3 0 T r o u b l e s h o o t i n g C a s t Film

The cast film process is shown in Fig. 30.1. A verti- 30.1 P r o b l e m 1 — M o l t e n W e b Tears
cal die lays a uniform thickness film (less than 0.010 Easily W h e n Exiting the Die
inch [0.254 mm]) on a high-speed roll to cool the film.
Depending on the rate, a second chill roll is used in Assume low melt strength from using the wrong resin
some situations. After the second polishing roll or chill (too high an MFI or low molecular weight). If too much
roll, an idler roll is used to remove the film off the high- regrind or the wrong formulation is not the cause, poten-
speed roll on the way to the nip or puller rolls. After the tial causes and corrective actions are
puller, roll knives are located to slit the product to the • Polymer flow variations or fluctuations from the
desired width. A corona or flame treater station can be die can be caused by extruder surging, resulting
added to the cast line when the film has to have a print- from poor feed or other problems in the extruder
able surface. Both the corona and flame treatment (refer to problem 12 in Chapter 27 and problem 1
process oxidize the nonpolar polyolefin surface to a in Chapter 28).
polar surface that has better adhesion to inks and coat-
ings. The edge trim is normally removed by a pneumat- • A dirty die caused by contamination near or on the
ic system that conveys the film to a chopper, where it is die lips can create thin sections in the film due to
diced and returned to the extrusion feed system or flow restriction. Thin areas can cause the film to
somewhere else in the plant as regrind. Cast film has tear as it is being pulled away from the extruder on
better gloss, clarity, and gauge control versus blown the polished roll. An improperly adjusted die lip
film due to differences in the process and the rapid opening creates thin sections in the film that can
quenching provided by the chill roll, minimizing the lead to holes or film tearing as it is drawn and
crystalline size, growth, and concentration. Improved pulled away from the die.
gauge control versus blown film is provided by the die • Low melt temperature can limit the molten poly-
and the cooling process. Cast film is produced at a high- mer flow as it exits the die and is pulled away by
er throughput rate than blown film. the high-speed rolls, causing the film to tear.
This chapter, similar to Chapter 29 discussing sheet, Raising the melt temperature in the last extruder
builds on concepts already introduced. General prob- zones, adapters, and dies by increasing the setpoint
lems associated with mechanical or product aspects in temperatures can help alleviate this problem.
the extruder were presented in Chapters 27 and 28. • Polished chill rolls are running too fast for the
Concepts presented there also apply to cast film. extruder throughput, pulling the molten polymer
Additional troubleshooting concepts presented here are faster than it is delivered from the die.
centered on the process from the die to the windup;
some problems associated with the die are presented in Figure 30.2 summarizes the potential causes and cor-
Chapter 29. rective actions for the film tearing or breaking as it exits the
die and is being laid down on the polished rolls. Other

Nip Rolls
Extruder
Slitter

Windup

Nip RoIIi
Idler Roll

H i g h ^ Polished
Chill RoIb

Figure 30.1. Simulated cast film process.

 I W o b T e a r s B e t w e e n the Die and Chill Roll

Fluctuations in polymer Flow uniformity №lt temperature Wong roll

flow at die mi caus9d by the die too low speed
Check material flow in Clean die lips Increase the Match roll speed
feed hopper Qxtruder to throughput-
Cheek to see if temperatures on DQcrQasQ mil
1
Adjust Cruder there is the last 2jK3nes, speed or
temperatures in zones 1 eontsmi nation in adapter, transfer increase
end2 the die restricting piP^s. and dies throughput
flow
Check for Cruder
surging and cormot
Figure 30.2. Potential causes and corrective actions to employ when the web tears.

potential causes, such as too much regrind, wrong polymer, in the film gauge. Hot or cold spots in transition
molecular weight too low, wrong polymer formulation, zones, die, or adapter may lead to nonuniform melt
and extruder surging, were covered in previous chapters. viscosity, creating nonuniform flow from the die.
Verify that the melt temperatures across the die are
equivalent. If not, increase or decrease the die tem-
30.2 Problem 2 — F i l m Thickness perature selectively across the die to equilibrate the
Variation melt temperature and polymer viscosities.

Changes in film gauge uniformity across the roll or Figure 30.3 summarizes the potential causes and cor-
web over time can be caused by the die, poor melt qual- rective actions to employ in the event gauge nonunifor-
ity, and surging. Potential corrective actions are summa- mity occurs across the sheet or over time.
rized below.
• The main cause for variation in thickness across the
web or in the transverse direction is the die lip 30.3 Problem 3 — L i n e s , Streaks,
opening. The die lip opening has to be parallel to and Foreign Contamination
the roll surface, and the adjustment bolts have to be
properly set to provide uniform thickness. Dirty Causes of film contamination, streaks, and lines are
lips or contamination can restrict flow in particular similar to those found in sheet. They are normally associat-
areas, leading to gauge inconsistencies. ed with contamination, poor mixing, or equipment damage.
• Surging in the extruder and feed inconsistency can Potential causes and corrective actions are outlined below.
cause gauge variations. In a flood-fed extruder, the • Lines in the machine direction are normally caused
feed hopper has to be maintained at a relatively by contamination in the die (degraded material,
constant resin level during the run to ensure the remnants from a blown screen pack, foreign mate-
same pressure on the resin entering the extruder. As rial fed with polymer that can't pass through die
the hopper level changes drastically, the resin actu- opening, and so forth), a scratch or burr on the die
ally being pulled into the extruder by the screw can lips, die lip build-up, a scratch on the roll surface,
vary. When producing cast film, slight variations in or something dragging on or contacting the film.
throughput can cause large differences in gauge. To rectify die problems, the die must be purged; if
Poor flow characteristics in the feed hopper and the the problem still exists after purging, the die must
extruder feed section that are associated with be disassembled and the die lips resurfaced to
regrind can create major gauge problems. remove scratches and burrs. Causes for lines due to
• Variations in the melt viscosity, resulting from equipment damage outside the die have to be iden-
changes in the melt temperature, regrind levels, or tified and the damaged equipment replaced or
formulation changes, can cause dramatic changes resurfaced to eliminate the problem. Die deposits
 Gouge Variation Aorois the Web or Oirir Time

Die adjustment! Inconsistent feed to the fvtelt Viscosity Variations

rat ruder
Check dm lip opening to Oheok heaters and
assure it is uniform Material not feeding thermocouples for proper
uniformly operation
V'Qrify dig lips am parallel
to chill roll Regrind c re at ing feed Aisure there are no hot or
inconsistencies cold spots
We riff die lips i r e dean
Keep feed hopper in Assure formulation is
Rernoip any foreign stan/o fed eitruder at correct
material end dean die consistpnt IGVQI
Cheok regrind level
Figure 30.3. Potential causes and corrective actions for gauge variation.

have to be removed periodically to keep them from (high-molecular-weight particles or cross-linked

building up and affecting the film quality. particles that don't melt) can create imperfections in
the film. If gels are present, attempts are made to
• Black specks can be generated over time if the
filter them out with fine screen packs. This approach
process is running too hot and/or material is hanging
is not always successful, as small gels may soften,
up in the die and degrading. Black specks can result
elongate, and pass through the screens. It may be
from shutdown and start-up operations when poly-
necessary to change the resin source to totally
mer left in the die or extruder is allowed to cool and
eliminate gels. High temperature in the die, com-
degrade. Once degraded polymer is generated, the
bined with dead or stagnant areas in the die (behind
die either has to be disassembled or purged. Black
deckles), can cause PE to cross-link and form gels.
specks normally appear at the beginning of a run.
• Contamination in the film can be coming from the Figure 30.4 summarizes potential causes for lines,
feedstock, particularly if regrind is being used to streaks, or contamination in film with corrective actions
supplement the feedstock. In polyethylene, gels to use in each situation.

Linei^ Streaks, and Foreign ttoniMrnination

Lines in the machine direction Black specks Oonteminttion in the

material
Contamination in dis - Degraded Clean die
material, remnants of mmrnn paok - Cheok feed stock
Remove Purge die
Lower melt tempemtun©
&rateheddie lip need resurfacing Lmmr rneft to present degradation,
temperature if OeIs1 and crcsslinking
Burr on die lip mquiris rasurfadng result of
degradation Chook regrind
Die deposits on outside of die lips

Steratahis or other darings on Gh ill

rolls or take off equipment - Refurbish
to correct problem
Figure 30.4. Potential causes and corrective actions for lines, streaks, and foreign contamination.
30.4 Problem 4—Extrudate Width rected by adjusting the puller and/or winder speeds
Is T o o N a r r o w and synchronizing the speeds with the chill roll.
• Fluctuations in polymer flow due to surging, block-
Potential causes and corrective actions for the film age in the die, or improperly set die lips cause the
being too narrow are given below. polymer exiting the die to be thick and thin. This
• The die width is too narrow to produce the desired can cause extrudate sagging with excessive material
film width or the deckles are not properly posi- that leads to wrinkles. Problems are easily corrected
tioned. Film being laid down on a chill roll is drawn by cleaning the die, resetting the die lips, or elimi-
by the roll, requiring it to neck down and become nating the surging.
narrower than the die width. When deckles are • Nonuniform cooling on the roll related to curl or
used, their length must account for the extrudate warpage in thicker materials can cause the film not
necking, while providing a little extra width on to track properly and wrinkle. Temperature differ-
each side to provide for edge trim. entials across the roll surface have to be within 2°F
(1°C) to provide uniform cooling.
• Slow the chill roll to reduce the draw and reduce
the necking. This change has to be accompanied by • Chill roll and die misalignment creates molecular
a change in the die lip opening or the film gauge orientation, leading to curl or twist normally asso-
will be incorrect. ciated with warpage in thicker parts. In film,
wrinkles are created when the film does not track
• The polymer rheology is incorrect for the process uniformly on the rolls. A casting unit is normally
being run. Melt viscosity is too low, generating too installed on tracks to ensure proper alignment
much neck down as the polymer is pulled away between the rolls and the die.
from the die by the chill roll. To increase the melt
viscosity, lower the melt temperature or change to a Figure 30.6 summarizes the potential causes with
lower melt flow index resin. corrective actions to use in the event wrinkles occur in a
film operation.
Figure 30.5 summarizes the potential causes and cor-
rective actions to use if the film is too narrow.
30.6 Problem 6 — R o u g h n e s s on
Film Due to Melt Fracture
30.5 Problem 5—Wrinkles
A r e F o r m e d in t h e F i l m A rough film surface similar to a sharkskin appear-
ance is attributable to high friction in the die lip area.
Potential causes for wrinkles in the film and correc- Potential causes for film roughness and corrective
tive actions to eliminate them are outlined below. actions to eliminate it are outlined below.
• The winding tension is too high, pulling the film • The problem can be eliminated by opening up the
across the polished casting or laydown roll. This die gap and raising the die temperature. Increasing
can be caused by the winder and/or the puller the die lip opening requires the line to be run at a
speeds being too high. The problem is easily cor- higher speed with more molecular orientation to

E x t r u d a t e o r F i l m W i d t h I s too N a r r o w

Die related RGdlJCQ H&Ck dO'iMl Polymer rheology

Adjust or use proper Eim Slow chill roll and lino Verify proper melt
deckles SpQQd temperature
Die is too narrow Slowing line speed - Lo^mr melt temperature
Regapdo to incroesg* viscosity if
neck dovn is too great.

Figure 30.5. Potential causes and corrective actions if the film is too narrow.
 Wrinkles

Winding tension is Fluctuations in polymer Cooling on ranting Casing unit not

too high flow out of die roll not uniform properfy
aligned with die
•Slowpuller rolls Surging Gaused by the Adjust roll
9xtmd9r or feod temperature Check roll
• aonnyMndup ipe@d uniformity alignmint
1
Die gap improperly set assuring it is
Sf nohroniffi line pamJIeltodie
speeds Blockage in the die gap

Hot spots in the die (

adapter, or transition
pipe generating
nonuniform rralt
¥iscQiity and flow
Figure 30.6. Potential causes and corrective actions in the event of wrinkles.

obtain the same gauge. This may make the solution • Another approach is to increase the melt tempera-
to the problem impractical. Increasing the die tem- ture to lower the resin viscosity, allowing the poly-
perature, attempting to heat up the die lip area, also mer melt to flow better through the die lip opening.
may be impractical. New die lips with a smoother
finish may be required to reduce the drag in the die Potential corrective actions for melt fracture in films
lip area. are shown in Fig. 30.7.

Film R o u g h n e s s D u e to Melt Fracture

Qianges in the opemtion of the die Melt temperature too low

Increase die temperature to increase Raise melt temperature to reduce

temperature of die lips viscosity

RMinish dm lips mt\ a lamer friction

material

Open die lips to el low more polymer flow

Figure 30.7. Corrective actions for film roughness attributed to melt fracture.
Review Questions

L What causes film to wrinkle and how can each cause be eliminated?
2. Film is easily tearing between the die and casting unit; what corrective actions ought to be initiated
to eliminate the problem?
3. What are some potential sources of lines or foreign contamination in film?
4. How can black specks be eliminated from Film?
5. The film being produced cannot be properly trimmed because it is too narrow; what are some
potential actions to widen the film?
6. What causes gauge variations in cast film and how can they be eliminated?