Below are the most frequent problems reported in UAE markets—and how Vishwakarma Plast provides engineered solutions.

1. Wear & Tear Due to Abrasive Materials

The Problem

UAE processors often use polymers with glass-filled compounds, flame-retardant additives, or recycled material. These cause:

• Barrel internal wear
  
• Screw flight abrasion
  
• Loss of compression ratio
  
• Reduction in shot size consistency
  

Vishwakarma Plast Solution

Our Injection Screw & Barrel Sets are manufactured using:

• EN41B nitriding alloy steel
  
• High-wear bimetallic barrel liners
  
• Hardfacing on screw flights (Colmonoy coatings)
  
• Advanced CNC hard-turning for perfect surface finish
  

These metallurgical upgrades significantly increase wear resistance, ensuring long service life in Dubai, Sharjah, and Al Nahda operations.

2. Material Flow Issues & Poor Plasticization

The Problem

Irregular melt flow, incomplete melting, or inconsistent output typically stem from:

• Worn metering section
  
• Poor screw design for polymer type
  
• Incorrect channel depth
  

Vishwakarma Plast Solution

Our team designs OEM-compatible and polymer-specific screw geometries, optimized using:

• 3-stage profiles (feeding–compression–metering)
  
• Precisely calculated channel depth
  
• Matching L/D ratios
  
• Improved back pressure handling
  

This ensures smoother plasticization and uniform melt flow—critical for high-speed molding in Jebel Ali and Ras Al Khaimah.

3. Compression Ratio Problems

The Problem

An incorrect compression ratio can cause:

• Burn marks
  
• Silver streaks
  
• Overheating
  
• Increased melt temperature
  
• Poor homogenization
  
  

Vishwakarma Plast Solution

We customize compression ratios based on UAE polymer usage:

• PP, PE → Low compression screws
  
• ABS, PS → General purpose screws
  
• PA, PC, PBT → High compression screws
  

Our Custom Screw & Barrel Manufacturer India facility uses CNC machining, deep-hole boring, and heat treatment to ensure accuracy up to ±0.02 mm.

4. Temperature Imbalance in Barrel Zones

The Problem

When heaters and thermocouples fail or the barrel metal is fatigued, this results in:

• Overheating in metering zone
  
• Cold slug formation
  
• Increased part weight variation
  

Vishwakarma Plast Solution

We engineer barrels with:

• Uniform wall thickness
  
• High thermal stability steels
  
• Polished internal surfaces for better heat transfer
  

This design helps maintain stable temperatures in high-demand operations in Abu Dhabi and Al Ain.

5. Feeding–Melting–Metering Inconsistencies

The Problem

If any of the three zones underperform, processors face:

• Short shots
  
• Overpacked parts
  
• Higher cycle time
  
• Output fluctuations
  

Vishwakarma Plast Solution

Our optimized screw profile ensures:

• Efficient solid conveying
  
• Rapid melting without thermal degradation
  
• Stable metering and backpressure balance
  

Processors across Al Nahda rely on these designs to maintain consistent productivity.

6. Bimetallic vs Nitrided – Confusion in Selection

The Problem

Many UAE buyers struggle to choose between:

• Nitrided Barrel (cost-effective, general-purpose)
  
• Bimetallic Barrel (premium, long-life, abrasive-resistant)
  

Vishwakarma Plast Solution

We guide UAE clients on the ideal configuration:

We also supply hybrid solutions such as bimetallic barrel + nitrided screw to balance cost and longevity.

7. Corrosion & Chemical Attack

The Problem

PVC, flame-retardants, and halogenated additives create internal corrosion.

Vishwakarma Plast Solution

We manufacture screws and barrels using:

• Corrosion-resistant alloys
  
• Hard chrome plating
  
• Specialty bimetallic liners
  

This ensures long-term reliability for processors from Ajman to Dubai.

8. Output Variations & Inconsistent Shot Size

The Problem

Often caused by:

• Flight wear
  
• Incorrect check ring performance
  
• Barrel ID expansion
  

Vishwakarma Plast Solution

Our CNC-machined screw flights and precision-ground barrels guarantee:

• Stable output
  
• Accurate shot size
  
• Minimal leakage and backflow
  

This helps eliminate quality issues in high-precision molding shops in Al Nahda.