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In polyethylene (PE) film extrusion, die buildup and carbonized deposits are common challenges that reduce production efficiency, compromise film surface quality, and increase downtime. These problems are especially prevalent when using masterbatches with poor demolding properties or insufficient thermal stability.

Understanding the root causes and implementing effective solutions—such as knowing which processing additives can prevent die buildup in PE film extrusion—can help packaging manufacturers, film extrusion companies, and compounding suppliers improve productivity, minimize defects, and achieve consistent film quality.

1. Why Die Buildup Occurs in PE Film Extrusion

 • Poor Demolding Performance

When the PE melt lacks proper lubrication, the molten polymer sticks to the die surface. Over time, these deposits oxidize and carbonize, forming stubborn buildup.

Industry Example: A film producer reported severe die adhesion within just 3 hours when using an unoptimized PE masterbatch, resulting in frequent downtime and reduced production efficiency.

• Insufficient Thermal Stability of Masterbatches

Approximately 80% of die buildup issues stem from low thermal stability of additives in masterbatches, such as dispersants or carrier resins. Low-quality recycled resins or unstable additives decompose under high temperature and shear, leaving black or brown deposits on the die.

2. Effective Solutions to Reduce Die Buildup

• Traditional Approach: Fluoropolymer-Based PPAs

Historically, fluoropolymer-based PPAs were widely adopted to reduce die buildup and enhance processing efficiency in PE film extrusion.

However, this approach now faces increasing challenges:

- Regulatory Risks: Many fluoropolymer-based PPAs contain PFAS, which are subject to strict global restrictions.

- Compliance Uncertainty: Manufacturers relying on PFAS-based solutions face higher compliance risks and potential market limitations.

- Sustainability Concerns: Industries and customers increasingly demand PFAS and fluorine-free alternative solutions that align with sustainability goals.

• Fluorine-Free Alternatives: PFAS-free Polymer Processing Aids

PFAS-free PPAs not only match the performance of conventional Fluorine PPAs, but also:

√ Enhance production efficiency by reducing downtime and improving melt flow

√ Improve film quality with smoother surfaces and more consistent thickness

√ Support compliance with Non-PFAS, PFAS-free innovation

3. Looking for the Right PFAS-Free PPA Solution?

Are you facing polymer processing challenges such as die buildup, melt fracture, or inconsistent film quality—while seeking to eliminate fluorine additives?

Or are you searching for a trusted manufacturer of PFAS-free PPAs that deliver both high performance and sustainability?

• SILIKE SILIMER PFAS-Free PPAs – Green and Effective Processing Additive Solutions for Film Extrusion

SILIKE SILIMER PFAS-Free Polymer Processing Aids (PPAs) are engineered to provide sustainable, high-performance solutions for modern extrusion lines.

•  Why Choose SILIKE PFAS-Free Polymer Process Aids for Film Extrusion?

√ 100% PFAS-Free & Fluorine-Free: Fully compliant with global environmental regulations

√ Wide Application Range: Suitable for LLDPE, LDPE, HDPE, mLLDPE, PP, and various polyolefin film products, including blown film extrusion, cast film extrusion, multilayer films, flexible packaging, and transparent films.

√ Enhanced Production Efficiency: Reduces downtime, improves melt flow, and prevents surface defects such as sharkskin and melt fracture

√ Aesthetically Pleasing Film Quality: Delivers smooth surfaces, consistent thickness, and high-quality final products

√ Supports Sustainability: Aligns with regulatory trends and customer demands for eco-friendly solutions

• Customer Success Case: Packaging Film Producer Boosts Efficiency with SILIKE PFAS-free PPA Processing aids 

 A leading packaging film manufacturer in Southeast Asia faced frequent die buildup and downtime,their extrusion lines required cleaning every 6–8 hours, causing high maintenance costs and inconsistent film quality.

Switching to SILIKE PFAS-Free Functional Additives enables blown film extrusion lines to achieve better slip performance, reduced die buildup, longer production runs, and environmental compliance—all without compromising performance.

Today, many manufacturers focused on sustainability are seeking alternatives that deliver the same processing benefits without environmental risks. SILIKE PFAS-free PPAs are the modern answer—solving extrusion defects like melt fracture and sharkskin while improving both efficiency and quality. Of course, some manufacturers are still waiting and seeing. Sometimes we communicate with those customers who are looking for alternatives to fluorine-free PPA.What Comes First in Your Extrusion Line? For your PE film extrusion process, what matters most?

- Surface quality to impress your customers

- Production speed to maximize efficiency

- Protect the environment and care for health

- Regulatory compliance to stay ahead of PFAS bans

With SILIKE PFAS-Free PPAs, you don’t have to choose—you get all four.
→ SILIKE: 20+ Years of Innovation in Silicone-Based Additives

For more than 20 years, SILIKE has been committed to advancing the balance between technology and sustainability. Since 2004, we have specialized in silicone-based additives for polymers and rubber, creating eco-friendly and high-performance solutions trusted worldwide.

Our silicone-based plastics additives and thermoplastic elastomers products have become the green solution provider across multiple industries, including: Footwear materials, Cables & wires, Automotive interiors, Pipes, Engineering plastics, Films & packaging, WPCs, Coating, and more..

With silicone as our foundation and innovation as our tool, SILIKE continues to develop materials that shape a sustainable polymer future.

Looking to minimize die buildup, extend run times, and boost polyolefin film quality?
SILIKE’s Non-PFAS Process Aids are your next-generation solution for sustainable and efficient polymer extrusion. Contact Amy Wang: amy.wang@silike.cn, visit www.siliketech.com