POLYPROPYLENE

SHEET EXTRUSION
GUIDE
DEFINITION OF SHEET
Extruded Using a Die: Sheet usually has a thickness greater than 0.010 inches (0.254
millimeters).

Sheet extrusion for polypropylene usually falls into two major categories:

1. Thick Sheet (>0.125 in/>3.175mm) which is used for structural parts,

tank liners, etc.

2. Thin sheet (<0.125 in/<3.175mm) which is shaped by a forming process

and used in packaging.

POLYPROPYLENE SHEET EXTRUSION GUIDE 1

WHY SHOULD I USE HUNTSMAN
POLYPROYPLENE FOR MY SHEET EXTRUSION?

Polypropylene is a strong, low density polymer which exhibits outstanding resistance to heat, good
surface characteristics (hardness, gloss, rigidity, etc,), excellent mechanical properties and low taste
and odor.

Some of the features, which make polypropylene a valuable sheet extrusion material, are:

STRENGTH AND LIGHT WEIGHT chemicals, detergents, low boiling hydrocarbons

and alcohols. However, caution should be
With a specific gravity of 0.90 – 0.91, polypro-
exercised in the presence of halogenated solvents
pylene has the lowest density of all the commod-
and hydrocarbons, which may permeate and
ity thermoplastics. Its high strength-to-weight soften polypropylene. Testing to simulate ex-
ratio makes it attractive in many applications
treme use conditions is strongly recommended.
requiring greater rigidity than that possible using
other polyolefins.
PROCESS TECHNOLOGY CAPABILITES
HEAT RESISTANCE Huntsman provides a wide range of sheet extru-
sion polypropylene products. With the diverse
Polypropylene has better heat resistance than any capabilities of our polymerization plants, we can
other low cost thermoplastic. It is suitable for obtain polypropylene products that exhibit
continuous low stress applications up to 275ºF properties “unique” to the industry. Huntsman
(135ºC). can produce Polypropylene sheet grades for
industrial applications that uses thick to ex-
STRESS CRACKING tremely thin guage products for high clarity food
Polypropylene is normally not susceptible to containers. Our polymerization processes have
environmental stress cracking. the ability to produce products from high stiff-
ness and excellent impact to sheet that requires
low stiffness and good impact. We at Huntsman
CLARITY are able to produce homopolymers, random
The “see-through” clarity properties of polypro- copolymers, impact copolymers, TPO’s, and
pylene are the maximum obtainable among the blends based on our customer needs.
polyolefins. Nucleation and new clarifiers,
especially in thin sheet and the final formed part
enhance this clarity.

SOLVENT AND CHEMICAL RESISTANCE

At both ambient and elevated temperatures
polypropylene exhibits excellent resistance to
direct attack form non-oxidizing inorganic

POLYPROPYLENE SHEET EXTRUSION GUIDE 2

GRADE SELECTION
Factors Affecting Processing
MELT FLOW
The melt flow of a given polypropylene grade is
indicative of both its extrudability and the
subsequent formability of the sheet from which
it is extruded. Low melt flow grades require
more work to plasticate the resin, and provide
lower extruder outputs for a given power con-
sumption. However, since sheet made from low
melt flow grades had high melt strength, it can
be melt thermoformed. The higher melt flow
polypropylene grades have less melt strength and
sheet extruded from these grades is usually
processed using Solid Phase Pressure Forming
(SPPF). See Table A, below for typical proper-
ties of several Huntsman polypropylene sheet
extrusion grades.
USE OF REGRIND
In the sheet extrusion and forming process
regrind ratios of 50% are not uncommon. Rec-
ognizing the need for polypropylene grades that
will resist thermal degradation associated with
the use of regrind, Huntsman has formulated
extrusion grades that maintain their physical
properties after five or more re-extrusions.

Table A: Recommended Huntsman grade for sheet extrusion

HOMOPOLYMERS
TENSILE @
YIELD FLEX M ODULUS IZOD @ 23ºC HDT @ 66PSI

M ELT ELONG.-
PRODUCT (g/10min) (ps i) (M Pa) @ YIELD (ps i) (M Pa) (ft-lb/in.) (kJ/m) (ºF) (ºC)

P9G1Z- 030X 0.5 248 36 11 200,000 1379 1.3 .06 190 88

6310 0.5 5200 36 >90 245,000 1690 1.7 .09 2 16 102

6311 0.8 5400 37 >50 260,000 1795 1.0 .05 245 118

P4G2Z- 073A 1.9 5400 37 9 215,000 14 8 3 0.6 .03 198 92

P4G2Z- 073B 2.0 5700 39 7 240,000 16 5 5 0.9 .05 226 108

6311cs295* 2.0 5400 37 >50 260,000 17 9 5 0.7 .04 245 118

P4G2K- 135X* 2.1 5655 39 8 230,000 15 8 6 0.9 .05 207 97

* Clarified

POLYPROPYLENE SHEET EXTRUSION GUIDE 3

Table A: Recommended Huntsman grade for sheet extrusion (continued)

RANDOM COPOLYMER
TENSILE @
YIELD FLEX M ODULUS IZOD @ 23ºC HDT @ 66PSI

M ELT ELONG.-
PRODUCT (g/10min) (ps i) (M Pa) @ YIELD (ps i) (M Pa) (ft-lb/in.) (kJ/m) (ºF) (ºC)

9231* 1.0 3900 27 >300 14 0 , 0 0 0 10 0 0 1. 8 . 10 196 91

P5L2K- 055X* 1.9 5220 36 11 18 0 , 0 0 0 1241 1.0 .05 192 89

P5L2K- 025* 1.9 4900 34 11 16 7 , 0 0 0 1150 1. 2 .06 194 90

P5L2Z- 038 2.0 4785 33 12 18 0 , 0 0 0 1241 0.8 .04 181 83

* Clarified

IMPACT COPOLYMER
TENSILE @
YIELD FLEX M ODULUS IZOD @ 23ºC HDT @ 66PSI

M ELT ELONG.-
PRODUCT (g/10min) (ps i) (M Pa) @ YIELD (ps i) (M Pa) (ft-lb/in.) (kJ/m) (ºF) (ºC)

14S05A 0.4 4200 29 >100 18 0 , 0 0 0 12 4 0 nb nb 195 91

37S 04A 0.4 4 10 0 28 >100 17 5 , 0 0 0 12 0 7 nb nb 2 12 100

38S 05A 0.55 3700 25 >700 15 5 , 0 0 0 10 7 0 nb nb 196 91

38S 07A 0.7 3700 25 >700 15 5 , 0 0 0 10 7 0 nb nb 196 91

P9H1A- 029X 0.7 4200 29 16 15 5 , 0 0 0 10 7 0 nb nb 189 87

14S1A 1.0 4100 28 >100 15 5 , 0 0 0 10 7 0 5.0 .3 200 93

18S2A 2.0 3500 24 >700 16 0 , 0 0 0 1100 nb nb 199 93

SPECIALTY COPOLYMER
TENSILE @
YIELD FLEX M ODULUS IZOD @ 23ºC HDT @ 66PSI

M ELT ELONG.-
PRODUCT (g/10min) (ps i) (M Pa) @ YIELD (ps i) (M Pa) (ft-lb/in.) (kJ/m) (ºF) (ºC)

9402 1.0 3900 27 >300 15 0 , 0 0 0 1035 6.2 .33 190 88

9403 1.0 3300 23 >250 12 5 , 0 0 0 860 nb nb 175 79

9234 1.5 4200 29 >700 15 0 , 0 0 0 1035 5.7 .3 185 85

9230 T2 3.0 4300 30 >100 229,000 1580 1. 1 .06 225 107

POLYPROPYLENE SHEET EXTRUSION GUIDE 4

HUNTSMAN SPECIALIZED PRDUCTS
IMPACT/STIFFNESS BALANCE
Polypropylene homopolymers is widely used for
sheet extrusion. However, homopolymer grades
favor the stiffness side of the impact/stiffness
balance and becomes brittle at temperatures of
41ºF (5ºC) and lower. Utility at these tempera-
tures is drastically reduced if impact resistance is
required.
Polypropylene impact copolymers are recom-
mended when greater impact strength is desired
than can be obtained from homopolymers.
However, copolymers are generally less rigid
than homopolymer polypropylene. In contrast to
homopolymers, the stiffness is not a function of
melt flow, but is dependent on the percentage of
rubber phase in the copolymer.
Polypropylene random copolymers were devel-
oped to combine clarity and impact strength.
They exhibit clarity equal to or better than
homopolymers, and have moderate impact
strength at temperatures down to 32ºF (0ºC),
with limited utility down to -4ºF (-20ºC). The
heat resistance of polypropylene homopolymer
is retained.
GLOSS AND CLARITY
The gloss and clarity provided by homopolymer
polypropylene grades are dependent on the melt
flow of the particular grade used as well as the
processing method employed to extrude the
sheet. With an increase in melt flow there is an
increase in gloss and clarity. And, the cooler the
chill rolls used in extrusion of the polypropylene
sheet, the greater the gloss and clarity.
If glossy sheet is melt formed the gloss and
clarity will be lost. However, if it is processed
using SPPF process the gloss and clarity of the
sheet will be retained. In any case, the gloss and
clarity of finished parts will not exceed the
initial sheet properties.
In general, homopolymer and impact copolymer
POLYPROPYLENE SHEET EXTRUSION GUIDE
grades of polypropylene provide comparable
levels of gloss. However, impact copolymers
have poor clarity.
NUCLEATED POLYPROPYLENE
General purpose polypropylene is composed of a
relatively small number of large crystallites. In
nucleated polypropylene, the addition of a
nucleating agent gives rise to additional sites for
crystallite formation. The resulting structure is
composed of a large number of small crystal-
lites.
Specific processing and performance character-
istics of nucleated polypropylene grades, which
should be considered when selecting a product
for your application, include the following:
¨ High stiffness, clarity, and elevated distor-
tion temperatures under load (DTUL) can
be obtained by nucleating polypropylene.
¨ Nucleation decreased the recrystallization
time, which helps reduce part warpage in
the forming process.
¨ Nucleation can increase the stiffness and
DTUL by 10%, however the impact
strength correspondingly decreases by as
much as 50%.
¨ Gloss and clarity are enhanced by the large
number of small crystallites which result
from the addition of a nucleating agent.
RADIATION RESISTANCE
Huntsman has the capabilities to produce sheet
extrusion grades with “state of the art” radiation
resistance. This meets the industry standards of
2.5 megarads, which is minimum of 60Co
radiation, as well as maintaing performance.
Please contact your technical service engineer
for additional information.
SPECIAL FOOD PACKAGING CONSIDERATIONS
The majority of polypropylene sheet production
5
is thin sheet (<0.125in/<3.175mm) intended for
rigid packaging applications. The polypropylene
used in these applications must meet FDA
requirements and must have good organoleptic
properties.
While all Huntsman polypropylene sheet extru-
sion grades are manufactured to comply with
FDA regulations for use in food contact applica-
tions, some grades may have specific conditions
of use limitations. For this reason, we strongly
urge you to involve your Huntsman sales repre-
sentative in the identification of appropriate
Huntsman polypropylene sheet extrusion grades
for your specific end-use.
Huntsman screens its polymers to meet the
specific organoleptic requirements of the user,
including odor testing, taste transfer, flavor
scalping, and other food/container interactions.
This often requires close interaction with the
customer to define his requirements and is
especially critical in barrier packaging applica-
tions.
Another major end use for extruded sheet is
thick sheet used for structural applications. A
typical example is chemical treatment vats.
These applications require creep resistance, heat
stability, stress crack resistance, and chemical
inertness.

POLYPROPYLENE SHEET EXTRUSION GUIDE 6

EXTRUSION EQUIPMENT SELECTION
OUTPUT CAPACITY are not recommended for polypropylene sheet
extrusion.
Commercial sheet extruders typically use 3-½ in.
(88.9mm), 4-½ in. (114.3mm) and 6 in.
(152.4mm) diameter extruders, while 2-½ in. SCREW DESIGN
(63.5mm) diameter extruders are less commonly The screw design determines the melting, mix-
used. Output capacity ranges for various diam- ing, and metering capabilities of an extruder.
eter extruders with varied L/D ratios are as Single stage and two-stage screws are both
follows: commonly used. Single stage screws are more
Extruder prevalent in the industry because polypropylene
Diameter L/D Ratio Output Capacity normally does not need venting. However, filled
2 ½ in. 24:1-36:1 200-400 lb./hr. grades and the use of additives, which carry
64mm 91-181 kg/hr moisture or volatile components, necessitate
vented extrusion. Recommended screw designs
3 ½ in. 24:1-36:1 400-700 lb./hr for single and two-stage configurations are
89mm 181-318 kg/hr illustrated in Figures 1A and 1B.
4 ½ in. 24:1-36:1 800-1400 lb./hr Screws are often bored to allow cooling of the
114mm 363-635 kg/hr feed zone. This is useful for cooling high melt
6 in. 24:1-36:1 1500-2500 lb./hr flow materials to increase shear, which ensures
152mm 680-1134 kg/hr melt homogeneity.

OUTPUT TO POWER RATIO
Depending on the screw diameter, output to
power ratios range from 4 to 7.5 lbs./hr (1.8 to
3.4 kg/hr) per horsepower for each inch (mm)
extruder diameter. The range is strongly depen-
dent on the screw design and polymer rheology.
Larger L/D ratios result in larger output to
power ratios. High melt flow resins require less
power input than fractional melt flow resins to
achieve equivalent output rates.
Typical extruder L/D ratios are 24:1 and 30:1. A
minimum L/D ration of 30:1 is preferred be-
cause longer residence time ensures melt homo-
geneity and provides 20-30% greater energy
efficiency. L/D ratios greater than 36:1 can
potentially promote polymer degradation. They
POLYPROPYLENE SHEET EXTRUSION GUIDE
MIXING SECTIONS
Mixing sections are required when melt homo-
geneity and compositional uniformity is not
achieved by simple plastication. Dynamic
mixing sections can be placed at the screw tip or
in the decompression zone of a two-stage screw.
Dulmadge, Maddox, pineapple and pin mixers
are the most common types.
Static mixers are placed down-stream of the
extruder adapter. The mixing vanes/flights are
mechanically constrained by the outside walls of
the extension section. The most commonly used
static mixers are Koch™ and Kenix™ mixers.
The principle disadvantage of static mixers is the
potential for material contamination.
7
Figure 1A: Screw design for single stage polypropylene

Figure 1B: Screw design for two stage polypropylene

POLYPROPYLENE SHEET EXTRUSION GUIDE 8

BACK PRESSURE
In addition to melt plasticating, the extruder
must also develop enough pressure to propel the
melt through the die. The pressure generated is
dependent on screw design and melt rheology.
Back pressure is necessary at the adapter, which
the valve controls it, to enhance backflow and
induce shear mixing, thereby achieving better
melt homogeneity. It also limits the magnitude
of surging. Typical back pressures will range,
respectively, at recommended extrusion tem-
peratures.
Normally 40 to 200 mesh screens are inserted in
front of the breaker plate to remove any filter-
able contamination. A plugged screen pack can
result in excessive back pressures and should be
changed at regular intervals.
DIES
The function of a die is to deform a plastic melt
to a specific, uniform geometry, without surface
imperfections of degradation resulting from
stagnation in the die block. To maintain uniform
geometry, the melt must have the same average
flow rate across the entire outlet cross section.
Surface imperfections and degradation are
minimized by designing the die to minimize
shear rates at high flow rate, while simulta-
neously minimizing residence time in the
dieblock. Several types of dies meet these
requirements for sheeting polypropylene.
COATHANGER DIES
For most applications (gauge >0.012 in/>0.3048
mm) is a single manifold, coathanger die,
equipped with restrictor bar and adjustable land
is sufficient. The coathanger manifold symmetri-
cally distributes the melt outward to the edges of
the die. The restrictor bar is used to ““choke off”
the manifold cross-section in such a manner that
uniform flow rate is provided across the entire
length of the outlet. The adjustable land provides
gauge control of the extrudate. A minimum land
gauge to length ratio of 20:1 is required when
POLYPROPYLENE SHEET EXTRUSION GUIDE
extruding polypropylene to avoid die swell and
melt break which can cause a rough surface
appearance.
USE OF DECKLE BARS
At times it is necessary to make sheet that is
narrower than the full width of the die. This is
usually accomplished with deckle bars on the die
face at the edges. This results in some stagnation
and polymer degradation behind the deckle bars,
but some of it can be alleviated by bleed holes in
the die end-plates. Occasionally internal
deckling can be accomplished by inserting
machined brass shims in the die. This reduces
stagnation but the technique is restricted to sheet
of a rather narrow gauge range.
FIXED LAND DIES
For thin gauge (<0.012 in/<0.3048 mm) applica-
tions, fixed land dies are used, but it is necessary
to have the die designed to match the rheology
of the polymer to be extruded. This type of die is
more commonly found in cast film applications.
MULTI-MANIFOLD DIES AND FEEDBLOCKS
With the advent of co-extrusions, multi-manifold
dies and/or feedblocks have become necessary to
converge multiple extrudates into sheet form.
Feedblocks divide and recombine multiple melt
streams into a single multilayer stream prior to
entering the die. Feedblocks typically will
combine up to seven melt streams. The streams
must have similar melt rheology and thermal
stability.
Multi-manifold dies are necessary for applica-
tions requiring more than seven layers, or for
combining materials that are rheologically or
thermally incompatible. Multi-manifold dies are
also used when there are a large difference in
layer thickness (for example, coating applica-
tions). They can be fed directly by the extruders
or by a combination of feedblock and extruders.
Combinations of feedblock and multi-manifold
dies allow encapsulation of thermally sensitive
9
materials to be coated by high processing tem-
perature resins. They have also been used to
produce sheets of nine or more layers, and for
coextruding high viscosity, filled layers with low
viscosity coating layers.
ROLLSTACK
As the molten plastic web leaves the die, it is
transferred to a vertical stack of three rolls,
which function to cool the plastic, gauge the
sheet to a desired thickness and impart surface
texture. The web can be threaded up or down the
three rollstack, although the downstack configu-
ration is the most common way.
The rolls are driven by a variable speed drive,
and are interconnected so that all the rolls have
the same surface speed. The rollstack should be
geared to handle a range of speeds from 0 to 100
feet (0 to 30.5 meters) per minute.
The rolls usually range in size from 12 to 24
inches (305 to 610 mm) in diameter, and have a
highly polished chrome surface. However,
special roll surfaces such as nickel plating for
corrosive polymers or textured rolls for surface
texture are occasionally used.
To make quality polypropylene sheet, uniform
temperature control is essential. Total tempera-
ture variance across each roll should be less than
41ºF (5ºC) to avoid warpage and structural
variations.
The top and bottom rolls are movable and can be
mechanically adjusted to the desired gap. They
are held in position by pneumatic or hydraulic
“hold down”. In most cases pneumatic systems
are sufficient, however, in cases where the sheet
is “floating” the rolls, additional “hold down” is
applied via a pneumatic or hydraulic booster.
Caution should be exercised with add-on booster
systems to prevent warpage of rolls or the
rollstack frame. “Hold down” forces will range
from 70-350 lb. (31.8-158.8 kg) per inch (mm)
of sheet width (PLI).
“Hold down” is applies only at the first nip to
POLYPROPYLENE SHEET EXTRUSION GUIDE
avoid cold working the recrystallized sheet with
excessive pressure application (calendaring) in
the second nip. In general, higher “hold down”
force is required for thinner sheet to maintain its
dimensional uniformity and surface quality.
AUXILIARY EQUIPMENT
Other equipment is used in conjunction with the
basic extrusion line.
HOPPER DRYERS, CRAMMERS, AUGUR FEEDERS
Hopper dryers can be used to pretreat the mate-
rial feeding the extruder system. In the case of
polypropylene, hopper dryers are most com-
monly used to dry regrind or filled polymers. In
some cases, they are used simply to anneal or
raise the temperature of the feed. Preheating the
feed increases output and minimizes surges.
Hopper crammers are required when using low
bulk density resin such as regrind or powder to
insure uniform supply of resin to the extruder
feed zone. This also minimizes surging. Dry
additives are metered into a hopper at the feed
throat with an augur feeder. They are particu-
larly useful for fine powders and solid color
concentrates. Liquid color concentrates can be
injected at the throat of the hopper with liquid
metering pumps.
MELT PUMPS
Downstream of the extruder, melt pumps are
increasingly utilized to meter the extrudate from
the extruder to the die. Melt pumps are positive
displacement gear pumps that can generate high
and relatively constant head pressures. Thus,
they can be used to pump a wide variety of
plastics through the die with maximum extrudate
dimensional uniformity at cost effective output
rates.
Care must be exercised in section of the extruder
screw design when using a melt pump. The gear
pump inlet pressure is lower than normal back
pressure encountered in screw metering opera-
10
tions. The screw is not required to generate high
pressures, so it must be designed to generate
sufficient shear energy to thoroughly melt and
homogenize the polymer at the lower operating
pressures. A polypropylene screw design for use
with melt pumps has a longer feed section, a
shorter metering section, shallower channel
depth and lower compression ratio than a con-
ventional design.

OTHER ADDITIONS
A variety of useful equipment additions which
can be added for convenience and operating
efficiency include:
¨ Automatic screen changers cut downtime
labor costs.
¨ Thermocouples on the roll inlet and outlet
or mounted onto the surface of the rolls
provide better measurements for a more
accurate temperature control of the rolls.
¨ Dial indicators for nip gauge adjustments
allow safe and convenient gap adjustment
compared to using feeler gauges.
¨ Caliper or nuclear source gauging devices
are finding increasing use for continuous
measurement and control of sheet thick-
ness. Typically these devices are provided
with a computer system which feeds back
transverse sheet dimensions to an automatic
flex lip die and machine direction measure-
ments to a line speed controller. This
system can control to + ½ % deviation. It is
especially helpful for quality control and to
minimize sheet scrap loss.
¨ Takeoff equipment includes shears for
thick sheet or winders capable of 100 feet
(30.5 meters) per minute for thin sheet.
¨ Antistatic devices are necessary for
polypropylene to minimize dirt accumula-
tion and shock hazards to the operators.

POLYPROPYLENE SHEET EXTRUSION GUIDE 11

EXTRUSION PROCEDURES AND CONDITIONS

TEMPERATURE SETTINGS extrudate uniformity problems such as surging,

voids, and unmelted resin are avoided.
Because there are many types of extruder de-
signs the settings for each extruder may vary. In
the absence of previous experience with Hunts- SCREW SPEED
man polypropylene, the following extrusion Generally, the extruder speed is set as high as
conditions are recommended. possible for increased efficiency. However, the
EXTRUDER PROFILE screw speed setting vs. Extruder power con-
Zone 1 (Feed Zone) 380-420ºF (193-216ºC) sumption is dependent on the screw design and
melt rheology. For coextrusion dies, consult with
Zone 2 400-440ºF (204-227ºC) a Huntsman technical personnel for further
Zone 3 410-450ºF (210-232ºC) information.
Zone 4 440-470ºF (227-243ºC)
Zone 5 440-470ºF (227-243ºC) ROLLSTACKS
Adapter 440-470ºF (227-243ºC)
Rollstacks can be configured either up or down
Melt Temperature 450-480ºF (232-249ºC) stack. The following settings are recommended
Back Pressure 1500-2500 psi (10-17 MPa) for best results when extruding Huntsman
polypropylene.
DIE PROFILE (COATHANGER & FIXED LAND DIES)
Zone 1 380-450ºF (193-232ºC) Rollstack settings:
Zone 2 380-450ºF (193-232ºC) Top roll 80-150ºF (27-66ºC)
Zone 3 400-470ºF (204-243ºC) Middle roll 100-175ºF (38-79ºC)
Zone 4 380-450ºF (193-232ºC) Bottom roll 80-150ºF (27-66ºC)
Zone 5 380-450ºF (193-232ºC) Die gap settings: 10% over desired gauge
The melt rheology, or melt flow, of the polymer 1st nip gap settings: 1-3% over desired gauge
is the principle factor used for selecting tempera-
2nd nip gap settings: “dead on” desired gauge
ture settings. For low melt flow polypropylene
resins, higher temperature settings are required. The first nip gap is set below gauge to compen-
For high melt flow resins, lower settings are sate for the 18% volume decrease during solidi-
more appropriate. fication of the melt. However, if the sheet polish
is inadequate, or “lakes” occur, the gap of the
first nip may be increased, and the bank read-
BACK PRESSURE justed to allow more melt through the first nip.
The variation in back pressures also a function For increased gloss, clarity and lower haze after
of melt rheology, with lower melt flow materials forming, lower rollstack temperatures are pre-
producing higher back pressure. The recom- ferred. It is imperative that the web is partially
mended back pressure are essential to insure that molten (in the core) when it reaches the second
POLYPROPYLENE SHEET EXTRUSION GUIDE 12
nip. If the web is supercooled, stress induced
crystallization (SID) occurs as a result of forces
applied in the nip, and the resulting sheet can be
difficult to form.
Special attention should be paid to setting roll
temperatures and line speed conditions when
sheeting nucleated grades. For a given melt
flow, non-nucleated polypropylene will “set-up”
or solidify more slowly than nucleated polypro-
pylene. This allow more working time on the
rolls, and ease of polishing in the second nip.
When a nucleated grade is sheeted at the same
conditions as a non-nucleated grade it will be
difficult to polish in the second nip because the
material will have already solidified.
For nucleated grades, the roll temperatures must
be increased by 20 to 30ºF (-7 to -16ºC) and the
line speed raised to decrease the time on the
rolls, so the sheet is still molten enough for
surface polishing in the second nip. It is also
possible to cold work the sheet if it has solidified
before reaching the second nip. If this occurs,
the sheet will be unformable by Solid Phase
Pressure Forming, and will exhibit excessive
stress relaxation (ripples, shrinkage) when
heated to melting. This is a common error made
by operators who are new to polypropylene
extrusion. It is strongly suggested that you
consult your Huntsman sales representative if
you have experienced problems forming sheet
extruded from Huntsman polypropylene.

DRYERS
Dryers are normally used with filled polypropy-
lenes with temperature settings ranging from 280
to 320ºF (138 to 160ºC). If polypropylene is
stored in a cold warehouse is should be brought
to at least ambient temperature before extruding.
Polypropylene can be pre-heated in a dryer to
increase throughput.

POLYPROPYLENE SHEET EXTRUSION GUIDE 13

TROUBLE SHOOTING GUIDE TO SHEET
EXTRUSION
PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY
Material build- up on die lips, or
Clean die or residue.
scratched die.

Die lip setting too close to, or below

Increase die lip setting.
desired sheet thickness.

Line in She e t – Extrus ion Uneven bank causes lines where melt
Adjust die for even gauge.
D ire ction Continuous loses contact with roll surface.

Damaged roll surface. Resurface roll.

O ne- sided shrinkage due to cold

center roll. (Sheet appears Increase center roll temperature.
corrugated.)

Extruder surge causes bank to Eliminate extruder output variation

increase and decrease. (Appears as (metering screw or melt pump
bank or bead roll ripple marks) fluctuations). See "Surging".

Polish rolls are not concentric. Replace rolls.

Worn lead bearings on rolls. Replace bearings.

Line s in She e t - Extrus ion Increase hold down. [N ote: exercise

D ire ction D is continuous Insufficient hold down pressure on top care not to exceed rollstack
roll allowing roll to float. (Appears as capabilities. Typical holddown force is
ripple marks.) 70- 350 lbs. (32- 159 kg.) per inch of
sheet width.]

Excessive winder tension - pulling

Slow down winder.
sheet through pull rolls.

Dry compound before extruding - use

Moisture in compound.
vented extruder.

Extruder output varies (surging). See "Surging".

Minimize bank and run rollstack at

Chill roll "chatter" from overloading.
within specified torque range. For
(Appears as fine parallel lines running
very thin sheet, independent roll drives
perpendicular to chill rolls.)
may be required.
Line in She e t - Trans ve rs e
Decrease speed (tension) of pull rolls,
D ire ction
Pull roll chatter or slippage. and clean to ensure positive gripping
action.

Winder pulling sheet through pull rolls. Slow down winder.

Polish rolls, reduce roll temperatures,

Web sticking to cool rolls.
and reduce melt temperature.
POLYPROPYLENE SHEET EXTRUSION GUIDE 14
PROBLEM POSSIBLE CAUSE
Bank is too large, rising and falling, or minimize differences in transverse web
"walking".
Improper die temperature settings
cause uneven flow across die.
Line s in She e t - Parabolic
M arks
Viscosity mismatch in co- extrusion.
Material contamination in extruder or
die.
Poorly polished rolls.
Temperature differential between
center, and top or bottom rolls is too
low or too great.
Surface Impe rfe ctions - Low
Insufficient bank in first nip (starved
Glos s
nip gap).
Improperly gauged chill roll nip gaps.
Web is not contacting second nip to
polish surface
Cold spot on roll surfaces.
Surface impe rfe ctions - Spot Uneven bank.
on s urface
Air bubbles trapped between center
roll and sheet before first or second
nip.
POLYPROPYLENE SHEET EXTRUSION GUIDE
SUGGESTED REMEDY
Adjust line speed, adjust die gap to
thickness, and eliminate extruder
surging.
Adjust die temperature - lower hot
zone and/or raise cold zone
temperatures.
Select polymer grades with matched
rheology, adjust melt temperatures to
match rheology, or modify feedblock
configuration.
Purge extruder and die. If problem
persists, break down line and scour
components.
Clean and polish rolls.
Adjust roll temperatures to
recommended settings.
Decrease chill roll speed, increase
output by increasing screw speed, or
adjusting restrictor bar.
Adjust gaps to recommended gauge
settings.
Increase first nip gap to allow more
material through to second nip.
Purge fouling or air bubbles from chill
rolls. Maintain uniform temperature
control across chill rolls. (Inlet/outlet
temperature difference should be less
than 10ºF or - 12ºC.)
Adjust die lips to ensure uniform flow
across die.
Reduce rollstack speed, increase first
nip gap, and increase center roll
temperature. After these adjustments,
open the roll gaps to allow trapped air
to pass through, then re- close and
resume operation.
15
PROBLEM
Surface Impe rfe ctions -
Bubble s or Fis h Eye s ,
D imple s , Pits , and Lake s
Surface Impe rfe ctions -
Rough Surface (Sharks kin,
alligator or tre ad marks )
POLYPROPYLENE SHEET EXTRUSION GUIDE
POSSIBLE CAUSE
Moisture in the feed.
Air entrapment in melt.
Roll temperatures are too cold.
Melt is inhomogeneous.
Poor roll contact caused by dirt on
rolls.
Melt is too hot resulting in polymer
decomposition.
Second gap is starved causing "lakes".
Improper roll temperature settings.
Poor roll contact in second nip.
Melt temperature is too low, or
viscosity is too high.
Die land gauge to length ratio is too
low. (Melt break or excessive die
swell at high output.
Material is solidifying too quickly on
center roll.
Moisture in feed.
Improper screw design.
SUGGESTED REMEDY
Dry pellet/additives before extruding,
and use extruding venting.
Increase back pressure and lower
rear extruder zone temperatures.
Reduce screw speed to ensure
uniform feed compression and
plastication. Vent the extruder. Use
screw design with increased feed zone
and transition length. Increase overall
compression ratio of screw.
Raise roll temperatures.
Increase back pressure and reduce
screw speed to ensure uniform feed
compression and plastication. Vent the
extruder. Use screw design with
increased feed zone and transition
length. Increase overall compression
ratio of screw.
Clean rolls and polish.
Lower melt temperature by lowering
extruder zone temperatures.
Increase first nip gap to allow more
material through to second nip.
Readjust roll temperatures to
recommended settings.
Increase take- off speed, increase pull
roll tension, increase first nip gap, or
reduce line speed.
Increase melt temperature or decrease
output rate. Increase die land gauge to
length ratio. Increase first nip hold
down pressure.
Increase melt temperature or decrease
output rate. Increase first nip hold
down pressure.
Increase roll temperatures, increase
line speed, or increase melt
temperature.
Dry material before extruding − use
vented extruder.
Change out screws. Increase back
pressure. Decrease output rate.
16
PROBLEM
She e t Curl - Edge Curl
Stre aks and D is colorations -
Additive D is pe rs ion
Stre aks and D is colorations -
Contamination
Stre aks and D is colorations -
D e compos ition
Stre aks and D is colorations -
Plate Out
Surging - Imprope r
Equipme nt or Se tup
POLYPROPYLENE SHEET EXTRUSION GUIDE
POSSIBLE CAUSE
Temperature differential across rolls or Adjust roll temperatures to
between rolls is too great.
Insufficient cooling.
Poor color dispersion.
Melt inhomogeneity and insufficient
mixing in extruder.
Improper cleaning or extruder and
die.
Residual contaminants in feed hopper
or transfer tubes of extruder throat.
Melt temperature is too high resulting
in material decomposition.
Excessive roll temperatures.
Excessive extruder temperatures.
Excessive additives in the polymer.
Improper screw design.
Insufficient back pressure valving.
Adjust temperatures to recommended
settings or invert temperature profile
Incorrect extruder temperature profile.
(adapter zone should be the same
temperature as the die).
Bridging in feed zone.
Insufficient melt homogeneity (mixing).
SUGGESTED REMEDY
recommended settings.
Reduce line speed and reduce roll
temperatures.
Use color concentrate vs. Dry blend.
Ensure that the concentrate carrier
(liquid of solid) is rheologically
compatible with polypropylene.
Change screw. Increase back
pressure by valving. Use static or
dynamic mixers.
Purge extruder and die. If problem
persists, break down line and scour.
Static mixers and screw may require
decompositional cleaning.
Purge entire delivery system.
Lower extruder zone temperatures.
Reduce roll temperatures and increase
line speed.
Reduce extruder temperatures to
recommended settings.
Reduce additive levels and consult a
Huntsman representative.
Change screw, or alter to meet
recommended design specification.
Add valving or screen packs to
increase back pressure. Lower screw
speed.
Increase back pressure valving.
Cool hopper zone. Cool feed zone of
screw.
Control screw temperature. Change
screw design. Increase back pressure.
Use hopper crammer if there is a large
particle size difference in feed material
(excessively large or small particles in
regrind).
17
PROBLEM
Surging - Equipme nt
M alfunctions
Poor M e lt The rmoforming or
SPPF Proce s s ability -
Exce s s ive M achine
Dire ction Orie ntation
POLYPROPYLENE SHEET EXTRUSION GUIDE
POSSIBLE CAUSE
Malfunctioning thermocouples or
heaters.
Drive malfunction.
Variation in line power.
Too much tension on pull rolls.
Winder pulling sheet through pull rolls.
Excessive calandering in first or
second nip.
Excessive drawdown between die and
rollstack.
Sheer induced crystallization at first or
second nip.
Cold working in first or second nip.
SUGGESTED REMEDY
Checking for overheating or
underheating. Verify correct controller
functions (temperature reading, control
setting response). Replace
malfunctioning equipment.
Consult with extruder manufacturer.
Check drives and utility connections.
Decrease speed of pull or increase
chill roll and line speeds.
Decrease winder tension.
Adjust the die gauge closer to finished
sheet gauge. Increase melt
temperature. Decrease hold down
pressure in second nip.
Increase output or decrease line
speed.
Increase melt temperature or output
and line speed.
Increase melt temperature or output
and line speed to ensure that sheet is
not completely solidified before
entering the nip. Decrease hold down
pressure. Use die lip adjustment and
line speed to achieve gauge instead of
calendaring to gauge in rollstack.
18
SOLID PHASE PRESSURE FORMING (SPPF)/
THERMOFORMING

DESCRIPTION
Thermoforming and Solid Phase Pressure Forming (SPPF) use somewhat similar methods to form
or shape polypropylene sheet. The forming or shaping is accomplished by applying heat and pres-
sure to the polypropylene sheet. The forming can be a post operation but there are zone in-line
formers. The plastic is softened by the heating process and then is formed by being forced against
the tooling (mold) until it cools.

The difference between the two forming processes is that in SPPF the polypropylene is formed
below the crystalline melting point, while in thermoforming the material is formed in the melt
phase. SPPF does not require special thermoforming equipment, however, accurate control at the
heating unit is necessary to assure a uniform temperature between 300-320ºF (149-160ºC). The
thermoforming machine forms products within the thermoforming window. The stress, strength,
rigidity, and flexibility determine the proper temperature range. Compared with products formed in
the melt phase, SPPF can produce stiffer parts with less material. SPPF improves the sidewall
strength and sometimes clarity (monolayer applications) of the container and increases the stress
factor. Plug assist and higher forming pressures are required for SPPF and the plug design is more
critical than in conventional melt phase forming.
For grade selection and equipment manufacturers of both SPPF and thermoforming equipment,
please contact your Huntsman sales representative.

POLYPROPYLENE SHEET EXTRUSION GUIDE 19

 POLYPROPYLENE SHEET EXTRUSION GUIDE

3040 Post Oak Boulevard Houston, TX 77056

Technical Services: 1-888-635-8324
Web Site: www.huntsman.com

The data and information represented herein refer to typical values obtained in our laboratories by the methods or apparatuses indicated, and should be so considered.
Since processing variables are a major factor in product performance, this information should serve only as a guide. Since customers’ testing conditions are outside our
control, the reproducibility of our data in a customer’s testing facility is not guaranteed. There is no implied warranty of merchantability or fitness for a particular
purpose. Establishing satisfactory performance of the resin for the intended application is the customer’s sole responsibility. No warranty is given concerning the existence
or non-existence of any patents claiming any pertinent subject matter presented herein. The Company assumes no obligation, express or implied, or liability for use of the
information and data presented.
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