Blown Film Extrusion: Optimizing Production Processes and Troubleshooting
Purpose and Scope of the Publication
Blown film extrusion is one of the most demanding processes in plastics processing. Bubble stability, thickness control, surface quality, parameter repeatability, and reduction of production losses are the result of multiple interdependent process factors that are not always easy to identify under real production conditions.
Process instability rarely has a single, obvious cause. In industrial practice, quality problems usually arise from the interaction of phenomena related to cooling, stretching, film orientation, raw material properties, and line settings. This publication was prepared for professionals who must make technological decisions on a daily basis under conditions of parameter variability, quality pressure, and responsibility for process stability.
The purpose of this book is to organize process-related knowledge and to explain the relationships between symptoms observed on the line, their possible causes, and corrective actions that have practical relevance in industrial environments, with a clear focus on the blown film extrusion process as it operates in real production settings.
Nature of the Publication
The book “Blown Film Extrusion – Process Optimization and Troubleshooting” is a practical technical reference based on many years of industrial experience and the analysis of hundreds of real production cases. The publication was developed as part of the engineering activities of Rolbatch Engineering and created in cooperation with teams of technologists and process engineers working on blown film extrusion lines.
This publication focuses entirely on blown film extrusion technology from a process and decision-making perspective. Each topic is addressed starting from observable process symptoms, followed by analysis of potential causes and practical corrective actions that can be implemented under real production conditions.
Scope of the Book
The publication covers, among others:
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blown film extrusion process explained step by step,
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bubble stability and factors influencing bubble behavior,
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the role of cooling and freeze-line position in final film quality,
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coloring of PE films, masterbatch selection, and causes of streaking and color non-uniformity,
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practical troubleshooting of production issues such as wrinkling, folding, and the “orange peel” effect,
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haul-off, winding, and quality control aspects,
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methods for process optimization and reduction of production losses.
Each topic is presented from a production-oriented perspective, with emphasis on real operating conditions rather than laboratory or theoretical assumptions.
The book also provides context for understanding process layouts, typical machine configurations, raw material behavior, and process-related cost drivers, without separating these elements from the overall production process.
Intended Audience
This publication was prepared for:
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blown film extrusion line operators,
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process technologists and engineers,
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production and quality management staff,
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students of technical disciplines related to plastics processing.
The book is used both in industrial practice and in technical education, serving as a reference resource and as supporting material for internal training programs in manufacturing plants.
Book as a Complement to Online Training
The publication is a standalone technical reference while also complementing the training programs offered by Rolbatch Academy.
Supplementary Materials
The online training programs include, among others:
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video recordings,
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photographs from real production lines,
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extended process descriptions and implementation examples.
Combining the book with online training materials helps deepen technical understanding and organize practical experience gained in production environments.
Language Versions and Availability
The publication is available in the following language versions: Polish, English, German, Spanish, Italian, Russian, and Chinese.
Some language versions are available for immediate shipment, while others are offered on a pre-order basis as they are currently being prepared for print.
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In-stock versions are typically shipped within 5–10 business days.
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Pre-order versions are shipped within up to 2 months from the date of order.
The current availability status (in stock / pre-order) is always displayed when selecting a specific product variant.
Upon request, it is also possible to receive online access to a preview version of the book, including the table of contents and selected excerpts, to review the scope and writing style before making a purchase decision.
To receive access, please contact us by email or WhatsApp and provide the email address to which the online preview access should be sent.
Publishing Information
Edition: 2nd expanded edition
Length: approx. 320–350 pages (depending on language version)
Language: according to the book cover
Publication parameters (language, binding type, and print version) are determined by the selected product variant.
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What distinguishes Dr. Magdalena Laabs’ books?
Dr. Magdalena Laabs’ publications uniquely combine practical expertise with clear and accessible language. With over 20 years of experience in the industry, she understands how important it is to explain complex technical topics in a simple, structured, and understandable way. Read more ->