Extrusion & Post
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LDPE Blown Film Die Buildup
Problem Phenomenon
Degraded carbonized material gradually accumulates at the die lip, the film shows lines and rough surfaces, and it falls off periodically
Cause Analysis
Die lip buildup is mostly due to excessive melt and die temperatures; die lip misalignment, edge damage, excessive fillet radius, or fine scratches also cause the melt to drag and stay, which peels off periodically after carbonization
Solution
① Insert a copper sheet between the die lips to clean the buildup; ② check die lip misalignment and damage; ③ lower the melt and die temperatures; after adjustment, take continuous samples to verify the effect, and resume mass production only after confirming stability
Key Takeaway
Die lip buildup is a dual signal of temperature and die lip condition; copper sheet cleaning plus temperature management is the standard treatment; after confirming effectiveness, solidify the parameters and practices into the work instruction to prevent recurrence
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