How to solve the frequent film breakage in film blowing machines

In the conventional manufacturing process of film blowing machines, the frequent occurrence of film breakage undoubtedly constitutes a troubling problem. In the actual production process, due to various reasons, the product often fails to work properly due to equipment failure. This situation not only causes serious damage to the continuity and robustness of the production line, but also may reduce the quality of the product and increase the company's manufacturing costs. If the film breakage phenomenon cannot be handled in a timely and effective manner, it will directly cause the instability of the film quality, and even cause safety accidents, causing huge economic losses to the factory. The occurrence of film breakage problems often represents a decrease in production efficiency and unnecessary consumption of resources. Once the film is broken, the product will be scrapped or unable to perform normal packaging operations. Therefore, solving the frequent film breakage problems of film blowing machines is particularly critical to improving production efficiency and the quality of the final product.

Are there any abnormal or unstable factors in the extrusion system of the film blowing machine?
As one of the key components of the film blowing machine, the stability of the extrusion system has a direct impact on the continuity and uniformity of the film. Whether the extrusion system is normal or not not only determines the quality of the film roll, but also has an important impact on production efficiency. If there are abnormal or unstable conditions in the extrusion system, such as screw wear or improper temperature control, these may cause instability in the extrusion volume, which will have an adverse effect on the continuity of the film. Since under normal circumstances, the material flow rate during the extrusion process is basically constant, when the extrusion is interrupted, it will cause the product quality to decline. In severe cases, it will cause equipment damage or even scrapping, causing huge economic losses to the company. In order to properly deal with this problem, we must regularly inspect and maintain the extrusion system, which covers core components such as screws, heaters and temperature sensors. In addition, adjusting the temperature control parameters of the extruder to ensure the stability of the extrusion temperature is also an effective way to prevent film breakage. For those screws with high wear, they should be replaced quickly to ensure that the extrusion system is always in the best working condition
 Is the die design and adjustment of the film blowing machine appropriate?
The design and adjustment of the mold play a decisive role in the effect of film extrusion. Different types of die heads also have great differences in product performance. If the internal flow channel design of the die is not appropriate or the gap between the die lips is not adjusted properly, the film may be subjected to uneven stretching or shearing force during the extrusion process, which may trigger the film to break. If the traditional method is used to process films of different sizes and shapes, there will be large errors, and even the desired product cannot be obtained. Therefore, when selecting the die design, we must consider the specific specifications and requirements of the film. On this basis, we accurately adjust the gap between the die lips to ensure that the film is uniformly stretched and sheared during the extrusion process. By optimizing the process parameters, the probability of film breakage can be effectively reduced. In addition, periodic cleaning and maintenance of the die to avoid impurities and stains from adversely affecting the extrusion effect also constitutes a key means to prevent film breakage.
Are the quality and melt index of the raw materials up to standard?
The quality and melting degree of the raw materials are the core elements that determine the quality of film extrusion. If the quality of the raw materials is unstable or the melt index is not up to standard, the film may break during the extrusion process. Since the melt index is restricted by many factors, there are large differences between different manufacturers. Therefore, it is necessary for us to select raw material suppliers with stable quality and meet the standards, and conduct strict quality inspection and screening of these raw materials to ensure that their quality and melt index meet the specified standards. The inspection results of raw materials are directly related to the quality of film products and production costs. In the manufacturing process, periodic inspection of the quality and melt index of raw materials, and timely adjustment of the production process based on these data are key measures to prevent film breakage.
Are the traction speed and cooling system of the film blowing machine coordinated?
The harmonious coordination between the traction speed and the cooling system is very critical for the continuous production and quality of the film. Since the traction speed is closely related to the physical properties of the material, it directly affects the mechanical properties of the film. If the stretching speed is too fast or the cooling effect is not ideal, it may cause the film to break during the extrusion process. Since the drafting roller is one of the important equipment on the film production line, it has a simple structure, reliable performance and low cost. Therefore, considering the specific specifications and requirements of the film, we should reasonably adjust the traction speed. This paper takes a company's film production line as an example to analyze the main factors affecting the traction speed by establishing a mathematical model. On this basis, we optimized the design and parameters of the cooling system to ensure that the film can obtain sufficient cooling effect during the extrusion process. This paper analyzes the characteristics of film production and proposes several methods to reduce the film breakage rate. Regularly perform necessary maintenance and maintenance on the cooling system to ensure its stable operation, which is also a key means to prevent film breakage.
 Is the operation and maintenance of the film blowing machine standardized?
The stable operation of the film blowing machine and the quality of the film depend to a large extent on the standardization of operation and maintenance. In film production, due to various reasons, scratches and other problems may appear on the surface of the film, and even damage the film in severe cases. Improper operation or untimely maintenance may cause frequent machine failures, thereby affecting the continuous production of the film. At present, the phenomenon of film core breakage caused by operating errors occurs from time to time, which seriously hinders the normal operation of the film blowing machine and brings huge economic losses. Therefore, in order to ensure the standardization of operation and maintenance work, it is necessary for us to formulate a comprehensive and detailed set of operating procedures and maintenance plans. Systematic training and evaluation of operators to improve their operating ability and maintenance awareness is also an effective way to prevent film breakage. Starting from the actual situation, this paper expounds the common film breaking phenomenon and its causes in the film production line, and puts forward corresponding preventive measures. Regular maintenance and care of the film blowing machine can timely identify and solve possible problems, thereby ensuring the stable operation of the machine and the high-quality production of the film.

In summary, to solve the frequent film breaking problems of the film blowing machine, it is necessary to consider comprehensively from multiple dimensions. Reducing the incidence of film breaking under the premise of ensuring the normal operation of the extruder is an important research direction. We have the responsibility to regularly inspect and maintain the extrusion system, optimize the design and adjustment of the die head, select raw materials with stable quality, reasonably adjust the traction speed, optimize the cooling system, and ensure the standardization of operation and maintenance. In daily work, we should also detect and control the film, such as monitoring the film thickness, tension and tensile properties through the online monitoring system. The implementation of these suggestions can effectively avoid the occurrence of film breaking events, thereby improving the production efficiency and product quality. This paper analyzes the causes of film breaking in the film blowing machine, proposes corresponding countermeasures and implements them, and achieves good results. We recommend that each company develop a detailed solution strategy and implementation plan based on the current actual situation, and continuously monitor and evaluate the implementation results to ensure that the film blowing machine can operate stably and achieve high-quality production.