Abstract: A method of forming a thermoplastic polymer film includes melting and subjecting a polymer resin material to shear stresses in a range of 250 kPa to 400 kPa to form a refined resin material and forming the thermoplastic polymer film from the refined resin material. The film is substantially free of microgels having a largest dimension greater than 50 microns. The film has a thickness in a range of 15 micron to 80 microns. The film has a microgel count in a range of 0 to 0.2 per mm2 of microgels having the maximum dimension greater than 10 microns.

Abstract: A method of refining a polymer resin material is provided. The method comprises melting and subjecting the resin material to shear stresses in a range of 250 kPa to 400 kPa to form a refined resin material. The refined resin material may be extruded, solidified and cut into reduced microgel resin pellets, which may be subsequently melted and extruded to form a reduced microgel film.