The production of PET preforms is a process that necessitates precision. Be it a mass production of thousands of units per day or a custom design, a single miscalculation could result in expensive idle time, inferior quality, and dissatisfied customers. Through working with DRJ Plasttech, I’ve had the opportunity to see everything from surface flaw issues to performance-related failures. As such, the good news is that most of the common problems associated with PTE preforms have solutions. In this article, we will identify the seven major types of production problems with PET preforms and share ways to rectify the issue quickly. Table of Contents When PET Preform Production Doesn’t Go as Planned 1. Flash Formation 2. Short Shot (Incomplete Fill) 3. Bubbles and Voids 4. Black Spots and Contamination 5. Crystallinity Issues (Hazy or Brittle Preforms) 6. Uneven Wall Thickness 7. Thread or Neck Finish Defects DRJ Plasttech’s Approach to Preventing PET Preform Production Issues Final Thoughts: Don’t Let Preform Problems Hurt Your Bottom Line Want help with your current production setup or sourcing top-quality PET preforms? FAQs about PET Preform Production Problems When PET Preform Production Doesn’t Go as Planned This guide is intended for Managers and Supervisors in Procurement and Operations who deal with PET Preform production. This guide will outline the basic 7 problems faced when producing PET Preforms. These problems are not listed in order of frequency or importance. 1. Flash Formation The Issue: Excess plastic found along the parting line of a preform can result in sporadic ridges or wings being produced. What causes it: Fix it fast: DRJ Pro Tip: Fixing flash early helps eliminate future sealing issues during blow moulding. Fixing flash form problems on the mould results in significant cost savings due to rework. 2. Short Shot (Incomplete Fill) The Problem: The preform does not fill the mold resulting in either part of the preform collapsing or incomplete filling of each cavity. What causes it: Fix it fast: DRJ insight: short-shots can kill an entire batch of material. Routine cleaning and temperature checks of the runner channel/base will help to prevent these types of issues from occurring. 3. Bubbles and Voids The problem: Affects clarity and integrity due to small bubbles of air trapped within the preform. What causes it: Fix it fast: Expert Tip: Bubbles are a common result of inadequate drying practices. At DRJ Plasttech, our systems utilize a state-of-the-art resin drying system to prevent this during bulk production. 4. Black Spots and Contamination The problem: Dark specs/streaks on PET preform surfaces decrease visual appeal & safety.  What causes it: Fix it fast: Why it’s important: Inconsistencies may fail FDA/ISI compliance testing, which no water bottle manufacturer can risk. 5. Crystallinity Issues (Hazy or Brittle Preforms) The Problem: The preforms are not produced as clear and impact-resistant products but as foggy and very brittle. What causes it: Fix it fast: Expert tip from DRJ Plasttech: When your customers receive the product, they are judging quality based on its appearance. Foggy-looking products can create issues during the subsequent blow moulding process and weaken shelf appeal. By automating your systems to record the melt and mould temperatures to the degree, you eliminate the guesswork! 6. Uneven Wall Thickness The problem: An inconsistency in the thickness of blow-moulded preform containers creates a thicker or thinner area on the container wall than normal, making the finished bottle weak. What causes it: Fix it fast: DRJ advantage: We perform ultrasonic alignment checks on moulds and sample parts throughout our production runs; therefore, we keep the wall variance of any container less than 1%. 7. Thread or Neck Finish Defects The Problem: Capping, sealing, and fitting of containers produced on a blow-moulding machine can be affected by deformations or inconsistencies in the area of the neck. What causes it: Fix it fast: Note from DRJ: The neck area of preforms for water bottles is a very important part of the process. Some very slight issues with the threads on the bottle will cause rejects from the capping line. We always work to keep the neck ring specs within ± 0.05 mm deviation. DRJ Plasttech’s Approach to Preventing PET Preform Production Issues DRJ Plasttech believes that the best way to prevent problems is to be proactive. We manufacture PET preforms through a combination of automated machinery, well-defined quality assurance processes and procedures, and inline monitoring systems that enable us to conduct on-site inspections of all preforms before shipping. All dimensional characteristics, wall thicknesses and optical colour clarity of our preforms are evaluated by our facility’s real-time inspection systems before shipping. Your business is not just about ordering preforms from us. When you partner with us, you get a team of professionals dedicated to producing products of the highest quality. Final Thoughts: Don’t Let Preform Problems Hurt Your Bottom Line If your PET preform problems occur, they not only have the potential to cost you money (in wasted materials, rejected bottles, shut-down productions, and dissatisfied clients) but also may be solved or at least avoided by executing proper process controls throughout the production process, training all individuals involved with the project, and only working with reliable suppliers. Need a PET preform partner with an understanding of your production challenges? Count on DRJ Plasttech! DRJ Plasttech has established itself as a premier manufacturer of PET preforms due to its outstanding technical service and superior consistency in its manufacturing process in Gujarat and surrounding states. Want help with your current production setup or sourcing top-quality PET preforms? Contact our technical team to discuss how we can support your operations. Or request a free sample batch of our most popular water bottle preforms. FAQs about PET Preform Production Problems 1. Which PET preform production issues are most prevalent? Short shots, flash, haze or brittleness, inconsistent colour, uneven wall thickness, and flaws in the neck or threads are some of the most frequent issues with PET preforms. Poor process control, worn moulds, or incorrect machine settings are frequently the cause of