Ok...lets take this a step at a time.
With a twin injector the plastics have to be within a degree or two of each other and the plunger seals have to be avbsolutely free to move. If you need to, take the twins apart, wash with alcohol and then lube well with worm oil when re-assembling. On your next shoot with it try heating the plastics at the same time in a microwave making sure the quanities are the same and maybe try heating the plastics to just under the 350 degree mark...330 or 340. Do not make one plastic a soft and the other a firm or medium until you get things ironed out. Take all of the variables away and start over. Something is the hang-up and everything has to be on the same playing field to find the problem. I'd start with the injector system. Then I'd move to the plastic. If one color is blowing back into the other its telling me that the pressure isn't equal. Take a serious look at the block to see if there is something in there you are missing too.
On a hand pour, try adding a touch of softener to the injected color and make sure you heat it to around 360-365 and hold pressure on the plunger when it stops after the cavities are filled. Try injecting a hair slower too so no air has a chance to slide in between the colors. Having one or the other color softer allows it to melt at the seam way easier and the pressure at the end is obvious.


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