viton™ freeflow™ film

VITON™ FREEFLOW™ FILMImproving the Efficiency and Quality of Polyolefin Extrusion with Polymer Processing Aids

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Experts predict that the extruded plastics market will reach $291 billion by 2026, growing at a compound annual growth rate (CAGR) of 4.7%.¹ An optimized, high-speed polyolefin extrusion system that runs without interruption and produces high-quality films, plastic sheets, molded plastics, and tubing will be critical to achieve this projected growth.

For years, manufacturers have added polymer processing aids (PPAs) to resins to reduce common extrusion process problems like melt fractures and die buildup. The latest generation of PPAs require smaller amounts to improve extruder efficiency and product quality, which translates into greater opportunities for market growth.

Strong demand for improved plastic quality, higher yields, and increased production

¹Source: https://www.mordorintelligence.com/indus-try-reports/automotive-belts-and-hoses-market


Types of Polyolefin Processing Challenges

Naturally, manufacturers—especially producers who make extruded blown films and product like tubing, cable jacketing, and pipes—want to avoid processing issues that lead to lost revenue: products that fail inspection, flow line disruptions, or reduced output from downtime.

Melt fracture and extrusion instabilities are two main obstacles these manufacturers typically encounter that impact product quality, produc-tion rates, and yield.

Melt fracture will limit flow rates

Melt fracture involves stresses in the die and is often resin-related. The melt fracture—caused by extruded material sticking to the die wall and subsequently slipping as pressure builds—results in a jagged surface on the extrudate. This surface defect is also called “sharkskin” due to the regular pattern of ridges in which ruptures appear.

Extrusion Instabilities will Affect Quality and Limit Output

Die buildup causes one major instability. Mate-rial attaches to the extrudate, breaks off, and is carried downstream onto the product, affecting extrudate quality. Surface irregularities can negatively affect the product’s aesthetics and optical and mechanical properties. Often, the only solution requires shutting down the extru-sion lines to clean the die of unwanted deposits.

The operational issues manufacturers can expe-rience depends on the type of extruded product. Examples include:

• Blown film: Melt fracture causes visible im-perfections and can increase die pressure

• Wire and cabling: Die buildup distorts sur-face appearance

• Cast film: Die buildup contributes to visible and structural imperfections

• Pipe extrusion: Die buildup leads to visible imperfections and poorer physical properties

• Blow molding: Die buildup negatively impacts the appearance and structural integrity of final products, in addition to cycle time


Addressing Extrusion Problems Using Polymer Processing Aids

One simple—though not yet economical—solution used to reduce melt fracture and die buildup involves slowing the extrusion output rate. However, slowing the rate may only reduce (not eliminate) these problems.

A more practical, cost-effective approach is to use a small amount of a PPA in resin formulations. In this process, fluoropolymers migrate to the metal die surface and deposit a thin layer on walls. The polymer slips through the extruder at a uniform speed, which eliminates melt fracture and reduces die buildup.

Achieving a Smooth Process Throughput PPAs reduce friction by coating the inside of dies with a nonstick coating. This coating allows the extrusion to flow more freely and rapidly through the die opening, which eliminates sharkskin and enables higher production rates.

Reduced Die Buildup and DowntimeThe process of cleaning die buildup causes significant downtime during the production process. A suitable PPA should have nonstick properties that prevent low molecular weight fractions from accumulating at the die exit, which is a major cause of die buildup.

Faster Product ChangeoverAdding a PPA to a resin melt stream produces a slippery coating on the die surface, which makes for a faster transition between products.

The bottom-line benefits of using PPAs for extrusion


PPAs: Working Smarter, Not HarderAdding PPAs to the resin melt stream renews and replenishes the slippery coating on the die surface continuously during the extrusion process for many products. Below are some of the most common applications that benefit from PPAs.

Blown Film Applications

PPAs prevent sharkskin melt fracture and help achieve a smooth, clear film with a high-gloss finish. Combining the properties of PPAs with improved production rates, easier product transitions, and reduced yield loss leads to higher quality film at a lower cost.

Extruded Shapes

PPAs help keep the die face clean by reducing die buildup in the production of extruded shapes like tubing, cable jacketing, and piping. Cleaner dies reduce imperfections and the potential for product scrap or rework. They also lengthen intervals between downtimes required for cleaning. Smoother extrusion conditions lead to higher throughput and improved surface finish on extruded products.

Fibers and Monofilaments

PPAs reduce die buildup and resulting strand breakage. Improved throughput, faster winding speeds, and less downtime lead to higher yields and profitability.


Next generation PPAs help to transform film production by addressing common pitfalls in the extrusion manufacturing process: throughput, downtime, and scrap.

They offer more consistent performance over a broader range of processing conditions and minimize discoloration caused by thermal breakdown. They also reduce olfactory effects during processing and in final products—all at lower concentrations than older PPA technology. Viton™ FreeFlow™ PPA—the latest generation PPA—contacts and coats die surfaces more efficiently than other products on the market, so manufacturers need fewer PPAs to achieve the same results.

Introducing the Next Generation of PPAs

The Viton™ FreeFlow™ Z family of PPAs work with some of the most demanding and challeng-ing resins under a broad range of processing conditions and formulations. Like previous-gen-eration PPAs from Chemours, Viton™ FreeFlow™ Z100, Z110, Z200, and Z210 PPAs offer improved thermal stability. Greater tolerances enable extruders to push the manufacturing envelope to broader temperatures for in-creased flexibility. Also, the efficiency of Viton™ FreeFlow™ PPAs helps to maximize output.

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The information set forth herein is furnished free of charge and based on technical data that Chemours believes to be reliable. Chemours makes no warranties, express or implied, and as-sumes no liability in connection with any use of this information. Nothing herein is to be taken as a license to operate under or a recommendation to infringe on any patents or trademarks.

©2019 The Chemours Company FC, LLC. Viton™ and any associated logos are trademarks or copyrights of The Chemours Company FC, LLC. Chemours™ and the Chemours logo are trademarks of The Chemours Company.

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With Viton™ FreeFlow™ PPAs, you can do more with less.

When it comes to polyolefin manufacturing and processing, Viton™ FreeFlow™ PPAs increases the flow of ideas. With lower dosage requirements than competitive products by at least a factor of two to three,¹ manufacturers and processors get the same or even higher throughput with the highest product quality, all while lowering operating costs and reducing waste. And, because Viton™ FreeFlow™ PPAs have fewer negative reactions with other additives, customers can rely on them to deliver consistently efficient performance throughout their operations.

Why Viton ™ FreeFlow ™ PPAs?

• Faster startup by eliminating melt fracture faster than other PPAs

• More cost-effective production by increasing output and reducing waste

• Produces clear, high-quality film by improving surface finish; film is smoother at any thickness, and pipe is stronger

• Longer production run times and prolonged equipment life by reducing die buildup caused by other additives, enabling them to operate at lower pressures

• Performs extremely well in the presence of other additives, reducing the need to increase dosage and costs

About Viton™ FreeFlow™ Polymer Processing Aids

Our team of experts in Viton™ FreeFlow™ PPAs collaborates with customers to identify the right grade to meet needs and achieve peak component performance.

Peace of mind with a partner you can trust.

¹Source: https://www.marketsandmarkets.com/PressReleases/extruded-plastic.asp

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