Downtime Killers: How to Troubleshoot Common Blown Film Line Faults

Even the best production lines face occasional issues. When they do, quick troubleshooting can save time, material, and frustration. Understanding common problems and their causes helps operators keep production moving and quality high.

This guide highlights typical blown film line faults and how to fix them before they turn into costly downtime.

Film Gauge Variation

Uneven film thickness is one of the most frequent issues. It can be caused by inconsistent cooling, blocked die channels, or unstable bubble control. Regularly inspect air rings, temperature zones, and die lips. Keep all heaters and sensors calibrated for accurate readings.

Learn more about stable film control in How the Blown Film Process is Done Efficiently and Sustainably.

Wrinkling or Misalignment

Wrinkles usually come from poor tension control or misaligned rollers. Check nip rolls, turning bars, and idlers for uneven wear. A well-set Web Guiding System keeps the film centred and reduces waste from edge damage.

Bubble Instability

If the bubble fluctuates in size or shape, inspect the cooling airflow and extrusion rate. Uneven temperature or a blocked air ring can lead to collapse or distortion. Keeping airflow even around the die helps stabilise the bubble and maintain consistent output.

Winding Defects

Poorly wound rolls can lead to crushed cores, telescoping, or uneven film tension. Calibrate winding speeds and maintain even tension throughout the roll. Upgrading to automated winding controls can reduce manual errors and improve consistency.

Final Thoughts

Preventing downtime starts with small checks done often. Consistent monitoring, clean equipment, and precise control systems all help prevent common line faults. With a solid maintenance routine and reliable web handling systems, you can keep production smooth and output steady. Speak to an expert today.