Blown Film Troubleshooting Guide

Problem Causes(s) Possible Solution(s) Problem Causes(s) Possible Solution(s) Problem Causes(s) Possible Solution(s)

Insufficient Mixing Increase back pressure by increasing screen mesh Dirty Air Ring (Cont.) Check the seal between the air ring and die Poor Insufficient treatment (cont.) Decrease gap between film and treatment system

Gauge Variation (cont.)

Printability
Applesauce

Extrusion temperature too high Decrease die and adaptor temperatures Check hoses for kinks or bends restricting air flow (cont.) Use lower slip concentration
Extrusion temperature too low Increase die and adaptor temperatures Surging of the extruder Check drive speed of the extruder Dirty die Pull and clean the die examining for contaminates
Die gap too wide Decrease die gap Check temperature controllers Examine die for burnt material
Extrusion rate Decrease output rate Examine feed section housing Use purge material to clean the die
Excessive regrind Change the amount of regrind being added to virgin material Check the regrind feed for force feeding the extruder Clogged ports and/or spirals Problem will usually resolve itself within an hour or less

Port Lines
Excessive tension in the winder Adjust winder tension Die heat variation Check for burnt out heater bands/Check temperature controllers Jagged frost line Adjust cooling system to cool bubble uniformly
Low level of antiblock additive Increase concentration of antiblock Nip rollers Check that the nip roller drives are running smoothly and not surging Make sure the cooling system is working property
Blocking

Film collapsing too hot
Insufficient cooling
Excessive surface treatment
Lower frost line height/Lower melt temperature/Reduce output Contamination Clean silos and transfer systems periodically
Check the concentricity of the die gap
Use chilled air/Raise nips/Reduce output Excessive regrind Drop ratio of regrind material to virgin material
Raise the bottom die zone in 10°F increments
Reduce treatment level Defective heaters Check and recalibrate
Melt temperature too low Raise the melt temperature

Excessive nip roll pressures
Too much static electricity
Inconsistent melt feed to die
Bubble Instability
Gels
Reduce pressure Dirty screw and/or barrel Purge and clean system
Die too cold or too hot in Adjust die temperature to narrow the difference in temperatures between the two
Use anti-static agent/Incorporate anti-static devices Poor resin quality Check resin homogeneity and gel/speck level comparison to melt temperature
Insulate the die body
Adjust temperature profile to provide for more uniform flow Poor mixing Check screw design
Damaged or scuffed rollers Replace rollers

Scratches
Dirty die Pull and clean the die examining for dirt, pelletized, or burnt matter Dirty screen pack Change out screen pack
Use purge material Improper melt temperature Increase melt temperature Rollers not turning Check roll drag and bearings, roll speed, and/or roll balance
Excessive nip tension Adjust lower nip drive speed

Inadequate
Drawdown
Worn screw and/or barrel Use humped profile settings to begin earlier melting High frost line Decrease frost line
Check for the presence of pelletized material in last zones Insufficient back pressure Use smaller mesh screen pack Scratches from collapsing Eliminate source of scratches
frame, nip, or idlers
Replace screw and/or barrel Extruder surging Reduce surging using a barrier screw
Air currents Eliminate air drafts/Reduce air output Wrong resin Check resin specifications/Use different resin Low blow-up-ratio Increase blow-up-ratio (BUR)
Misalignment Align nip rolls to die Insufficient mixing Use ascending heat profile Use smaller die or tougher resin
Excessive cooling air velocity Adjust temperatures Poor quality resin/wrong resin Check specifications of the resin

Low Gloss/
High blow-up-ratio Decrease blow-up-ratio (BUR)

Melt Fracture High Haze

Chatter

at die Raise the frost line Improper melt temperature Increase melt temperature gradually Use larger die or tougher resin
Non-uniform gap between Check gap between top of die and bottom of ring Inadequate cooling of the film Check or modify cooling system Die lines Clean die lips
Material and air ring cone Possible polymer buildup in gap Poor mixing in extruder/die Increase mixing in the extruder

Dirty die and/or die lips (foreign
matter lodged inside the die)
Die Lines
Splitty Film
High frost line Lower the frost line
Clean die and/or lips with copper pad or brass shim Inadequate die gap Increase die gap Contamination (degraded resin Clean die lips, then reduce melt temperature
Increase adaptor and die temperatures and screen mesh to increase back pressure Extrusion temperature Increase melt temperature or dirt lodged under edge of

die lips which makes film split

Scratched die lips Repair surface at a machine shop Reduce output at weld)
Insufficient blending of molten Increase mixing in extruder by adjusting barrel and die temperatures/Increase back pressure Excessive friction at die lips Add processing aid to coat die lips and reduce COF
polymer
Increase melt temperature
Thin spots in film Check for die concentricity
Inadequate purging Increase purging time between resin changes Extrusion temperature too high Adjust extrusion temperatures
Extrusion temperature too high Gradually adjust melt temperature
Inconsistent melt feed to die Check temperature settings and functional parts or too low or too low
Erractic Output

Poor Clarity
Examine screw for pelletized material in last zones Low blow-up ratio Increase blow-up-ratio (BUR)
Insufficient cooling (frost line Decrease melt temperature
(Surging)

Dirty die
Worn screw and/or barrel
Plugged screen pack
Increase temperature settings across the barrel Poor mixing Increase mixing in extruder too high)
Increase bubble cooling rate/Reduce frost line
Pull and clean the die Inadequate frost line height Increase frost line height
Poor resin choice Check for resin suitability
Use humped profile settings to begin earlier melting Inadequate film cooling Check the cooling system
Dirty die pin Clean pin/Add additive to die plate/Remove reclaim from die
Replace screen pack Poor resin quality or wrong Check resin specifications
Roller surfaces rough Rework rollers to ensure smoothness

Streaks
Bridging Cool throat resin grade
Bubble guides and collapsing Repair or replace to ensure smoothness
Erratic cooling Check temperature settings Overtreatment Adjust to proper level of treatment frames are rough
Inconsistent melt feed to the die Check temperature settings Resin oxidation Reduce melt temperature

Poor Heat Seal

Gauge Variations

Improper treater bar clearance Adjust

Adjust temperature profile to provide for a consistent melt feed Gauge variations Check die uniformity
Air leakage from the bubble Repair or replace the nip roller
Dirty die Clean die and/or die lips with copper pad or brass shim Check for bubble instability

Uneven Film
Improperly adjusted die Follow procedures for adjusting die bolts Check for air ring leaks Check for leakage in the inflation system

Width
Misaligned die Center and align die to nip Examine for defective heater bands Check for control valve problems if using an internal bubble cooling (IBC) system
Misaligned air ring Center air ring with die Check for possible surging Bubble pumping or breathing Decrease the air velocity of the air ring
Dirty air ring Examine for lodged polymer Sealing bar warped Examine for distortion Increase the opening of the collapsing frame
Change the air filter Poor Printability Insufficient treatment Increase treat energy Tension varies or is too high Reduce tension as roll size increases