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Are you facing common extrusion challenges like melt fracture, shark skin, or die build-up in your PE/PP film, pipe, fiber, or profile production lines? These issues are not only frustrating but can also slow down production, increase downtime, and degrade surface quality.

PFAS-free processing aids (also known as polymer processing aids or PPAs) are additives used in plastics manufacturing, particularly extrusion processes like film, pipe, fiber, and profile production. Traditional PPAs often rely on fluoropolymers (a subset of PFAS, or per- and polyfluoroalkyl substances, known as “forever chemicals” due to their persistence and potential health/environmental risks). Due to tightening global regulations—such as the EU’s Packaging and Packaging Waste Regulation (PPWR) banning PFAS in food-contact packaging starting August 2026—many suppliers have developed effective PFAS-free alternatives. These alternatives help prevent issues like melt fracture (sharkskin effect), die build-up, and high friction during processing, while improving throughput, surface quality, and reducing downtime. They are increasingly adopted in polyolefins (e.g., PE, PP), recycled materials, and food-contact applications

In this article, we’ll explore how SILIKE SILIMER PFAS-Free PPAs can help you resolve these problems, boost productivity, and stay ahead of regulatory requirements.

Why Should You Act Now: The Pain Points You Can’t Ignore

Polymer Manufacturers across the globe face significant hurdles in extrusion processes. Here are the most common problems that affect your production lines:

• Melt Fracture: This occurs when the polymer flow rate is too high, causing the polymer to tear as it exits the die, resulting in rough surfaces that compromise quality.

• Shark Skin: A scaly surface that forms when the material moves too quickly through the die, leading to uneven flow and poor finish.

• Die Build-Up: Materials like PE and PP can stick to the die, resulting in build-up that disrupts the extrusion process, forcing frequent downtime for cleaning.

These issues increase operational costs and reduce production efficiency, leaving your business vulnerable to market competition. How can you fix these problems and stay ahead of upcoming regulations?

PFAS-Free Compliance is Just Around the Corner

Starting in August 2026, the EU Packaging and Packaging Waste Regulation (PPWR) will ban PFAS in food-contact packaging. This shift is forcing manufacturers to look for alternatives to harmful chemicals that can affect their production processes and safety standards.

Here’s where SILIKE’s SILIMER Series PFAS-Free Solutions comes in.

SILIKE’s SILIMER Series PFAS-Free PPAs provide a sustainable, high-performance solution that helps your extrusion production lines run smoother, faster, and more efficiently—all while keeping you fully compliant with food-contact packaging regulations.

How SILIKE PFAS-free PPA Processing Aids Solve Your Extrusion Problems

Switching to SILIKE SILIMER PFAS-Free Functional Additives offers a range of benefits that will streamline your production and address the key challenges your extrusion lines face:

√ Eliminate Melt Fracture & Shark Skin
Our Non-PFAS Process Aids improve the flow behavior of the polymer, significantly reducing melt fracture and shark skin defects. This results in smoother surfaces and a cleaner, more professional finish.

√ Reduce Die Build-Up & Cleaning Downtime
With improved die lubrication, our non pfas additives help prevent materials from sticking to the die. This reduces the frequency of die build-up, meaning less downtime for cleaning and a more efficient production process.

√ Increase Line Productivity
SILIKE PFAS and fluorine-free alternative solutions enhance polymer flow, enhancing smoother operation and higher throughput. Less downtime and fewer interruptions lead to more efficient production and faster cycle times.

√ Meet PFAS-Free & Food-Contact Compliant
SILIKE SILIMER PPAs help you meet global regulatory standards, including the EU Packaging and Packaging Waste Regulation (PPWR), and support that your production is safe for food-contact materials.

√ Support Your Sustainability Goals
Switching to SILIKE PFAS-free PPAs aligns with your sustainability goals by reducing environmental impact and ensuring compliance with the latest regulations.

√ No Interference with Post-Extrusion Processes
Unlike other additives, SILIKE 100% Pure PFAS-free PPA, fluorine-free PPA products, PFAS FREE, fluorine-free PPA masterbatches do not interfere with printing, laminating, or sealing, maintaining the high quality of your product without compromising downstream processes.

Real-World Results: Manufacturers Already Benefiting

Manufacturers who have already switched to SILIKE SILIMER PFAS-Free PPAs have reported:

• Higher throughput: Faster production speeds without sacrificing quality.

• Fewer interruptions: Reduced die build-up means fewer cleaning cycles and more uptime.

• Safer production: Compliance with PFAS-free regulations for safer, food-contact material production.

These manufacturers are now enjoying higher efficiency, greater regulatory compliance, and increased profitability.

Ready to Solve Your Extrusion Problems? Here’s How to Get Started

Are you ready to eliminate extrusion challenges and embrace a sustainable, compliant, and high-performing solution? 

Contact SILIKE now to learn how  SILIMER PFAS-Free PPAs can optimize your extrusion lines. We can provide you with a case study and walk you through the exact benefits our solution brings to manufacturers just like you.

Don’t wait until August 2026! Take action now to future-proof your extrusion lines and ensure you stay ahead of the latest regulatory changes.