In this thesis, a commercial “soft” roller-based contact cleaning method used in flexible film manufacturing was investigated experimentally and theoretically. It is known from the sponsoring company Teknek that their roller products are used to clean flexible optical films. However, as the optical films become thinner, there are specific problems to do with the optical film wrapping around the cleaning roller. This effect causes production down time and a significant revenue loss for the major film production companies who are the key customers of Teknek. To address the “wrapping” problem, rollers and exemplar film surfaces were analysed in terms of their topography, material, and contact mechanics in order to understand the wrapping phenomena. The project encompassed experimentation via a series of wrapping trials under lab conditions and the use of a developed cleaning simulator rig involving the surface metrology of both rollers and film, the material chemistry, and the surface energy measurements. Additionally, a theoretical wrapping model was developed based on the renowned contact mechanics model, JKR theory. The model highlighted a possible correlation between roller topography and film wrapping. To support the model development, further adhesion testing was carried out. From the collected experimental data, the theoretical model was refined and validated. In conclusion, a theoretical model has been established on the basis of surface roughness and contact mechanics. JKR theory has been improvised using surface metrology data and shows that surface roughness plays a vital role in the wrapping phenomena. The theoretical model has been compared to each combination of cleaning roller and optical film. The results show there to be a correlation between the film roller topography and wrapping