of equipment. For example, establish equipment files, record the operation and maintenance records of the equipment, and regularly inspect and evaluate the equipment.
Establish a quality inspection system: Establish a complete quality inspection system to conduct comprehensive inspection and monitoring of products. For example, conduct appearance inspection, dimensional measurement, physical performance testing, etc. on products.
Strengthen quality inspection: Strengthen the inspection of product quality, and timely discover and solve quality problems. For example, conduct sampling inspection of products, and analyze and deal with unqualified products.
Improve the inspection level: Improve the inspection level to ensure the accuracy and reliability of the inspection results. For example, use advanced inspection equipment and technology to improve inspection efficiency and accuracy.
Through the implementation of the above measures, the scrap rate in plastic products processing can be effectively reduced. In the actual production process, enterprises should pay attention to raw material quality control, optimize processing technology, strengthen equipment maintenance and quality inspection, continuously improve product quality and production efficiency, reduce scrap rate, and achieve sustainable development of the enterprise.
