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Problem Causes(s) Possible Solution(s) Problem Causes(s) Possible Solution(s) Problem Causes(s) Possible Solution(s)
Baggy Edges Excessive bow Adjust the bowed roll Surging of the extruder (cont.) See if the regrind feed is force feeding the extruder (blenders) Low MD Tear Extruder output/take up Increase output and/or take up speed
Strength
Hot melt Decrease the barrel temperatures Check for wearing of the screw and repair/replace as necessary Resin melt index Use a resin with a lower melt index
Cloudy
(cont.)
Bars
Erratic cooling Check the air knife blower speed and adjust as necessary Examine the filters for possible clogging and clean/replace as necessary Extrusion temperature Decrease extrusion temperature
Strength
Low MD
Collapse
Tensile
Core
Tightly wound film Decrease winder tension Ensure proper screw design Resin density Use a resin with a higher density
Web Shrinkage Decrease the temperature on the secondary chill roll Check for wearing of the screw and repair/replace as necessary Die gap Decrease die gap
Dirty Die Clean die and/or die lips with copper pad or brass shim Modify screw design with static mixers to achieve homogeneity Extruder output/take up Increase output and/or take up speed
Resin density Use a resin with a higher density
Die Lines
Increase adaptor, die temperatures and screen mesh to increase back pressure Die gap Decrease the die gap
Streaks
Poor Barrier
Properties
Damaged die lips Change die lips Chill roll temperature Decrease the chill roll temperature Chill roll temperature Increase the chill roll temperature
Repair surface Air gap Decrease the air gap Extrusion temperature Decrease extrusion temperature
Inadequate purging Check current purging time and increase as necessary Screen pack Increase restriction Air gap Increase the air gap
Extrusion temperature Increase the extrusion temperature Winder tension Increase tension of the winder Screen pack Increase restriction
Excessive Neck-In Edge Tearing
Die gap Decrease the die gap Erratic melting and mixing Check temperatures and adjust accordingly Extrusion temperature Increase extrusion temperature
Screen pack Increase restriction Check for wearing of the screw and repair/replace as necessary Chill roll temperature Decrease chill roll temperature
Gels
Air gap Increase the air gap Check for wearing of the barrel Screen pack Increase restriction
Poor Haze
Extruder output/take up Decrease the output and/or take up speed Check for resin contamination and purge if necessary Resin melt index Use resin with a higher melt index
Extrusion temperature Decrease the extrusion temperature Screen pack Increase restriction Die gap Increase the die gap
Resin density Use a resin with a lower density Excessive winder tension Decrease the tension Air gap Increase the air gap
Hazy Hard
Roll Roll
Resin melt index Use a resin with a lower melt index Excessive lay on pressure Decrease pressure Resin density Use resin with a higher density
Air gap Decrease the air gap Plate out on chill roll Check roll temperature Additives Decrease the additive formulation
Extruder output/take up Increase the output rate and/or take up speed Use a vacuum box to remove excessive additives on the roll Resin density Use resin with a lower density
Poor Heat
Die gap Increase the die gap Additives Increase additive formulation, namely the slip level Treatment level Decrease the level of treatment being used
Seal
High Coefficient
Additives Increase additive formulation, namely the ash level Extrusion temperature Decrease extrusion temperature Resin melt index Use a resin with a higher melt index
of Friction
Extrusion temperature Decrease extrusion temperature Chill roll temperature Increase the chill roll temperature Additives Decrease the additives formulation
Chill roll temperature Increase chill roll temperature Treatment level Decrease the level of treatment applied to the film Resin density Use a resin with a lower density
Poor Impact
Film Blocking
Extruder output/take up Decrease the output and/or the take up speed Die gap Decrease the die gap Resin melt index Use a resin with a lower melt index
Winder tension Decrease the winder tension Resin density Use resin with a higher density Chill roll temperature Decrease the chill roll temperature
Resin melt index Use a resin with a lower melt index Low MD Extrusion temperature Increase extrusion temperature Die gap Decrease the die gap
Treatment level Decrease the level of treatment Elongation Screen pack Increase restriction
Die gap Decrease the die gap Extrusion temperature Increase extrusion temperature Extrusion temperature Increase the extrusion temperature
Transparency
Air gap Decrease the air gap Chill roll temperature Decrease the chill roll temperature Chill roll temperature Decrease the chill roll temperature
Low Gloss
Resin density Use a resin with a higher density Screen pack Increase restriction Screen pack Increase restriction
Poor
Chill roll temperature Increase the chill roll temperature Resin density Use a resin with a higher density Die gap Decrease die gap
Puckering
Film
Extruder output/take up Decrease the output rate and/or take up speed Resin melt index Use a resin with a higher melt index Air gap Decrease air gap
Resin density Use a resin with a lower density Die gap Decrease the die gap Additives Decrease the additive formulation
Erratic cooling Check the chill roll temperatures and adjust as necessary Additives Decrease the additive formulation Rolls not turning Check the drag
Scratches
Film Striking
on Chill Roll Check the passages Resin density Use a resin with a higher density Check the roll speed and adjust accordingly
Stiffness
Low
Film Too Narrow die slot Adjust the deckles Chill roll density Increase the chill roll temperature Check the balance
Narrow from
Chill Roll High neck-in Adjust the edge pinners air flow and relocate pinners Air gap Increase the air gap Low melt temperature Increase melt temperature
Shark
Skin
Floppy Web Insufficient roll tension Increase the tension as necessary Resin density Use a resin with a lower density Apply heat to the die lips
Strength
Low MD
Surging of the extruder Check drive speed of the extruder Chill roll temperature Increase the chill roll temperature Narrow die gap Increase the gap
Variation
Tear
Gauge
Check temperature controllers Extrusion temperature Decrease the extrusion temperature Insufficient winding tension Increase the tension
Soft
Roll
Examine feed section housing Air gap Decrease the air gap Decrease the taper