Common Issues in Flooring Extrusion Machines and How to Solve Them

Flooring extrusion lines—whether for SPC, WPC, LVT, or PVC products—are complex systems that require coordinated performance across feeding, extrusion, cooling, hauling, cutting, and stacking. Even high-quality machines can encounter issues after long-term operation or improper parameter settings. Understanding these common problems and knowing how to troubleshoot them will help manufacturers improve product quality, reduce downtime, and increase overall efficiency.

Below are the most frequent issues seen in flooring extrusion production—and practical solutions you can apply immediately.

1. Unstable Extrusion Output

Symptoms:

Fluctuating extrusion pressure

Inconsistent product thickness

Visible waves or uneven surfaces

Possible Causes & Solutions:

✔ Feeding inconsistency – Check hopper level, dryness of materials, and stability of the feeding system. Ensure the metering feeder is calibrated.

✔ Screw wear – Worn screws reduce plasticizing efficiency; replace or repair them.

✔ Temperature settings incorrect – Optimize barrel temperature from feeding zone to die head to maintain stable melt flow.

2. Poor Plasticizing or Incomplete Fusion

Symptoms:

Bubbles inside the board

White spots or unmelted particles

Weak mechanical strength

Solutions:

✔ Increase barrel temperatures to improve melting.

✔ Reduce feeding speed if the material is not melting sufficiently.

✔ Check CaCO₃ ratio and additives—excess filler can cause poor fusion.

✔ Inspect screw design—low-quality or unsuitable screw profiles reduce plasticizing performance.

3. Product Thickness Variation

Symptoms:

Thickness too thick or too thin

Left–right asymmetry

Frequent thickness fluctuation

Solutions:

✔ Check die head bolts—ensure even fastening and proper die lip opening.

✔ Stabilize melt pressure with proper temperature control and screw speed.

✔ Ensure calender rollers are aligned; adjust leveling screws or hydraulic system.

✔ Keep automatic thickness gauge calibrated for lines equipped with auto-control systems.

4. Surface Defects (Scratches, Impurities, Fish-Scale Pattern)

Symptoms:

Scratches on SPC/WPC base layer

Foreign particles or black dots

Wavy “fish-scale” surface

Solutions:

✔ Clean die head and filter mesh to remove degraded material.

✔ Check cooling roller surfaces for dirt or metal burrs.

✔ Prevent dust contamination around the extrusion line.

✔ Replace old sealing rings in the extrusion system to avoid leaking burnt resin.

5. Warping or Poor Dimensional Stability

Symptoms:

Boards curl or warp after cooling

LVT layers shrink

SPC tiles not flat

Solutions:

✔ Ensure uniform roller temperature—uneven cooling creates stress.

✔ Optimize raw material formula; excessive CaCO₃ can lead to shrinkage.

✔ Reduce traction speed to avoid internal tension.

✔ Dry materials properly—moisture causes deformation.

6. Low Production Output

Symptoms:

Lower throughput compared to rated capacity

Increased energy consumption per ton

Solutions:

✔ Inspect screw and barrel wear—major cause of output loss.

✔ Optimize temperature settings for faster plastification.

✔ Ensure feeder output matches extrusion capacity.

✔ Clean vacuum chamber—poor vacuum lowers output and affects quality.

7. Frequent Die Head Blockage

Symptoms:

Pressure spikes

Melt leakage

Product surface defects

Solutions:

✔ Replace filter screen regularly to prevent contaminants entering the die.

✔ Use high-quality, stable raw materials to minimize impurity build-up.

✔ Increase die temperature slightly to improve melt flow.

✔ Perform scheduled die head cleaning to avoid carbonization.

How to Prevent These Issues in Advance

A well-designed machine from a reliable manufacturer can reduce more than 70% of operational issues.

To maintain stable production:

Use high-configuration equipment with precise temperature control and durable screw designs.

Follow a preventive maintenance plan—check gearboxes, lubrication, heaters, and sensors regularly.

Train operators on process parameters and troubleshooting skills.

Choose equipment with strong after-sales support for fast problem resolution.

Why Choose SKY WIN / Saivon Extrusion Lines?

SKY WIN provides high-configuration, high-quality extrusion equipment with:

20+ years of industry experience

Advanced screw and die design

Stable temperature & pressure control

Reliable electronics from international brands

Strong global installation and after-sales service

Our SPC, WPC, LVT, and PVC wall panel extrusion lines are widely used in more than 40 countries and trusted for their consistency, durability, and technology advantage.