Fault Slippage extruder of

Probable Cause Contamination of material Low molecular weight material component higher in the resin Higher extrusion temperature

Suggested Remedy Check material for contamination Use lower MFI material Reduce extrusion temperature

material in the

Film breakage

Slippage of material in the barrel Agglomerate formation at feed zone

See above Check cooling water circulation, reduce feed zone extrusion temperature

Film puncher

Contaminated die lip Improper temperature profile

Clean die lip Optimize temperature profile. Increase drying time or raise drying temperature Use fine mesh screen backed up by a coarser screen plate Use optimum quantity of antistatic masterbatch

Bubbles in film

Material contains too much moisture Too coarse screen High level of antistatic master batch

Wrinkles in film

Variation in width wise film thickness Quench tank temperature too low Film guide rolls of quench tank not rotating properly.

Adjust die lips Increase quench tank temperature Check film guide rolls for jamming

Tape breakage

Contaminated die lip, variation in die gap setting, higher quench tank temperature, too low hot plate temperature, high stretch ratio, damaged hot plate surface.

Clean and reset die lips, reduce quench tank temperature , optimize hot plate temperature, slightly reduce the stretch ratio, see for deposits or serration’s caused by running tape and repair it.

Low

tensile

Higher melt stretch ratio at quenching, higher air gap in melt stretch zone, too low hot plate/ oven temperature, lower stretch ratio.

Reduce melt stretch ratio, reduce quench tank temperature, reduce air gap, increase hot plate / oven temperature to optimum level, increase stretch ratio.

strength of tape

Higher elongation tape of

Higher melt stretch ratio at quenching, higher air gap, too low hot plate/ oven temperature, lower stretch ratio

Reduce melt stretch ratio, reduce quench tank temperature, reduce air gap, increase hot plate / oven temperature to optimum level, increase stretch ratio.

Variation in tape denier

Non uniform film thickness, variation in spacer thickness, variation in first godet speed (due to improper functioning of four quadrant, close loop feed back drive), slippage at godet pressure roll or damaged rubber pressure roll, temperature sensor or controller not working properly.

Adjust die gap and clean die if required, check first godet speed control system, check rubber pressure rolls for damage or slippage, check for variation in set temperature and actual temperature of hot plate/oven.

Fibrillation longitudinal

or

Contaminated die lip, non-uniform film thickness, blunt cutting blades on spacer rod, wrinkles in film or tapes, serration on hot plate, lower hot plate temperature, too high stretch ratio, higher winding tension, damaged traverse guide of winders.

Adjust die gap and clean die if required, replace damaged cutting blades, correct film for wrinkles, polish hot plate surface at damaged portion, increase hot plate / oven temperature and reduce stretch ratio, adjust winding tension.

splitting of tapes