Efficient Die Cleaning to Save Time and Boost Productivity

In plastic processing, dies are critical for shaping products to precise specifications. Over time, these dies can accumulate plastic residue, degraded material, and contamination, negatively impacting product quality and process efficiency. Regular cleaning is essential to ensure consistent performance and prolong the service life of dies.

Challenges of Traditional Die Cleaning Methods

Traditionally, die cleaning has involved manual methods such as scrubbing with brushes or using rotary tools. While this approach might eventually clear away contamination, it comes with significant challenges:

• Lengthy Color Changes: The cleaning process can take up to two hours for complex color changes (e.g., transitioning from darker to lighter colors).
• Excessive Resin Usage: Manual cleaning often requires large amounts of virgin or recycled polypropylene (PP), sometimes up to 20 kg, to flush out contaminants.
• Potential Risks to Operators and Tooling: Manual cleaning poses risks such as burns from handling hot material and possible damage to the dies' surface, leading to premature wear or costly refurbishment.

A More Efficient Approach: Using Purging Compounds

Many plastic processors are turning to purging compounds for a faster, more effective cleaning solution. A recent test comparing traditional cleaning methods to using Asaclean EX highlighted significant advantages.

With Asaclean EX, cleaning time was reduced by up to 85%, from 30 minutes to just 4 minutes per die. Additionally, the amount of material needed for cleaning was drastically reduced: only 3 kg of purging compound and 4 kg of PP were required. This not only saves time but also reduces material waste.

The absence of abrasive tools in this process helps preserve the dies' surface and dimensions, ensuring longer intervals between maintenance cycles and preventing the costly damage associated with traditional cleaning methods. A technician noted that this approach may even eliminate the need to fully remove the die, allowing for quicker color changes by only cleaning key components on-site, potentially saving up to 1.5 hours per changeover.

Operational Advantages

The benefits of purging compounds for die cleaning extend beyond time and material savings. Adopting this method can improve overall plant operations in several ways:

• Minimized Downtime: Faster cleaning reduces production interruptions, allowing machines to return online quickly.
• Increased Safety: Reducing manual interaction with hot materials and tools lowers the risk of injury to operators.
• Extended Tooling Life: Maintaining the die reduces the frequency of refurbishment or replacement, lowering long-term maintenance costs.

Conclusion

Optimizing the die-cleaning process for plastic processors is a simple yet effective way to enhance production efficiency, reduce material costs, and extend tooling life. By incorporating purging compounds into your maintenance routine, you can minimize downtime and increase your operation's overall productivity while ensuring the quality of your end products remains consistent.