3 0 T r o u b l e s h o o t i n g C a s t
The cast film process is shown in Fig. 30.1. A verti-
cal die lays a uniform thickness film (less than 0.010
inch [0.254 mm]) on a high-speed roll to cool the film.
Depending on the rate, a second chill roll is used in
some situations. After the second polishing roll or chill
roll, an idler roll is used to remove the film off the high-
speed roll on the way to the nip or puller rolls. After the
puller, roll knives are located to slit the product to the
desired width. A corona or flame treater station can be
added to the cast line when the film has to have a print-
able surface. Both the corona and flame treatment
process oxidize the nonpolar polyolefin surface to a
polar surface that has better adhesion to inks and coat-
ings. The edge trim is normally removed by a pneumat-
ic system that conveys the film to a chopper, where it is
diced and returned to the extrusion feed system or
somewhere else in the plant as regrind. Cast film has
better gloss, clarity, and gauge control versus blown
film due to differences in the process and the rapid
quenching provided by the chill roll, minimizing the
crystalline size, growth, and concentration. Improved
gauge control versus blown film is provided by the die
and the cooling process. Cast film is produced at a high-
er throughput rate than blown film.
This chapter, similar to Chapter 29 discussing sheet,
builds on concepts already introduced. General prob-
lems associated with mechanical or product aspects in
the extruder were presented in Chapters 27 and 28.
Concepts presented there also apply to cast film.
Additional troubleshooting concepts presented here are
centered on the process from the die to the windup;
some problems associated with the die are presented in
Chapter 29.
Extruder
H i g h ^ Polished
Chill RoIb
Figure 30.1. Simulated cast film process.
Film
30.1 P r o b l e m 1 — M o l t e n W e b Tears
Easily W h e n Exiting the Die
Assume low melt strength from using the wrong resin
(too high an MFI or low molecular weight). If too much
regrind or the wrong formulation is not the cause, poten-
tial causes and corrective actions are
• Polymer flow variations or fluctuations from the
die can be caused by extruder surging, resulting
from poor feed or other problems in the extruder
(refer to problem 12 in Chapter 27 and problem 1
in Chapter 28).
• A dirty die caused by contamination near or on the
die lips can create thin sections in the film due to
flow restriction. Thin areas can cause the film to
tear as it is being pulled away from the extruder on
the polished roll. An improperly adjusted die lip
opening creates thin sections in the film that can
lead to holes or film tearing as it is drawn and
pulled away from the die.
• Low melt temperature can limit the molten poly-
mer flow as it exits the die and is pulled away by
the high-speed rolls, causing the film to tear.
Raising the melt temperature in the last extruder
zones, adapters, and dies by increasing the setpoint
temperatures can help alleviate this problem.
• Polished chill rolls are running too fast for the
extruder throughput, pulling the molten polymer
faster than it is delivered from the die.
Figure 30.2 summarizes the potential causes and cor-
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
Slitter
Windup
Nip RoIIi
Idler Roll
 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
flow at die mi caus9d by the die
Check material flow in Clean die lips
feed hopper
Cheek to see if
1
Adjust Cruder there is
temperatures in zones 1 eontsmi nation in
end2 the die restricting
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,
molecular weight too low, wrong polymer formulation,
and extruder surging, were covered in previous chapters.
30.2 Problem 2 — F i l m Thickness
Variation
Changes in film gauge uniformity across the roll or
web over time can be caused by the die, poor melt qual-
ity, and surging. Potential corrective actions are summa-
rized below.
• The main cause for variation in thickness across the
web or in the transverse direction is the die lip
opening. The die lip opening has to be parallel to
the roll surface, and the adjustment bolts have to be
properly set to provide uniform thickness. Dirty
lips or contamination can restrict flow in particular
areas, leading to gauge inconsistencies.
• Surging in the extruder and feed inconsistency can
cause gauge variations. In a flood-fed extruder, the
feed hopper has to be maintained at a relatively
constant resin level during the run to ensure the
same pressure on the resin entering the extruder. As
the hopper level changes drastically, the resin actu-
ally being pulled into the extruder by the screw can
vary. When producing cast film, slight variations in
throughput can cause large differences in gauge.
Poor flow characteristics in the feed hopper and the
extruder feed section that are associated with
regrind can create major gauge problems.
• Variations in the melt viscosity, resulting from
changes in the melt temperature, regrind levels, or
formulation changes, can cause dramatic changes
№lt temperature Wong roll
too low speed
Increase the Match roll speed
Qxtruder to throughput-
temperatures on DQcrQasQ mil
the last 2jK3nes, speed or
adapter, transfer increase
piP^s. and dies throughput
in the film gauge. Hot or cold spots in transition
zones, die, or adapter may lead to nonuniform melt
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-
perature selectively across the die to equilibrate the
melt temperature and polymer viscosities.
Figure 30.3 summarizes the potential causes and cor-
rective actions to employ in the event gauge nonunifor-
mity occurs across the sheet or over time.
30.3 Problem 3 — L i n e s , Streaks,
and Foreign Contamination
Causes of film contamination, streaks, and lines are
similar to those found in sheet. They are normally associat-
ed with contamination, poor mixing, or equipment damage.
Potential causes and corrective actions are outlined below.
• Lines in the machine direction are normally caused
by contamination in the die (degraded material,
remnants from a blown screen pack, foreign mate-
rial fed with polymer that can't pass through die
opening, and so forth), a scratch or burr on the die
lips, die lip build-up, a scratch on the roll surface,
or something dragging on or contacting the film.
To rectify die problems, the die must be purged; if
the problem still exists after purging, the die must
be disassembled and the die lips resurfaced to
remove scratches and burrs. Causes for lines due to
equipment damage outside the die have to be iden-
tified and the damaged equipment replaced or
resurfaced to eliminate the problem. Die deposits
 Gouge Variation Aorois the Web or Oirir Time

Die adjustment! Inconsistent feed to the fvtelt Viscosity Variations

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

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

building up and affecting the film quality.
• Black specks can be generated over time if the
process is running too hot and/or material is hanging
up in the die and degrading. Black specks can result
from shutdown and start-up operations when poly-
mer left in the die or extruder is allowed to cool and
degrade. Once degraded polymer is generated, the
die either has to be disassembled or purged. Black
specks normally appear at the beginning of a run.
• Contamination in the film can be coming from the
feedstock, particularly if regrind is being used to
supplement the feedstock. In polyethylene, gels
particles that don't melt) can create imperfections in
the film. If gels are present, attempts are made to
filter them out with fine screen packs. This approach
is not always successful, as small gels may soften,
elongate, and pass through the screens. It may be
necessary to change the resin source to totally
eliminate gels. High temperature in the die, com-
bined with dead or stagnant areas in the die (behind
deckles), can cause PE to cross-link and form gels.
Figure 30.4 summarizes potential causes for lines,
streaks, or contamination in film with corrective actions
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
Is T o o N a r r o w
Potential causes and corrective actions for the film
being too narrow are given below.
• The die width is too narrow to produce the desired
film width or the deckles are not properly posi-
tioned. Film being laid down on a chill roll is drawn
by the roll, requiring it to neck down and become
narrower than the die width. When deckles are
used, their length must account for the extrudate
necking, while providing a little extra width on
each side to provide for edge trim.
• Slow the chill roll to reduce the draw and reduce
the necking. This change has to be accompanied by
a change in the die lip opening or the film gauge
will be incorrect.
• The polymer rheology is incorrect for the process
being run. Melt viscosity is too low, generating too
much neck down as the polymer is pulled away
from the die by the chill roll. To increase the melt
viscosity, lower the melt temperature or change to a
lower melt flow index resin.
Figure 30.5 summarizes the potential causes and cor-
rective actions to use if the film is too narrow.
30.5 Problem 5—Wrinkles
A r e F o r m e d in t h e F i l m
Potential causes for wrinkles in the film and correc-
tive actions to eliminate them are outlined below.
• The winding tension is too high, pulling the film
across the polished casting or laydown roll. This
can be caused by the winder and/or the puller
speeds being too high. The problem is easily cor-
rected by adjusting the puller and/or winder speeds
and synchronizing the speeds with the chill roll.
• Fluctuations in polymer flow due to surging, block-
age in the die, or improperly set die lips cause the
polymer exiting the die to be thick and thin. This
can cause extrudate sagging with excessive material
that leads to wrinkles. Problems are easily corrected
by cleaning the die, resetting the die lips, or elimi-
nating the surging.
• Nonuniform cooling on the roll related to curl or
warpage in thicker materials can cause the film not
to track properly and wrinkle. Temperature differ-
entials across the roll surface have to be within 2°F
(1°C) to provide uniform cooling.
• Chill roll and die misalignment creates molecular
orientation, leading to curl or twist normally asso-
ciated with warpage in thicker parts. In film,
wrinkles are created when the film does not track
uniformly on the rolls. A casting unit is normally
installed on tracks to ensure proper alignment
between the rolls and the die.
Figure 30.6 summarizes the potential causes with
corrective actions to use in the event wrinkles occur in a
film operation.
30.6 Problem 6 — R o u g h n e s s on
Film Due to Melt Fracture
A rough film surface similar to a sharkskin appear-
ance is attributable to high friction in the die lip area.
Potential causes for film roughness and corrective
actions to eliminate it are outlined below.
• The problem can be eliminated by opening up the
die gap and raising the die temperature. Increasing
the die lip opening requires the line to be run at a
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
to the problem impractical. Increasing the die tem-
perature, attempting to heat up the die lip area, also
may be impractical. New die lips with a smoother
finish may be required to reduce the drag in the die
lip area.
• Another approach is to increase the melt tempera-
ture to lower the resin viscosity, allowing the poly-
mer melt to flow better through the die lip opening.
Potential corrective actions for melt fracture in films
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?