In plastics manufacturing, efficiency is king. Effective changeovers are critical to maintaining high productivity and reducing costs, whether you're working in injection molding or extrusion. Many manufacturers rely on virgin resins or regrind materials during these transitions, believing they're cost-effective. But is this approach truly effective?
In this blog, we'll explore the limitations of purging with virgin resin and compare it to the advantages of using purging compounds. From reducing downtime to preventing contamination-related defects, purging compounds can transform your process and save you money in the long run. Let's break it down by process.
Injection Molding: The Pitfalls of Using Virgin Resin
Many manufacturers advocate for using virgin resins or regrind materials during changeovers to reduce costs. At first glance, this approach might seem like an effective way to save money on material usage. However, the reality is quite different—this cost-saving idea is often an illusion. Here's why.
The primary issue lies in "layering." While virgin resins may appear to facilitate effective changeovers, they lack the necessary technology to remove stubborn build-up inside the machine. This practice can sometimes exacerbate contamination issues, leading to recurring defects and higher long-term costs.
Purging compounds, on the other hand, are specifically designed with advanced cleaning additives to address these challenges. Relying on virgin resin for purging is akin to washing your clothes without detergent—it may look clean on the surface but doesn't remove the underlying contaminants.
The key to reducing changeover time—and costs—is minimizing material waste and machine downtime. Machine downtime is the primary driver of costs during a changeover, not the cost per pound of material. Purging compounds excel in this area, enabling faster transitions and preventing unplanned downtime caused by residual contamination, such as carbon deposits or previous colors.
Extrusion: Moving Beyond Inefficient Practices
Some manufacturers still resort to outdated methods in extrusion processes, such as tearing down equipment or flushing large quantities of virgin resin. While teardown can ensure a clean start-up, it is labor-intensive, time-consuming, and costly. Flushing with virgin resin, meanwhile, can require running multiple gaylords of product—often without fully resolving contamination issues.
One manufacturer committed to frequent teardown was losing an entire shift to manually cleaning their extruder and barrel. By transitioning to a purging compound solution, they harnessed advanced cleaning technology to significantly reduce their overall changeover time and return to production faster.
The Competitive Edge of Purging Compounds
Both injection molding and extrusion present unique challenges when it comes to cleaning and changeovers. Purging compounds provide manufacturers with a competitive edge by:
The choice is clear: purging compounds are the smarter, more efficient alternative to virgin resin or regrind. Whether addressing contamination, carbon deposits, or stubborn color changes, investing in the right solution ensures your process is streamlined and your machines stay productive.
Ready to Optimize Your Changeovers?
At Asaclean®, we specialize in purging solutions tailored to your needs. Whether you're tackling tough contamination or striving to reduce downtime, we're here to help.
Explore how our purging compounds can improve your operations today. Request a free sample or contact us to speak with a purging expert and take the first step toward a more efficient process.