BLACK SPECKS

sensitive (like PVC). It is not a good

idea to empty the barrel for every shot
because more time will be required to
bring the next mass of material up to
proper heat and degradation may occur.
TRAPPED MATERIAL

BlSpeck
Black specks can be defined as small
dark particles or spots
on the surface of an opaque injection
molding part or within a transparent
part.
MACHINE
EXCESSIVE RESIDENCE TIME IN
BARREL
Explanation: Under the best conditions,
a shot size should represent 50% of the
capacity of the injection cylinder (barrel).
This will result in processing the
material for one cycle while preparing
the material for the next cycle. Thus, a
mold requiring a four-ounce shot should
be run in a machine that has a barrel
with an eight-ounce capacity. The more
material left in the barrel between shots,
the greater the likelihood of thermal
degradation. This degradation is what
causes the black specks.
Solution: Strive for a 50% shot-to-barrel
ratio. This is ideal but can go as low as
20%, if the material is not too heat
sensitive (like polypropylene) and up to
80% if the material is extremely heat

Explanation: If any molten resin is

trapped along the flow path (most
notably in the heating cylinder), it will
stay there until it degrades. When this
happens, the degraded material becomes
carbonized, then chars and becomes
brittle. At that point, it will flake away
from the area of entrapment and enter
the melt stream appearing as black
specks or streaks.
Solution: Inspect the barrel liner, nozzle,
non-return valve, and check ring for
nicks, cracks, rough surfaces, peeled
plating or stuck resin. Then, stone and
polish as required, replace any damaged
mechanisms, and inspect the main and
secondary runners, as well as the sprue
bushing, for nicks, rough surfaces or
sharp corners. Round off sharp corners
and radius corners where possible to
minimize material trapping and shear
points.
CONTAMINATION IN INJECTION
BARREL
Explanation: Any type of contamination
in the injection barrel may be the cause
of streaks, spots, and specks. It may be
in the form of dust particles that fell
from the ceiling into an open hopper,
pellets from other materials, residual
resin from an improper changeover, or
even pieces of food that accidentally fell

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into a container of material ready to be

placed in the hopper.

loose and enters the melt stream,

appearing as specks or streaks.

Solution: To remove this type of

contamination it may be necessary to
increase the temperature of the injection
barrel and, using a purging material with
a wide melt range, purge the
contaminate(s) from the system.

Solution: Inspect the injection unit for

cracks and nicks in the walls. Sometimes
damaged cylinder walls can be welded
but it is usually more effective to replace
the cylinder liner. Pitted screws must be
welded, ground and replated, or replaced
with new stock.

UNCONTROLLED HEATER BANDS

OR THERMOCOUPLES
Explanation: Improperly sized or loose
heater bands or thermocouples can cause
localized degradation of the material by
exposing it to extreme heat. They may
be calling for more heat than normal due
to malfunction or improper sizing. Even
a heater band that is not working can be
the cause of such overheating. The
reason is that adjacent heater bands must
increase heat to compensate for the
nonworking band.
Solution: Check each heat zone to
ensure that all heater bands are working
properly, are properly controlled,
properly sized, and are tight against the
barrel. A conductive sealant should be
used to ensure full contact with the
barrel. Be sure to replace bands with the
proper size, voltage, and wattage
requirements as stated in the machine
manual.
DAMAGED BARREL OR SCREW
Explanation: A cracked injection
cylinder or pitted screw is a cause of
material hang-up and degradation.
Eventually this degraded material breaks

OIL LEAKS
Explanation: Hydraulic components or
fittings that are in the proximity of the
injection cylinder may leak. This
leakage may get into raw material
storage containers and find its way into
the material hopper. The oil will burn at
the temperatures needed for molding and
will degrade and char. This degraded
material is a source for streaks and
specks.
Solution: Eliminate all hydraulic leaks
as soon as possible after they occur.
MOLD
SPRUE BUSHING IS NICKED,
ROUGH, OR NOT SEATING
Explanation: A damaged sprue may
cause material to stick and be held in
residence at elevated temperature until it
degrades and decomposes. At that point,
it will break loose and enter the melt
stream as streaks or specks.
Solution: Inspect the internal surfaces of
the sprue bushing. Remove any nicks or
other imperfections. The tapered hole
should be highly polished. Check the
sprue bushing-to-nozzle seal with thin

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paper or bluing ink to ensure that the

nozzle is centered to the bushing and
that the hole and radius dimensions are
compatible for the nozzle and the
bushing.
IMPROPER VENTING
Explanation: Air is trapped in a closed
mold and incoming molten plastic will
compress this air until it auto-ignites.
This burns the surrounding plastic and
results in charred material in the form of
spots and specks.
Solution: Vent the mold by grinding thin
(0.0005-0.002) pathways on the
shutoff area of the cavity blocks. Vents
should take up a minimum of 30% of the
perimeter of the molded part. Vent the
runner, too. Any air that is trapped in the
runner will be pushed into the part.
CONTAMINATION FROM
LUBRICANTS
Explanation: Excessive use of mold
release will clog vents. The trapped air
cannot be evacuated and burns. Also,
grease that is used for lubricating cams,
slides, ejector pins, etc., can seep into
the mold cavity and contaminate the
molded part.
Solution: The remedy is to keep the
mold as clean as possible and clean the
vents if they become clogged. A white
ash will be present if the vents are
clogged. Also, make every effort to
eliminate the use of external mold
releases.
MOLD TOO SMALL FOR MACHINE
SIZE

Explanation: If the mold is placed in too

large of a machine, the chances are that
the heating cylinder of that machine will
be large enough to result in extensive
residence time of the raw material in the
heated cylinder. This will result in
degraded material that will be injected
into the mold causing streaks and
specks.
Solution: Place all molds in properly
sized machinery. A rule-of-thumb states
that the machine should inject between
20% and 80% of its capacity every shot.
MATERIAL
CONTAMINATED RAW MATERIAL
Explanation: The most common causes
of black specks and streaks are molding
compound contaminants. Such
contamination is usually the result of
dirty regrind, improperly cleaned
hoppers or granulators, open or
uncovered material containers, and poor
quality virgin material supplied by the
manufacturer.
Solution: This type of contamination can
be minimized by dealing with high
quality, reputable suppliers and by using
good housekeeping practices. Properly
trained material handlers will also help
reduce contamination.
OPERATOR
INCONSISTENT PROCESS CYCLE
Explanation: It is possible that the
machine operator is the cause of delayed
or inconsistent cycles. This will result in

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excessive residence time of the material

in the injection barrel. If such a
condition exists, heat sensitive materials
will degrade, resulting in black specks or
streaks.
Solution: If at all possible, run the
machine on automatic cycle, using the
operator only to interrupt the cycle if an
emergency occurs. Use a robot if an
operator is really necessary. And,
instruct all employees on the importance
of maintaining consistent cycles.

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