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Process Consistency

#1
Hi Family, i am chemist Bolu and i am new member in the house. I came across this forum when i was searching for a clue on how to have a consistent product quality with my new organization.
I work in a blown film industry as the assurance quality and there has been a lot of process inconsistencies which had degenerated into customer dissatisfaction. I need a contribution from someone experienced on the field: polyethylene blown film.
Major customer complains include:
1. Blown film thickness variation
2. blown film openability issue
3. blown film sealing
Thanks
 
Elsmar Forum Sponsor
#3
Thanks for your anticipated contribution and response.

My organization is into polyethylene and polypropylene packaging materials like shopping bags, plain rolls Agro sacks, shrink wraps etc. We do not have a standard operating procedure for our operations and there is no standard recipe formulation for our blown film.

We keep alternating the percentage composition of our HDPE/LDPE/MASTERBATCH/ and FILLER in the recipe formulation composition. This practice has cost the organization so much in terms of customer dissatisfaction.

Going forward, i need a standard recipe formulation for blown film shopping bags that will yield a better result in product performance. And also a standard operating procedure for blown film extrusion line.

Thanks
 

Ninja

Looking for Reality
Staff member
Super Moderator
#4
Hello Chemist, and welcome to the Cove.

You say Blown PET...do you mean Blown Polypropylene (BOPP)?
PET is typically melt stretched...

Either way, the blowing process tends to revolve primarily around heat consistency, pull speed consistency and pressure consistency on the blow stack.
Are you doing 10ft diameter blow stack? Or are you working with little tubes?

I see your follow up post...that references constant changes of chemical composition...when you change the material, you change everything...so what is it you are really asking? It seems like you already know the root cause, so how can we help?
 

Sidney Vianna

Post Responsibly
Staff member
Admin
#5
I would be very surprised if you get this type of assistance here because the people with the knowledge would likely be your competitors. To expect they part with valuable intellectual property to help a competing organization is just unrealistic.

Good luck.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#6
Specific advice is also likely to be irrelevant in many ways. There are so many factors that will influence teh outcome from your equipment to process settings to environmental conditions to raw material properties. What you probably need is a tutorial in how to design studies to understand these factors and where to set them to guarantee the output.
 
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