Book Table of Contents: Blown Film Extrusion – Process Optimization and Troubleshooting
Book Table of Contents
Blown Film Extrusion – Process Optimization and Troubleshooting
Below you will find the complete table of contents of the book, allowing you to verify which topics are covered and how detailed each area is.
This is a technical book based on real production problems encountered in blown film extrusion – from process settings and bubble stability to quality control, additives, and case studies from industrial plants.
Book Length Information
Depending on the language version, the book contains approximately 320 to 350 pages.
Since each language version has a different layout and total length, page numbers are not included in the table of contents.
Language Versions
The book is available or being prepared in the following language versions:
Some language versions are available immediately, while others are offered as pre-order editions.
Who This Book Is For
This book is intended for professionals working directly with blown film extrusion technology, in particular:
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blown film line operators
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process technologists and engineers
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production and quality managers
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professionals responsible for process stability, scrap rates, and customer complaints
The detailed table of contents allows quick access to specific issues, process symptoms, root causes, and corrective actions without the need to read the book from cover to cover.
Introduction
Chapter 1
Introduction to Blown Film Extrusion
1.1 What Is the Blown Film Process?
1.1.1 Stage 1: Plasticization of the polymer granulate
1.1.2 Stage 2: Formation of the film tube in the die
1.1.3 Stage 3: Film cooling
1.1.4 Stage 4: Film bubble stabilization
1.1.5 Stage 5: Film flattening and transport
1.1.6 Stage 6: Winding the film into rolls
1.1.7 How each stage affects final film quality
1.2 Typical Blown Film Production Lines
1.2.1 Single-layer lines
1.2.2 Multilayer lines
1.2.3 Specialized production lines
1.2.4 How to choose the right film production line
1.3 Introduction to Raw Materials – LDPE, LLDPE, MDPE, HDPE, PA, EVOH, and EVA
1.3.1 LDPE (Low Density Polyethylene)
1.3.2 LLDPE (Linear Low Density Polyethylene)
1.3.3 MDPE (Medium Density Polyethylene)
1.3.4 HDPE (High Density Polyethylene)
1.3.5 Polypropylene (PP)
1.3.6 Polyamide (PA)
1.3.7 EVOH
1.3.8 EVA
1.3.9 Melt Flow Index (MFI) – why it matters
1.3.10 How to select the right raw material
Chapter 2
Quality Issues in Blown Film Production – Diagnosis, Corrections, and Prevention
2.1 Non-Uniform Film Thickness – Diagnosis, Corrections, and Prevention Strategies
2.1.1 How to identify non-uniform film thickness
2.1.2 Main causes of thickness variation
2.1.3 Solving non-uniform thickness problems
2.1.4 How to effectively prevent thickness variation
2.2 Film Surface Defects – The “Orange Peel” Effect
2.2.1 How to recognize the orange peel effect
2.2.2 Main causes of the orange peel effect
2.2.3 How to diagnose the problem effectively
2.2.4 Process corrections
2.2.5 Prevention strategies
2.2.6 Typical operator and technologist mistakes
2.3 Streaks, Discoloration, and Non-Uniform Film Color
2.3.1 How to identify streaks and discoloration
2.3.2 Main causes of streaks and color variation
2.3.3 Diagnosis of color-related problems
2.3.4 Process corrections
2.3.5 Prevention strategies
2.3.6 Typical technological mistakes
2.4 Film Blocking – Antiblock Agents and EVA
2.4.1 How to identify film blocking
2.4.2 Main causes of blocking
2.4.3 Diagnosis
2.4.4 Technological corrections and solutions
2.4.5 Typical operator and technologist mistakes
Chapter 3
Film Bubble Stability – Practical Solutions
3.1 Factors Affecting Film Bubble Stability
3.1.1 Inflation air pressure and quality
3.1.2 Bubble cooling parameters
3.1.3 Melt temperature and viscosity
3.1.4 Screw speed
3.1.5 Die geometry and technical condition
3.1.6 Raw material quality and consistency
3.1.7 Environmental conditions in the production hall
3.1.8 Summary
3.2 Bubble Pressure and Cooling Control
3.2.1 Air pressure control
3.2.2 Bubble cooling control
3.2.3 Influence of cooling on freeze line and film orientation
3.2.4 Symptoms of incorrect cooling settings
3.2.5 Best practices for regulation
3.3 Screw Speed Optimization
3.3.1 Influence of screw speed
3.3.2 Symptoms of incorrect settings
3.3.3 Adjustment principles
3.3.4 Influence of raw material quality
3.3.5 Most common operator mistakes
3.4 Typical Line Setup Errors
3.4.1 Introducing parameter changes too quickly
3.4.2 Lack of synchronization between screw speed and haul-off
3.4.3 Ignoring bubble response
3.4.4 Lack of cooling control
3.4.5 Lack of die condition monitoring
3.4.6 Parameter settings without reference to raw material quality
3.4.7 Errors caused by production pressure
Chapter 4
Mechanical Damage and Its Prevention
4.1 Typical Types of Mechanical Film Damage
4.1.1 Common types of damage
4.1.2 Diagnosis
4.1.3 Causes
4.1.4 Corrections
4.1.5 Typical mistakes
4.2 Rapid Response to Quality Problems
4.2.1 Importance of reaction time
4.2.2 Rapid diagnosis
4.2.3 Most common mistakes
4.2.4 Preventive strategies
4.3 Machine Maintenance
4.3.1 Die cleaning
4.3.2 Filter replacement
4.3.3 Problems caused by neglected maintenance
4.3.4 Effective preventive strategies
Chapter 5
Winding and Film Transport Problems
5.1 Wrinkling and Winding Disturbances
5.1.1 Causes
5.1.2 Diagnosis
5.1.3 Corrections
5.1.4 Preventive actions
5.2 Conical Roll Shape
5.2.1 Problem identification
5.2.2 Main causes
5.2.3 Rapid diagnosis
5.2.4 Process corrections
5.2.5 Prevention
5.3 Film Roll Damage During Transport
5.3.1 Identifying damage
5.3.2 Main causes
5.3.3 Diagnosis
5.3.4 Corrections
5.3.5 Prevention
Chapter 6
Practical Film Quality Control
6.1 Key Quality Tests
6.1.1 Film thickness measurement
6.1.2 Melt Flow Index (MFI) testing
6.1.3 Granulate moisture measurement
6.1.4 Implementation of testing
6.1.5 Typical mistakes
6.2 Quality Control Methods from Industrial Practice
6.2.1 Importance of regular quality control
6.2.2 Proven control methods
6.2.3 Implementation procedures
6.2.4 Typical mistakes
6.3 Quality Control Checklists
6.3.1 Why checklists matter
6.3.2 Checklist structure
6.3.3 Practical example
6.3.4 Documentation of process parameters
Chapter 7
Modern Technologies and Additives
7.1 Additives Improving Film Quality – Practical Guide
7.1.1 Antiblock agents
7.1.2 Slip additives
7.1.3 EVA
7.1.4 UV stabilizers
7.1.5 Antistatic additives
7.1.6 Typical production mistakes
7.1.7 Additives used in stretch film production – PIB and cling concentrates
7.1.8 Effective additive implementation
7.1.9 Additional practical dependencies
7.2 Color Masterbatches Used in Film Production
7.2.1 Types of color masterbatches and pigment concentration
7.2.2 Single-pigment concentrates
7.2.3 Pigment dispersion
7.2.4 Color distortion mechanisms
7.2.5 Importance of masterbatch carrier
7.2.6 Colorants for stretch and shrink films
7.2.7 Color stability and repeatability
7.2.8 Influence of pigments on film properties
7.2.9 Typical coloring mistakes
7.2.10 Functional color masterbatch combinations
7.3 When to Use Quality-Improving Additives
7.3.1 Case 1: Severe film blocking
7.3.2 Case 2: Film handling problems on automated lines
7.3.3 Case 3: Low mechanical strength
7.3.4 When additives should be considered
7.3.5 Decision criteria
7.3.6 Dosing recommendations
7.4 How to Select Additives for Specific Film Types
7.4.1 Defining film type and application
7.4.2 Identifying production problems
7.4.3 Selecting additives based on customer expectations
Chapter 8
Case Studies from Production Plants
8.1 Typical Errors and Their Solutions
8.2 Real Production Optimization Examples from Rolbatch Practice
8.3 Examples of Industrial Line Implementations by Rolbatch
Book Summary
Glossary of Terms
About the Author
Bibliography
Rolbatch Academy Online Courses
“The Great Book of Plastics” Series
Acknowledgements