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MAINTENANCE | When Melt Pressure Sensors Fail: A Maintenance Manager’s Quick Response Guide

  • Writer: Bob
    Bob
  • Aug 30
  • 2 min read
extrusion scrap material and purge from incorrectly working pressure sensors

In extrusion and molding, maintenance managers know that small parts cause big headaches when they go wrong. Melt pressure sensors are a perfect example. When these sensors drift, fail, or are installed incorrectly, the consequences show up fast:

  • Scrap piles up because pressure readings are off.

  • Product defects multiply when temperature or flow control goes unstable.

  • Operators waste time chasing problems that are really sensor-driven.

The result: lost output, rising costs, and a lot of frustration on the floor.


3 Steps for Maintenance Teams When Sensor Problems Hit


Here’s a quick response checklist you can hand to your team to cut downtime and get the process back on track.


✅ Step 1: Verify & Isolate the Problem

  • Compare suspect readings against a calibrated reference or mechanical gauge.

  • Inspect wiring and connectors for looseness or damage.

  • Swap in a known-good sensor to confirm if the issue is sensor-related.

✅ Step 2: Clean, Calibrate, or Replace

  • Remove the sensor using proper torque tools.

  • Clean off polymer build-up or carbonized material at the tip.

  • Attempt calibration; if readings still drift, replace with a verified spare.

✅ Step 3: Document & Prevent Repeat Issues

  • Record the fault, corrective action, and sensor details (serial number, date, location).

  • Check other sensors on the line for early signs of wear or contamination.

  • Review preventive maintenance intervals — ensure regular calibration, cleaning, and spare inventory readiness.


Why It Matters for Maintenance Managers


The difference between a short interruption and a full-blown production problem often comes down to how quickly the maintenance team acts. By following a standard checklist, you reduce the risk of guesswork, speed up troubleshooting, and stop the same problem from returning.

Melt pressure sensors might be small, but for maintenance leaders, they’re one of the big levers in keeping scrap down and uptime high.


Contact NNS today for our FREE Troubleshooting Map! Great for new maintenance people!


 
 
 
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