The film blowing machine is the core equipment in the manufacture of plastic film. It plays an indispensable role in many industries such as packaging, agriculture and construction. With the development of the film industry, the quality requirements of plastic films are getting higher and higher, and the film blowing process is one of the key links to improve the quality of plastic films. However, in the actual production process, the stability of the film bubble of the film blowing machine often becomes a problem for manufacturers, which not only reduces the efficiency of production, but also directly affects the quality of the final product. In addition, due to the poor stability of the film bubble, it will also cause a certain degree of damage to the surface of the film, resulting in a decrease in the qualified rate of the product. Therefore, it is crucial to conduct in-depth research on the instability of the film bubble generated by the film blowing machine and seek appropriate solutions to improve the overall effect of plastic film manufacturing.
Is the temperature setting of the film blowing machine appropriate?
The importance of temperature setting
In the process of film blowing, the melting state of the plastic is decisively affected by the temperature. Because plastic has good fluidity, its melting point and plasticizing characteristics are closely related to the ambient temperature. Only under the right temperature conditions can the plastic raw materials be completely melted to generate a uniform melt, and further form a stable film bubble through blowing. Therefore, in order to ensure the stability of the film bubble, it is particularly important to properly adjust the temperature of the film blowing machine.
Performance of improper temperature setting
When the temperature of the film blowing machine rises to a certain level, the fluidity of the plastic melt will increase, which may cause the film bubble to become too thin, thereby increasing the risk of rupture; when the film bubble is cooled under high pressure, it is easy to shrink or break. However, when the temperature is too low, the fluidity of the plastic melt will decrease, causing the film bubble to become too thick and uneven. If the film bubble has uneven thickness or uneven distribution, it is easy to stretch. Both conditions may have a serious negative impact on the stability of the film bubble.
How to adjust the temperature setting
In order to fine-tune the temperature configuration of the film blowing machine, the operator needs to first master the melting temperature range of the plastic raw materials used, and make appropriate adjustments according to the actual production needs. In actual operation, the purpose of controlling the melt temperature can be achieved by adjusting the heater. In addition, we also need to regularly check the operating status of the heating components to ensure the accuracy of temperature management.
Is there a problem with the raw material formula or material quality?
Influence of raw material formula
The stability of the film bubble is directly affected by the proportion of different ingredients in the raw material formula. The morphology of the film bubble depends on the polymer composition and structure and the interaction between them. Different types of plastic raw materials have differences in melting characteristics, tensile strength and toughness, and these differences in performance will directly affect the generation and stability of the film bubble.
Importance of material quality
High-quality raw materials play a key role in ensuring the stability of the film bubble. The use of inferior raw materials may cause defects such as bubbles and cracks in the film bubble, which has a serious negative impact on the quality of the product.
Identification and handling of raw material quality problems
In order to ensure the quality of raw materials, operators must conduct strict quality inspections and tests on these raw materials. The moisture content and particle size distribution of the raw materials must be strictly controlled during processing. If the raw materials are detected to have quality defects, their use should be terminated immediately and replaced with standard raw materials. The quality inspection of raw materials should be based mainly on sensory judgment, and instrumental analysis should be used to determine whether they meet the quality standards. In addition, we also need to increase the storage and management of raw materials to avoid the quality of raw materials being reduced due to moisture, pollution and other factors.
Do the extrusion speed and traction speed of the film blowing machine match?
Relationship between extrusion speed and traction speed
When performing film blowing operations, it is necessary to ensure the harmony between the extrusion speed and the traction speed. Since the plastic itself has a high viscosity, it is very difficult to ensure that the extrusion speed is compatible with the traction speed. The outflow of the plastic melt is determined by the extrusion speed, while the stretching speed of the film bubble is determined by the traction speed. Therefore, in order to make the blown film have good physical and mechanical properties, it is necessary to ensure that there is an optimal matching value between the extrusion speed and the traction flow rate. Only when these two speeds are consistent can we generate stable film bubbles.
Speed mismatch problem
If the extrusion speed is too fast and the traction speed is too slow, the film bubble will become thinner and more likely to break due to excessive stretching; on the contrary, the film bubble is easily broken and cracks on the film surface are formed. However, if the extrusion speed is too slow and the traction speed is too fast, the film bubble may become too thick and uneven due to insufficient stretching. In addition, due to the relaxation or breakage of the polymer molecular chain in the melt, defects such as gaps and microcracks appear between the polymer chain segments, which causes relative slip between the film bubble layers and forms shear bands. Both of these conditions may cause instability of the film bubble.
How to adjust speed matching
In order to better match the extrusion speed and the pulling speed, the operator needs to make subtle adjustments according to the actual production needs. In order to ensure that the gap between the head and the barrel is within the specified range, the extruder head and barrel must be inspected regularly. In addition, the working condition of the transmission system needs to be checked periodically to ensure that its operating speed is accurate and stable.
How efficient and uniform is the cooling system?
The role of the cooling system
In the process of film blowing, the cooling system plays an indispensable role. Since the film blowing machine is a complex system, a suitable cooling method must be used to ensure that the film bubble grows stably and maintains the appropriate size and shape. The equipment can not only quickly reduce the temperature of the film bubble to make it quickly set, but also prevent the film bubble from deforming or rupturing due to overheating. In addition, slow cooling or uneven cooling can cause local overheating, which can cause the bubble to break or even crack the film. Therefore, the efficiency and balance of the cooling system play a key role in the stability of the bubble.
Problems with cooling efficiency and uniformity
When the efficiency of the cooling system is reduced or the cooling process is uneven, the bubble may deform or rupture due to local overheating. In some applications, bubble rupture may also occur due to excessive cooling medium flow. Such conditions will have a serious negative impact on the stability of the bubble and the quality of the final product.
Methods to improve cooling efficiency and uniformity
In order to enhance the efficiency and balance of the cooling system, the operator can optimize the layout and design of the cooling system, increase the number and power of the cooling fans, and adjust the flow and temperature of the cooling water appropriately. In order to ensure that the engine is operating efficiently, economically and stably, the cooling system needs to be regularly inspected. In addition, the working condition of the cooling system needs to be checked periodically to ensure that it can operate normally.
What are the skills and experience of the operator?
Importance of operator skills
The stable operation of the film blowing machine and the quality of the film bubble are largely affected by the technical ability and experience of the operator. In actual work, due to the constraints of subjective factors and objective conditions, there will be defects such as bubbles on the surface of the film, resulting in a decrease in the product qualification rate and an increase in production costs, which ultimately seriously hinders the improvement of corporate benefits. Only when operators have rich experience and specialized technical capabilities can they accurately identify and solve various problems that may arise in the production process, thereby ensuring the stability of the film bubble structure.
Manifestations of insufficient skills
If the operator's skills are not proficient enough, they may make operating errors or make wrong judgments. The formation of bubbles in the film bubble will cause equipment blockage, product contamination and increased energy consumption, and even cause safety accidents. These suggested problems will have a direct impact on the stability of the film bubble and the quality of the final product. In the production process, equipment failures caused by various factors are also common. For example, operators may cause incorrect temperature settings, speed mismatches, or raw material quality problems due to misoperation.
Ways to improve operator skills
In order to enhance the professional skills and rich experience of operators, enterprises may organize periodic training and learning activities. In this case, operators can participate in various training and competitions, such as various simulation competitions or actual operation competitions. Such activities may cover multiple aspects such as the teaching of theoretical knowledge, training of practical operation skills, and sharing of cases. In actual operation, operators must not only master the necessary theoretical knowledge, but also have strong operation capabilities, only in this way can they adapt to work needs. Through continuous learning and practice, operators can gradually improve their professional skills and ability to deal with emergencies.
Taking into account the main factors that lead to the instability of film bubbles in film blowing machines include inappropriate temperature settings, raw material formulations or quality problems, mismatching of extrusion and traction speeds, insufficient efficiency and uniformity of the cooling system, and insufficient skills and experience of operators. In view of the above influencing factors, they can be improved by adjusting the temperature, selecting appropriate raw material formulations or materials, increasing the extrusion speed and reducing the traction speed, reasonably controlling the cooling water volume, improving the cooling system design, and optimizing the operator skill training methods. In order to meet these challenges, the operation team needs to make targeted adjustments and improvements according to the specific conditions. Under the premise of ensuring the normal production of products, reducing energy consumption is an important way to improve economic benefits. In addition, in order to ensure that the film blowing machine can work stably and improve the quality of film bubbles, companies also need to strengthen the inspection and management of raw materials and improve the professional skills and experience of operators.
