Plan Ahead so You Can Disconnect Over the Long Weekend
It's almost that time of year again—the 4th of July. As we prepare to celebrate our independence, it's also a time when many businesses, including injection molders and extruders, are planning to shut down for the holiday. While a well-deserved break is crucial, preparing for the restart after the shutdown is equally essential. That's where Asaclean® Purging Compounds come into play.
Many companies tend to turn off the heaters, empty the screw and barrel, and call it a day, only to face high scrap rates and lengthy production start times when they resume work. But there's a better way. Utilizing Asaclean® for proactive sealing before the shutdown, you can prevent unwanted carbon buildup, unlock significant savings, and ensure a smooth startup after the holiday break.
Why Should You Be Concerned About Carbon Buildup?
Most thermoplastic resins degrade and contaminate the product if left in the barrel, even temporarily. Engineering or super-engineering resins increase this likelihood. Even when the heaters are off, the resin in the barrel takes hours to cool off and stop degrading.
Over this time, carbon forms and adheres to any available metal surface, leading to efficiency losses at startup. As a case study, let's consider ABS. When natural ABS sits at 460°F heat for 60 minutes, the resin quickly oxidizes and turns to carbon and black specks. If you shut off the heats, on a Friday evening with ABS in the barrel, you'll find a significant carbon buildup by Monday morning. Here is where Asaclean® shines. Sealing the screw and barrel with Asaclean® before shutting down prevents carbon buildup, ensuring a smooth and efficient startup.
Sealing and Purging with Asaclean®
"Sealing" refers to using a heat-stable purging compound like Asaclean® during shutdowns and extended downtime events. Upon startup, you run another barrel full of a purge through the system and switch to the next resin, thus kickstarting your production.
For injection molding, sealing is typically straightforward. Keep the barrel full of production resin, wipe down the hopper, and add the appropriate purging compound. When the purge begins exiting the nozzle, increase the back pressure and screw speed to their maximum safe values. Once the purge pile is free of contamination, turn off the heats immediately. The barrel must be full purging compounds to prevent oxidation and subsequent contamination. Upon startup, get the heats up, add production resin, and purge out the purge. You'll be ready for production in no time.
Extrusion requires a similar approach. Purge out the production resin, wipe out the hopper, and purge the extruder with a non-filled, thermally-stable purge compound until it's free of contamination and previous resin. Slow the screw down to keep the flights as complete as possible, then shut the heat off. Upon startup, turn the heats on and purge the purging agent with the following production resin.
The Advantages of Pre-Holiday Sealing with Asaclean®
Proactively sealing your equipment with Asaclean® before the 4th of July shutdown brings numerous advantages. It reduces the risk of carbon buildup, resulting in decreased scrap rates and quicker startups.
Moreover, it decreases the need for maintenance purging, contributing to a more efficient production process. All these add to substantial cost savings, making your operations more economical and profitable.
Notably, Asaclean® Purging Compounds ensure your machines are well protected even if your operations take a break for Independence Day. This protection translates into a smooth restart when you return from the holiday, allowing you to hit the ground running and deliver quality outputs faster.
How Can You Maximize Your Savings with Asaclean®?
Optimizing your use of Asaclean® starts with getting the suitable purging compound for your application. Choosing a product that works well at the production resin processing temperature is vital to prevent degradation and minimize purging times. It's also crucial to follow proper sealing instructions for your equipment. Correct sealing procedures are instrumental in preventing oxidation and subsequent contamination, whether it's injection molding or extrusion.
Don't Forget to Order Your Asaclean® Before Independence Day
Given the considerable benefits of using Asaclean® Purging Compounds, ensuring you have enough stock to last through the holiday shutdown is essential. With the holiday fast approaching, remember to place your order soon. We wouldn't want you to miss out on the benefits of sealing your equipment for the shutdown due to a lack of supplies.
Asaclean® has proven to be a game-changer for many businesses, reducing startup time significantly and improving production efficiency. Rodney Davenport, Vice President of CH3 Solutions, a very successful custom molder in Georgia, stated, "Sealing with Asaclean® has kept our machines in great shape, and startups from an extended shutdown are a breeze."
Enjoy the Long Weekend With Peace of Mind
The 4th of July is a time of celebration. But remember, your injection molding or extrusion equipment doesn't need to suffer from the break. Seal your machines with Asaclean® Purging Compounds before the holiday shutdown, and ensure you'll start up smoothly and efficiently when you're back.
Make the most of your Independence Day break, knowing you've done everything possible to prevent carbon buildup and improve post-holiday production quality. Preventive purging and proactive sealing are not just good practices—it's the smart way to safeguard your production and keep your business competitive. Happy Independence Day!
New to Sealing with a Purging Compound? Claim your FREE 10-minute consultation with our Purging Experts now and unlock the benefits. Schedule your consultation here!
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