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Structural Defects and Processing Limitations for Polymer Film Blowing Applications: A Comprehensive Review of
Ilke Pelgrims1,2, Annabelle Verberckmoes1, Ignatii Efimov1
1Centre for Polymer and Material Technologies (CPMT), Department of Materials, Textiles and Chemical Engineering, Ghent University, Technologiepark 130, 9052 Ghent, Belgium.
Polymers
|December 31, 2025
Summary
This review examines defects in polymer film production using film blowing extrusion. It details common issues in conventional and sustainable films, offering solutions to improve quality and efficiency.
Area of Science:
- Polymer Science and Engineering
- Materials Science
- Manufacturing Processes
Background:
- Film blowing extrusion is a dominant method for producing plastic films, crucial for flexible packaging.
- Increasing demand for high-quality, sustainable films necessitates addressing production challenges.
- Understanding process limitations and defects is vital for optimizing film blowing technology.
Purpose of the Study:
- To comprehensively review process limitations and defects in polymer film production via film blowing extrusion.
- To identify causes and mitigation strategies for defects in both conventional and sustainable film types.
- To contribute to improved process control, waste reduction, and enhanced film quality.
Main Methods:
- Literature review of defects in conventional polyolefin single-layer films.
- Analysis of process limitations and defects in sustainable film technologies (recycled, biodegradable, blends, multilayer, MDO films).
- Discussion of molecular and processing parameters influencing defect formation.
Main Results:
- Detailed examination of common defects: bubble instability, gauge variations, wrinkles, melt fractures, optical issues, blocking, and surface imperfections.
- Elaboration on the root causes of these defects, linked to molecular and processing parameters.
- Presentation of practical mitigation strategies for both conventional and emerging sustainable film types.
Conclusions:
- Addressing film blowing defects is essential for meeting modern application demands and enhancing polymer circularity.
- Effective defect management leads to improved process efficiency, reduced waste, and higher quality films.
- A combined experimental and modeling approach is recommended for future advancements in film blowing technology.
