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Cast Film Troubleshooting Guide

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

Gauge Variation (cont.)


Warm film Decrease the temperature on the secondary chill roll Erratic melt quality Check and adjust temperature profiles as necessary Chill roll temperature Increase the chill roll 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

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