07,22,2026 3 views
1、 Standardized operation process of silicone extruder
The operation of silicone extruders must strictly follow the full process specifications of "pre startup inspection, operation control, and post shutdown organization", to prevent illegal operations and reduce equipment loss and product defect rates from the source.
（1） Prepare for inspection before starting up
A comprehensive inspection before startup is the key to avoiding startup failures, covering four dimensions: equipment structure, electrical system, temperature control system, and raw material pretreatment. Firstly, check the overall structure of the equipment, clean the residual rubber, impurities, and metal particles inside the hopper, feeding port, screw, barrel, and mold to prevent impurities from entering the flow channel and causing blockage, frictional heat generation, or scratching of the screw and mold. At the same time, check whether all fixing bolts and transmission components are tightened and free of looseness or offset. Secondly, check the electrical and lubrication systems to ensure that the power lines and wiring terminals are securely connected, the heating coils and thermocouples are not damaged or detached, and the oil level of key transmission parts such as reducers and bearings meets the standard without any oil shortage or leakage issues.
Finally, do a good job in parameter setting and preheating. According to the characteristics of silicone raw materials and product specifications, temperature control parameters for the barrel, head, and mold are set in sections, following the principle of "gradually increasing temperature from the feeding area to the head" to ensure a reasonable temperature gradient in each area. After completing the parameter settings, turn on the preheating mode and preheat at a constant temperature for 30-60 minutes to ensure that the mold and barrel temperatures are uniform and stable, and to prevent uneven product molding and cracking caused by excessive local temperature differences. At the same time, pre treat the silicone raw materials in advance, remove impurities from the raw materials, and ensure that the raw materials are dry and pure.
（2） Startup operation and process control
After preheating is completed, start the machine in the order of "low-speed no-load start-up, gradual feeding, and steady acceleration". First, start the host and run it without load for 3-5 minutes. Observe the operating status of the equipment and confirm that the screw rotates smoothly, without any abnormal noise or jamming, and the pressure is normal. Then slowly open the feeding system and evenly feed the silicone raw material. It is strictly prohibited to add a large amount of materials at once or forcefully add materials, in order to avoid sudden increase in equipment load causing screw jamming and motor overload and burnout.
During the production and operation process, real-time monitoring of equipment parameters and operating status is required. Pay close attention to the temperature controller data. If the temperature in a certain temperature zone rises by more than 10 ℃ within 10 minutes, immediately stop the machine for troubleshooting to prevent high-temperature decomposition of materials and damage to equipment due to overheating; Equipment thermocouples can be added to the machine head to double verify temperature accuracy and ensure product stability during molding. At the same time, observe the extrusion pressure, screw speed, and discharge status. If there is uneven discharge, pressure fluctuations, equipment noise, abnormal vibration, etc., adjust the parameters in a timely manner and prohibit the equipment from running with faults. In addition, pay full attention to the working conditions of the cooling system, check the flow rate of cooling water and the sealing of pipelines, ensure that the material is quickly and evenly cooled after extrusion, and prevent product deformation.
（3） Standardize shutdown operations
It is strictly prohibited to directly shut down the power after production is completed. Standardized shutdown procedures must be followed to reduce equipment wear and tear. Firstly, stop feeding and keep the host running at low speed without load. After the remaining silicone material in the standby cylinder is completely extruded, turn off the power of the host. Then turn off the heating system and keep the cooling system running continuously. After the equipment temperature drops to room temperature, close the cooling water valve and the main power supply. Timely record the operating parameters, production duration, and equipment operating conditions after shutdown, providing data support for subsequent maintenance and fault tracing.
2、 Classification and refinement maintenance system for silicone extruder
The maintenance of silicone extruders should adhere to the principle of "prevention first, combination of prevention and control", establish a graded maintenance system of daily maintenance, weekly maintenance, monthly quarterly maintenance, and annual overhaul, comprehensively covering core links such as cleaning, lubrication, fastening, calibration, and wear detection, effectively extending the service life of equipment and reducing the incidence of failures.
（1） Daily maintenance (performed daily)
Daily maintenance is the foundation for stable operation of equipment, with the core being cleaning, inspection, and basic maintenance. Thoroughly clean the residual silicone on the surface of the hopper, screw, barrel, and mold after daily shutdown to prevent high-temperature carbonization accumulation of residual materials and avoid defects caused by carbide particles mixed into the product during the next production; Use specialized tools and compliant cleaning agents to clean the mold runner, ensuring a smooth and clean runner. Check the status of the heating coil, thermocouple, and liquid level probe, and wipe the material and scale adhered to the surface of the probe with alcohol to ensure accurate temperature and liquid level detection data. At the same time, check whether the equipment pipeline joints and sealing parts are leaking water or oil, tighten loose small bolts, clean the dust and debris on the surface of the equipment, and keep the entire equipment clean.
（2） Weekly maintenance (weekly shutdown execution)
Focus on conducting in-depth cleaning, lubrication, and component inspections every week. Thoroughly clean the cooling water filter, investigate pipeline blockages, check the sealing of pipeline joints, and prevent water leakage and abnormal pressure difference in the cooling system. When the pressure difference between the inlet and outlet of the filter exceeds 0.1 MPa, the filter screen must be thoroughly cleaned. Add lubricating grease to moving parts such as equipment transmission chains, bearings, and reducers, check the smoothness of the lubrication system oil circuit, and avoid dry friction that exacerbates component wear. Carefully inspect the wear of the mold, the polishing degree of the flow channel, check the clearance between the screw operation, and verify the temperature control accuracy of each temperature zone. Timely repair heating components with poor contact or temperature control failure.
（3） Monthly and quarterly maintenance (regular execution)
Monthly maintenance focuses on system condition detection and consumables replacement, checking the condition of gearbox gear oil, replacing suitable gear oil in summer and No. 45 mechanical oil in winter, and timely changing oil according to oil quality to ensure stable operation of the transmission system. Conduct a comprehensive inspection of electrical circuits and insulation performance, identify potential hazards such as aging, peeling, and loose connections, and tighten electrical wiring terminals.
Quarterly maintenance focuses on precise calibration and loss detection, calibrating temperature sensors, pressure instruments, and speed instruments to ensure accurate display of equipment parameters; Check the wear of the screw, and the maximum gap between the screw and the barrel should not exceed 0.3mm. If it exceeds the standard, it should be repaired or replaced in a timely manner; Check the wear and tear of seals and valves, replace aging and ineffective sealing accessories, and prevent leakage and dripping problems. At the same time, comprehensive debugging of the overall operating parameters of the equipment is carried out to optimize the extrusion process parameters.
（4） Annual major maintenance (to be carried out annually)
Conduct a comprehensive overhaul once a year during shutdown, dismantling core components such as screws, barrels, molds, transmission systems, and cooling systems for deep cleaning, rust removal, and polishing. Comprehensively inspect the wear level of core vulnerable parts such as screws, barrels, gears, bearings, etc., and replace parts with excessive wear, deformation, and aging in batches. Re calibrate the levelness and concentricity of the equipment, debug the operating conditions of the entire machine, repair hidden faults of the equipment, complete rust and corrosion prevention treatment of the entire machine, and restore the equipment to its optimal operating state.
3、 Common Fault Prevention and Handling Points
In the daily operation of silicone extruders, high-frequency faults such as discharge fluctuations, product surface stripes, abnormal temperature, and equipment noise are often caused by improper operation and inadequate maintenance. Targeted prevention and solutions are needed.
Fluctuations in extrusion discharge pressure and uneven discharge are mostly caused by uneven feeding, ineffective temperature control, or clogged filter screens. It is necessary to ensure constant and stable feeding, regularly clean the filter screens, and calibrate the temperature control system. If there are stripes or defects on the surface of the product, priority should be given to checking the polishing degree of the mold runner. The polishing level of the mold runner should reach Ra0.2 μ m or above, and scratches and carbon deposits on the runner should be repaired in a timely manner. Abnormal noise and excessive vibration during equipment operation are often caused by lack of oil in transmission components, loose bolts, and stuck screws. It is necessary to promptly add lubricating grease, tighten accessories, and clean foreign objects inside the barrel. When the temperature rises rapidly and abnormally, immediately stop the machine to check the working conditions of the cooling system and heating coil, investigate pipeline blockages and heating coil faults, and avoid material decomposition and equipment damage.
4、 Precautions for safe operation and maintenance
During the operation of the equipment, it is strictly prohibited to insert hands or tools into the hopper, machine head, mold, and other operating and high-temperature areas. It is also prohibited to disassemble equipment components with electricity to prevent safety accidents.
2. All maintenance and repair work must be carried out after shutdown, power off, and cooling down. It is strictly prohibited to disassemble and remove components or clean up debris when the equipment is in a high temperature or live state.
3. Strictly match silicone raw materials with equipment process parameters, prohibit equipment from operating at excessive temperature, pressure, or load, and avoid permanent equipment wear and tear.
4. Establish an equipment maintenance ledger, detailing daily and regular maintenance content, fault conditions, and maintenance records, to achieve full lifecycle management of equipment, facilitating subsequent work condition traceability and operation optimization.
