Tech Bulletin
Cast Film & Extrusion Coating
Die Lip Buildup: Causes and Remedies
What is Die Lip Buildup?
In This Bulletin Die lip buildup (DLBU) or die drool is the gradual accumulation of material on the die lips or at
the exit of extrusion dies. DLBU can be a chronic problem in high-output cast film or extrusion
• What is Die Lip Buildup? coating operations and is generally more likely to occur when extruding polymer blends that
are highly filled or pigmented.
• Causes of Die Lip Buildup
As the buildup accumulates, it degrades and may eventually create visible defects or gauge
• Troubleshooting variations in the film. These deposits must be physically scraped or removed from the die
causing lost production time, film waste, and increased operating expenses.
• Potential Remedies
NOVA Chemicals has studied DLBU extensively and developed this memo as a general guide
to help troubleshoot and reduce or eliminate DLBU problems.
Causes of Die Lip Buildup
There are many causes of DLBU and no single or universal solution has been identified
that will eliminate DLBU in all systems. However, recent studies at NOVA Chemicals and
published literature suggest that addressing the following factors can reduce chronic DLBU:
Die Exit Geometry
DLBU is more common in die exits that form 90° angles or have converging geometry.
Several studies have shown that die exits with flared or diverging angles accommodate
die swell at the exit and are less prone to buildup.
Component Separation and/or Entrapped Moisture DLBU in White
Blends of polymers with additives or inorganic materials are frequently prone to separate Pigmented PE
in high-shear, high-temperature extrusion processes. The separation of lighter components
often leads to die deposits. Moisture entrapped in the polymer or blend components can
accelerate separation and buildup.
Melt Pressure and Die Exit Velocity
Elevated pressures and exit velocities can create a vacuum or vortex at the die exit. This
vacuum can pull lighter components onto the die lips. Reducing melt pressures and exit Polymers exhibiting die
velocities can reduce the vacuum and DLBU. swell and polymers with
Polymer Architecture broad molecular weight
Polymers exhibiting die swell and polymers with broader molecular weight distributions distributions are typically
are often prone to generate DLBU. However, the lower molecular weight fractions of some more prone to generate
broad molecular weight distribution (MWD) polymers may act as lubricants that reduce
shear induced separation and thus reduce DLBU. Therefore, the best polymer architecture Die Lip Buildup.
will depend on the specific blend and processing conditions.
US/Pittsburgh | +1.412.490.4170 | 800.222.7213 x4170 | [email protected] | novachemicals.com 1 of 2
Tech Bulletin
Die Lip Buildup
Troubleshooting Die Lip Systematically remove blend components to isolate the source. If any components
Buildup Problems
NOVA Chemicals recommends the steps
1 such as color concentrates are hygroscopic, test the material after complete drying
to less than 0.05 weight % moisture.
listed here to troubleshoot DLBU problems.
Since these recommendations will result
in lost production time, consider running 2 Substitute the primary polymer with an alternate. Determine the effects of properties
such as molecular weight distribution, viscosity, and additive types and levels.
simulations on a smaller scale extruder with
the same materials and similar processing
conditions if possible.
3 Inspect the die exit for wear and surface irregularities. Notches or nicks at the die
exit can create different flow patterns leading to polymer adhesion and buildup.
4 Evaluate a wider die exit if possible by mechanically opening the gap.
5 Analyze the actual buildup for compositional analysis. Information related to the
molecular weight and chemical composition can help identify to root cause.
Potential Remedies to Die Lip Buildup Problems
Many chronic DLBU problems do not have a single solution and may require multiple
remedies. Consider the following recommendations:
Change the Die Exit Geometry
Using a diverging die exit can reduce the polymer melt pressure and velocity at the exit.
NOVA Chemicals recommends evaluating alternate exit geometries on smaller equipment
first and consulting your machinery manufacturer before making any permanent changes.
Evaluate a Process Aid to Specifically Address DLBU DLBU in Strand
While most process aids are designed to eliminate melt fracture, certain process aids are Die Control Sample
very effective at reducing or eliminating DLBU.
Plate or Coat the Die Interior
Uniform metallic coatings that resist abrasion and oxidation can reduce DLBU by reducing
shear and polymer adhesion at the die walls. Finally, consider changing base materials,
blend components, additives, and/or processing conditions. In general, blend components
with similar rheological profiles are preferred. Drying or replacing hygroscopic components
of blends can also reduce DLBU and improve film quality.
Control Sample with
Specific Process Aid
Publications and References
Chai, Choon K.; Adams, Gordon; Frame, Jason “Polyethylene Die Deposit - Measurement, Formation
Mechanism, and Routes to Reductions” Annual Technical Conference - Society of Plastics Engineers
(2001), 59th (Vol. 1), 401-406
Chaloupkova, K.; Zatlloukal, M. “Theoretical and Experimental Analysis of Die Drool Phenomena for
Metallocene LLDPE” Polymer Processing and Science - 2007. 871 - 881.
US/Pittsburgh | +1.412.490.4170 | 800.222.7213 x4170 | [email protected] | novachemicals.com 2 of 2
The NOVA Chemicals logo is a registered trademark of NOVA Brands Ltd.; authorized use/utilisation autorisée.
H16CT
