PVC Calendered Film: Top Ten Common Issues and Solutions

In the dynamic world of PVC calendered film production, encountering challenges is inevitable. But with the right knowledge and solutions, turning these hurdles into opportunities for improvement is entirely possible. Today, we delve into the top ten common issues faced by PVC calendered film manufacturers and provide effective strategies to overcome them.

1. Excessive Film Shrinkage

 Issue: Film shrinks excessively during production.

 Solution: Adjust the traction speed ratio to prevent overstretching in the cooling unit. Enhance cooling conditions and optimize the tension during winding to maintain stability.

2. Uneven Film Thickness

 Issue: Film thickness varies across the surface.

 Solution: Fine-tune the calendering machine's roller gap and consider techniques like middle roller crossing, bottom roller prebending, and temperature adjustments to achieve uniformity.

3. Uneven Wind-Up Rolls

 Issue: Film doesn't wind up neatly on the roll.

 Solution: Stabilize the winding machine's speed, enhance cooling to reduce film stickiness, adjust tension settings, and ensure film uniformity through precise tooling and cooling adjustments.

4. Rough Film Surface

 Issue: Film surface feels rough or uneven.

 Solution: Reduce material buildup between rollers, improve material mixing and plasticization, increase calendering temperatures, clean roller surfaces, and optimize the use of recycled material.

5. Poor Transparency with Cloudiness

 Issue: Film lacks clarity, appearing cloudy.

 Solution: Minimize material buildup in the final roller pair, increase calendering temperatures, adjust roller speed ratios, smooth roller surfaces, and ensure thorough additive dispersion.

6. Inferior Mechanical Properties

 Issue: Film lacks strength or flexibility.

 Solution: Boost calendering temperatures, enhance material mixing and plasticization, choose higher viscosity PVC resin, limit recycled material usage, and regulate lubricant quantities.

7. Fish Eyes (Transparent Particles)

 Issue: Film contains small, clear imperfections.

 Solution: Switch to a different resin, increase plasticization temperature and time, and enhance compatibility between additives and resin.

8. Film Decomposition and Discoloration

 Issue: Film deteriorates or changes color during production.

 Solution: Lower calendering temperatures, shorten exposure times, tweak formulas for better thermal stability, and cut down on recycled material usage.

9. Cold Spots on Film Surface

 Issue: Film has localized cooler areas.

 Solution: Raise calendering temperatures, decrease material buildup, improve mixing and plasticization temperatures, and enhance material flow within rollers.

10. Waxy or Powdery Surface Deposits

 Issue: Film surface has waxy or powdery residues.

 Solution: Adjust formulas for better additive compatibility with PVC, and increase the temperature of the stripping roller.

At our PVC film manufacturing facility, we embrace these challenges as opportunities for innovation and excellence. By adopting these solutions, we ensure that our products meet the highest standards of quality, performance, and customer satisfaction. Stay tuned for more insights into our journey of pushing the boundaries in PVC film production!