Bubble Film Machine Troubleshooting Guide

Effective troubleshooting ensures minimal downtime and consistent product quality. Below are common issues, their causes, and step-by-step solutions.

1. Uneven or Burst Bubbles

• Causes:
  • Impurities or moisture in raw materials.
  • Incorrect extruder/die temperatures.
  • Blockages or wear in the mold flow channel.
• Solutions:
  • Screen or dry raw materials to remove moisture/contaminants.
  • Adjust temperatures based on material specifications (e.g., LDPE/LLDPE).
  • Clean or polish mold surfaces; replace severely damaged molds.

2. Uneven Film Thickness

• Causes:
  • Fluctuating screw speed or worn screw/barrel.
  • Mismatch between extrusion and traction speeds.
  • Uneven die gap or air ring blockages.
• Solutions:
  • Stabilize screw speed by repairing motor controls.
  • Calibrate traction speed to match extrusion output.
  • Adjust die bolts for uniform gap; clean air rings for consistent cooling.

3. Excessive Machine Noise

• Causes:
  • Worn bearings, loose components, or lack of lubrication.
  • Motor issues (e.g., damaged fan or bearings).
  • Resonance from unstable machine placement.
• Solutions:
  • Lubricate or replace bearings; tighten bolts.
  • Repair/replace faulty motor parts.
  • Install shock-absorbing pads or reinforce the foundation.

4. Air Leakage in Bubble Formation

• Causes:
  • Faulty seals, damaged valves, or loose connections.
  • Insufficient compressor pressure.
• Solutions:
  • Apply soapy water to detect leaks; replace worn seals.
  • Ensure compressor meets pressure requirements.

5. Heating System Failures

• Causes:
  • Broken heating elements or faulty thermostats.
  • Power supply issues (e.g., blown fuses).
• Solutions:
  • Replace damaged heating elements; calibrate thermostats.
  • Check fuses, voltage, and wiring connections.

6. Film Tearing or Poor Winding

• Causes:
  • Incorrect tension control or worn winding rollers.
  • Scratches on traction rollers.
• Solutions:
  • Adjust tension sensors; replace damaged rollers.
  • Clean rollers with soft cloths to remove residue.

Technical Repair Scenario Diagram

The flowchart below summarizes key troubleshooting steps for quick reference:

Proactive Maintenance Tips

• Daily: Clean rollers, verify temperature sensors, and check for abnormal noises.
• Weekly: Inspect screw/barrel wear, calibrate pressure rollers, and adjust belt tension.
• Monthly: Lubricate bearings, validate thermostat accuracy, and clean air filters.
• Long-Term Shutdown: Clean components thoroughly, apply anti-rust oil, and store in dry conditions.

When to Seek Professional Help

If issues persist after basic troubleshooting (e.g., control panel errors or mechanical jams), contact a certified technician to avoid further damage.

By combining systematic checks with preventive maintenance, you can enhance machine longevity and production efficiency. For complex issues, always refer to the manufacturer’s manual.