**White Film Production Issues and Solutions**
White film is widely used in everyday life, from courier bags and milk packaging to toothpaste tubes and food packaging. It is produced by blending white masterbatch with resin in plastic extruders, followed by processes like blown film, stretching, and cooling. However, due to variations in raw materials among different white masterbatch manufacturers, as well as improper selection of the masterbatch by film producers, various issues can arise during production.
Below are some common problems encountered during white film manufacturing, along with possible causes and solutions for better quality control.
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**1. Crystal Formation on the Film Surface**
- **Cause 1: Poor Quality of Blown Film Material**
- Excessive use of recycled materials.
- Overuse of filler masterbatch.
- Defects in the new material during polymerization.
- **Cause 2: Issues with the White Masterbatch**
- Poor dispersion of the white masterbatch.
- High moisture content in the masterbatch.
- Insufficient density of the filter in the masterbatch.
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**2. Color Flow Pattern on the Film**
- **Cause 1: Incompatibility Between Masterbatch and Blown Film**
- The masterbatch may not be compatible with the base resin.
- **Cause 2: Screw Gap Issues in the Blown Film Machine**
- Improper adjustment of the screw gap can lead to uneven flow and color patterns.
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**3. Poor Heat Seal and Printing Strength**
- **Cause 1: Partial Cross-Linking During Corona Treatment**
- Over-treatment or incorrect settings can damage the film surface.
- **Cause 2: Incorrect Dispersant Type in the Masterbatch**
- Using an incompatible dispersant can affect adhesion and printability.
- **Cause 3: Excess Dispersant in the Formulation**
- Too much dispersant may reduce the film's ability to seal or print properly.
- **Cause 4: Slip Agent Interference**
- Some slip agents may interfere with heat sealing and printing.
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**4. Bubbles in the Film**
- **Cause 1: Issues with the Blown Film Material**
- Use of too much recycled or filler material.
- Defects in the new material during polymerization.
- **Cause 2: Problems with the White Masterbatch**
- Poor dispersion of the masterbatch.
- High moisture content.
- Excessive low-molecular-weight dispersant.
- Incompatibility between the color masterbatch and the blown film material.
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**5. Yellowing or Discoloration of the Film**
- **Cause 1: Incorrect Use of Titanium Dioxide**
- Improper concentration or type of titanium dioxide can cause discoloration.
- **Cause 2: Use of Phenol or Hindered Phenolic Antioxidants**
- These additives may react under heat and cause yellowing.
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**6. Unpleasant Odor in the Film**
- **Cause: Dispersants Containing Animal Fats**
- Some dispersants may contain animal-based ingredients that emit odors.
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**7. Excessive Deposits on the Blown Film Die**
- **Cause 1: High Content of Low-Molecular-Weight Dispersant**
- Excessive dispersant can leave residues on the die.
- **Cause 2: Presence of Slip Agent in the Blown Film Material**
- Slip agents may also contribute to deposits.
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To ensure high-quality white film production, it's essential to carefully select and test both the base resin and the masterbatch. Regular maintenance of the blowing machine and proper handling of materials can also help prevent many of these issues. By understanding the root causes and applying appropriate solutions, manufacturers can significantly improve the performance and appearance of their white films.
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