FILM COEXTRUSION

A Troubleshooting Guide

FILM COEXTRUSION:
A TROUBLESHOOTING GUIDE
Paul H. Jackson, Equistar Chemicals, LP
(This article originally appeared in Converting Magazine, November 1994.)

Successful production of coextruded products depends on several key factors,

including polymer selections, hardware design (screw, feedblock/die, handling
equipment, layer construction and optimal processing conditions). Proper selection
and adjustment of each factor will minimize difficulties and ensure high quality
coextrusion results.
Troubleshooting methods for coextrusion become increasingly complex as the
number of layers in the structure increases, as the asymmetry of multi-layer construction grows, or as processing and rheological characteristics of coextruded
materials differ greatly from one another. Understanding the problems associated
with nonuniform layer distribution and interfacial instability between layers or on
film surfaces is very important when troubleshooting the coextrusion process.

THE UNIFORMITY PROBLEM

Nonuniform layer distribution is one of the more common problems encountered in film coextrusion. This nonuniformity may appear in either the direction of
extrusion or tangential to the direction of film production.
Layer uniformity in the machine direction can be influenced by die imperfections, poor die design or adjustment, excessive extruder pressure variation, variable
film tension, or film bubble or web instability.
Layer uniformity tangential to machine direction can be influenced by poor
melt temperature uniformity, viscosity mismatch between layers, poor hardware
design, or viscoelastic flow characteristics induced by excessive shear stress.
Poor layer uniformity tangential to machine direction is caused by nonuniform
melt temperature across a melt pipe, feedblock and/or die, as well as poor melting in an extruder. Melt temperature variance alters viscosity uniformity, which
exhibits a change in flow characteristics and layer distribution. Melt temperature
of a single polymer stream can often vary by as much as 30F. A general rule of
thumb is to achieve 2F or less variation in melt temperature for each extruder.
Homogenous melt temperatures can be achieved through installation of a static
mixer in the melt pipe, a dynamic mixer on the extrusion screw or a more efficient
screw design, or through adjustment of pipe, feedblock and/or die temperatures.
Variation in the thickness of a film, which eventually reaches a steady-state
condition of nonuniformity (assuming homogenous melt temperature conditions
for each polymer), can be caused by a viscosity mismatch between layers. In a
coextrusion system, lower-viscosity polymers migrate to the region of highest
shear stress (nearest the die wall) and tend to encapsulate higher-viscosity polymers. The amount of migration is dependent on the degree of viscosity mismatch,
the length of the flow path, and the shear stress in the system.

IMPROVING LAYER VARIATION

Improvements in layer variations that are caused by viscosity-induced flow
behavior can be achieved through adjustment of melt temperature, modification of
distribution channels in the feedblock or die, or selection of a polymer with different
viscosity characteristics which most commonly are measured by melt index. Also,
annular dies typically are more tolerant of viscosity mismatch than flat-die systems.
1

Nonuniform layer distribution in the direction tangential to extrusion can also

be caused by poor hardware design. Improperly designed flow channels of the
feedblock or die can cause poor steady-state layer distribution of materials, even
with the most closely matched viscosities.
Nonuniform distribution of layers, in the form of parabolic flow lines, intermixing of layers, roughness between polymer boundaries, melt fracture, or
uncharacteristically high haze, can be caused by interfacial instability between
layers or on film surfaces. The instabilities are believed to be a result of the
viscoelastic behavior of polymers at the die land or region of highest shear stress.
Improvements in layer instabilities can be achieved by reducing the shear
stress between coextrusion layers and/or the die-land surfaces. Shear stress can be
reduced by decreasing total output rate, increasing skin-layer melt temperature
(decrease in viscosity), increasing the die gap, adding a process lubricant to the
skin material, or selecting a lower viscosity material.
An increase in the thickness of the skin layer can also reduce instability
between polymer layers by moving the interface further from the high-shear-stress
die wall. This is especially significant for asymmetric coextrusion constructions.
Finally, if coextrusion layers exhibit dramatic differences in melt elasticity, then
choose materials that match more closely in extrudate elasticity as measured by
extrudate swell.

TROUBLESHOOTING AT A GLANCE
Problem: Lines in the film surface
Possible cause: Die imperfections
Solutions:
Clean die buildup
Remove contaminants from polymer melt channel
Repair die nicks and burrs
Problem: Gauge bands on film roll
Possible cause: Poor die design
Solutions:
Install spiral-channel die design to eliminate weld lines
Install rotating nip assembly in tower
Possible cause: Poor die adjustment
Solutions:
Adjust concentricity of die gap
Center air ring in relation to die gap
Problem: Repeating pattern of variation in thickness of layer(s)
Possible cause: Excessive extruder pressure variation (surging)
Solutions:
Achieve 1 percent or less variation in total head pressure for each extruder
Adjust extruder temperature profile (feed and transition zones)
Increase back pressure with restrictor flow plug
Increase back pressure by installing fine-mesh screen pack
Change screw design of surging extruder(s)
Check for worn screw(s) and replace if needed
Check extruder feedthroat(s) for bridging and correct if needed
Possible cause: Variable film tension
Solution:
Eliminate variability in drive speed
Possible cause: Film bubble instability
Solutions:
Protect bubble from atmospheric air turbulence
Correct pressure instability of air ring and/or internal air flow
2

Problem: Intermittent and somewhat random variation in thickness of layer(s)

Possible cause: Poor melt temperature uniformity
Solutions:
Achieve 2F or less variation in melt temperature for each extruder
Adjust extruder temperature profile to ensure complete melting of
extrudate
Install new screw design with dynamic mixer for more efficient melting
capacity
Reduce screw speed for increased residence time to complete melting
of the polymer(s)
Adjust temperature of feed channels, die and/or feedblock
Problem: Variation in thickness of layer(s) that reaches steady-state distribution
Possible cause: Viscosity mismatch of polymer layers
Solutions:
Select polymers with matching viscosities
Adjust temperature of polymers to aid in matching viscosities
Possible cause: Poor hardware design
Solution:
Change die and/or feedblock design
Problem: Uncharacteristically high film haze
Possible cause: Viscoelastic flow characteristics induced by excessive shear stress
between layers and/or feedblock/die surfaces
Solutions:
Select lower-viscosity skin layer(s)
Increase melt temperature of skin-layer polymers
Increase die temperatures
Reduce total extrusion output
Increase die-gap opening
Add process lubricant to skin-layer polymer
Increase thickness of skin layers
Select polymer(s) that exhibit similar melt elasticity behavior
(extrudate swell)
Problem: Parabolic-shaped flow lines in direction of extrusion
Possible cause: Same as for uncharacteristically high, film-haze problem
Solution:
Same as for uncharacteristically high, film-haze problem
Problem: Intermixing of polymer layers
Possible cause: Same as for uncharacteristically high, film-haze problem
Solution:
Same as for uncharacteristically high, film-haze problem
Problem: Roughness between polymer-layer boundaries
Possible cause: Same as for uncharacteristically high, film-haze problem
Solution:
Same as for uncharacteristically high, film-haze problem
Problem: Melt fracture of film surface
Possible cause: Same as for uncharacteristically high, film-haze problem
Solution:
Same as for uncharacteristically high, film-haze problem

Coextrusion Processing Defined

The conversion of multiple thermoplastics,
flowing through separate streams, that are
combined into a common primary passage and
then shaped by a die. Multiple layers provide
properties that cannot be provided by a single
material for high barrier coextrusion processing.
The main classes are: film; sheet; tubing;
coating; and blowmolded shapes.

FILM COEXTRUSION: A Troubleshooting Guide

02

Successful Production of Coextruded

Products Depends on Three Key Factors
1.
Polymer Selections
2.
Design of Hardware
Screws, Feedblock/Die, Handling
3.
Coextrusion Layer Construction
4.
Optimal Processing Conditions

FILM COEXTRUSION: A Troubleshooting Guide

03

Layer Uniformity is Influenced by:

Variations in extrusion pressure
Nominal extrusion melt temperature
Viscosity-induced web flow

Bubble or melt instability

Variable film tension
Poor die design or improper adjustment
Die imperfections or contaminants

Interfacial Flow Instability

is Caused by:
Interfacial critical shear stress

FILM COEXTRUSION: A Troubleshooting Guide

04

Extrusion Pressure Variations

Variation in extrusion pressure, often referred
to as surging, is directly related to feeding
stability of an extruder.
Improving layer uniformity caused by pressure
variation can be achieved through:
Adjustment of back pressure
Screenback
Restrictor flow plug
Extrusion screw design of feed and transition
sections
Adjustment of extrusion screw-temperature
profile
Prevent polymer bridging in feedthroat
Replace/repair worn extrusion screw

FILM COEXTRUSION: A Troubleshooting Guide

05

HEAD PRESSURE

1850
1840
1830
1820
1810
1800
1790
1780
1770
1760
1750

HEAD PRESSURE

Head Pressure Trace

1805
1795
1785
1775
1765
1755
1745
1734
1725
1715
1705
0

15

30

45

60
TIME (seconds)

FILM COEXTRUSION: A Troubleshooting Guide

75

90

105

120

06

Layer Thickness Instability

Caused by Pressure Variation

FLOW
DIRECTION

STABLE FLOW
Uniform thickness

ONSET OF INSTABILITY
Small gauge variation

SEVERE INSTABILITY
Large gauge variation

FILM COEXTRUSION: A Troubleshooting Guide

07

Extrusion Flange
Back Pressure Adjustment

ADJUSTABLE VALVE

INSTRUMENT PORT

FILM COEXTRUSION: A Troubleshooting Guide

08

Typical Arrangement of
Coarse and Fine Screens Between
the Screw and Breaker Plate
RESIN FLOW

BREAKER
PLATE

COARSE SCREEN
FINE SCREENS
COARSE SCREEN

FILM COEXTRUSION: A Troubleshooting Guide

09

Melt Temperature Variations

Nonuniform melt temperature across a melt
pipe, as well as poor polymer melting in an
extruder, cause poor layer uniformity.
Homogenous polymer melt temperatures
can be achieved through:
Static and/or dynamic mixers
Adjustment of pipe and die temperatures
Adjustment of extrusion screw temperature
profile
Replace/repair worn extrusion screw

FILM COEXTRUSION: A Troubleshooting Guide

10

MELT TEMPERATURE

380
358
356
354
352
350
348
346
344
342
340

MELT TEMPERATURE

Melt Thermocouple Trace

380
358
356
354
352
350
348
346
344
342
340
0

15

30

45

60
TIME (seconds)

FILM COEXTRUSION: A Troubleshooting Guide

75

90

105

120

11

Typical Temperature Profile

of Polymer Melt Stream in Pipe

414
410
406
402
398
F

394
390
386
382
378
374
0
BARREL
WALL

1/8

1/4

3/8

1/2

5/8

BARREL
CENTER LINE

FILM COEXTRUSION: A Troubleshooting Guide

3/4

7/8

0
BARREL
WALL

12

Layer Thickness Instability Caused by

Nonuniform Melt Temperature

FLOW
DIRECTION

STABLE FLOW
Uniform thickness

ONSET OF INSTABILITY
Small gauge variation

SEVERE INSTABILITY
Large gauge variation

FILM COEXTRUSION: A Troubleshooting Guide

13

Adjustable Depth Probe

Melt Thermocouple

EXPOSED
THERMOCOUPLE
JUNCTION

FILM COEXTRUSION: A Troubleshooting Guide

14

Distributive Mixing Sections

Dulmadge mixing section (Dow)

Saxton mixing section (DuPont)

Pin mixing section (Barmag)

Pineapple mixing section

Cavity-transfer mixing section

(Davis-Standard)

Slotted-screw flight (Axon)

Two types of static mixers

(Kenics and Ross ISG)

FILM COEXTRUSION: A Troubleshooting Guide

15

Viscosity Related Behavior

Melt index selection and the related viscosityinduced flow behavior affect layer uniformity.
Improvement of layer variations caused
by viscosity-induced flow behavior can be
achieved through:
Adjustment of melt temperature
Modification of distribution channels
Select polymer of different viscosity or
viscoelastic characteristic

FILM COEXTRUSION: A Troubleshooting Guide

16

Viscosity-Induced Flow Behavior

Migration of lower viscosity polymer
to the region of highest shear stress.
The effect is encapsulation of P2 by P1.

P1
P1

FLOW DIRECTION
THROUGH A PIPE

P2

P2

The amount of migration or encapsulation

is dependent on the degree of viscosity
mismatch, the length of the flow path and
the critical shear stress for the given system.

FILM COEXTRUSION: A Troubleshooting Guide

17

Viscosity vs. Shear Rate

for Various Polymers @ 230C

VISCOSITY (poise)
100000

10000

EVOH
1.5 MI

1000
EVOH
5.5 MI
LDPE
HIPS

PP

100
10

100
1000
SHEAR RATE (1/sec)

FILM COEXTRUSION: A Troubleshooting Guide

10000

18

Interfacial Flow Instability

Excessive shear stress between layers, feedblock
and/or die surfaces causes interfacial flow
instability. Drag flow and differences in polymer
velocities of multiple layers create shear stresses.
Reduction of interfacial shear stress near a die
wall can be achieved through:
Decreasing skin-layer viscosity or increasing
melt temperature
Increasing die temperature
Increasing skin-layer thickness
Reducing total extrusion output
Increasing die-gap opening
Adding process lubricant to skin layer
Selecting polymers that exhibit similar
melt elasticity

FILM COEXTRUSION: A Troubleshooting Guide

19

Critical Shear Stress of Polymers

Viscosity vs. Shear Rate

Non-Newtonian Behavior
of Polymers

LOG Viscosity (poise)

Smooth Extrudate

Irregular Distortion Occurs

at Critical Shear Stress
(Melt Fracture)

Newtonian Fluid Behavior

LOG Shear Rate (1/sec)

FILM COEXTRUSION: A Troubleshooting Guide

20

Interfacial Instability in Coextrusion

Caused by Critical Shear Stress

FLOW
DIRECTION

STABLE FLOW
Smooth interface

ONSET OF INSTABILITY
Wavy interface develops

SEVERE INSTABILITY
Propagation of waviness
to surface

FILM COEXTRUSION: A Troubleshooting Guide

21

Polymer Interfaces and Critical Shear

Stresses Encountered in Coextrusion

THEORETICAL
SHEAR STRESS
METAL
POLYMER 1
POLYMER 2

Highest
Intermediate
Zero

POLYMER 1
METAL

FILM COEXTRUSION: A Troubleshooting Guide

22

Coextrusion Melt-Flow Model

A = Stable Behavior
B = Critical Behavior
(Occurrence of Instability)

A
B
Melt Velocity

Shear Rate

POLYMER 3

POLYMER 1
POLYMER 2
FILM COEXTRUSION: A Troubleshooting Guide

23

An Important Note
Pressure variation, nonuniform melt
temperatures, viscosity mismatch and the
effects of critical shear rate instabilities seldom
occur independently of one another. They
most often occur simultaneously, with variance
in the degree of severity.

FILM COEXTRUSION: A Troubleshooting Guide

24

Lyondell Chemical Company

1221 McKinney Street, Suite 1600
P.O. Box 2483
Houston, TX 77252-2583
Cincinnati Technology Center
11530 Northlake Drive
Cincinnati, OH 45249
(513) 530-4000

The information in this document is, to our

knowledge, true and accurate. However, since
the particular uses and the actual conditions of
use of our products are beyond our control,
establishing satisfactory performance of our
products for the intended application is the
customers sole responsibility. All uses of
Equistar products and anywritten or oral
information, suggestions or technical advice
from Equistar are without warranty, express or
implied, and are not an inducement to use any
process or product in conflict with any patent.
Equistar materials are not designed or
manufactured for use in implantation in the
human body or in contact with internal body
fluids or tissues. Equistar makes no
representation, promise, express warranty or
implied warranty concerning the suitability of
these materials for use in implantation in the
human body or in contact with internal body
tissues or fluids.
More detailed safety and disposal information on
our products is contained in the Material Safety
Data Sheet (MSDS). All users of our products
are urged to retain and use the MSDS. An
MSDS is automatically distributed upon
purchase/order execution. You may request an
advance or replacement copy by calling our
MSDS Hotline at (800) 700-0946).
Acrythene, Alathon, Flexathene, Integrate,
Microthene, Petrothene, Petrothene Select,
Plexar and Ultrathene are trademarks of
Equistar Chemicals, LP.

7832/1098