Are Your Screw Pulls Wasting Hours of Production Time?
Screw pulls are one of the most time-consuming maintenance tasks in plastic processing. Whether dealing with contamination, routine maintenance, or screw design changes, removing and cleaning a screw without the right tools can take hours—slowing production and increasing costs.
But what if you could cut your screw pull time by 92%?
With Asaclean® EX Grade, processors are turning this frustrating and labor-intensive process into a fast, simple, and highly effective operation. This blog will explore why EX Grade is the best-kept secret in the industry and how it can dramatically reduce downtime and labor costs.
Why Traditional Screw Pulls Waste Time and Money
If you're pulling screws without a purging compound, you’re likely spending far more time and money than necessary.
The Problem With Manual Screw Cleaning:
- Excessive downtime: Removing screws manually takes hours of valuable production time.
- Carbon buildup: Without a purge, old resin layers, carbon deposits, and contaminants require intense scrubbing, wire brushes, and even torches to remove.
- Increased labor costs: Manual cleaning often requires multiple operators, driving up labor expenses.
- Higher risk of injury: More handling increases the risk of burns, strain injuries, and accidents.
The solution? Using Asaclean® EX Grade eliminates excessive scrubbing, speeds up cleaning, and frees up valuable production time.
How Asaclean® EX Grade Makes Screw Pulls Easier Than Ever
Asaclean® EX Grade is designed to make screw pulls fast, easy, and effective. Here’s how it works:
- Softens and loosens resin buildup, so it slides off easily—like peeling a banana.
- Penetrates deep into screw flights to remove contamination before removal.
- Reduces manual scrubbing, eliminating the need for wire brushes or scraping tools.
- Minimizes labor and downtime, cutting cleaning time by up to 92%.
- Prevents contamination issues during reassembly, ensuring a cleaner startup.
What Does This Mean for Your Bottom Line?
A leading packaging manufacturer using Asaclean® EX Grade reduced screw pull time from 12 hours to just 3 hours, saving $25,000 in lost downtime over a year.
Before Asaclean® EX:
- 12 hours per screw pull
- $1,500+ lost per downtime event
- Heavy manual labor required
After Asaclean® EX:
- 3 hours per screw pull
- 75% faster cleaning
- Minimal manual cleaning needed
Wouldn’t you rather be producing good parts instead of spending hours cleaning screws?
The 3-Step Process to a Faster, Easier Screw Pull
Step 1: Purge Before the Screw Pull
- Run Asaclean® EX Grade through your machine to clean out contamination.
Step 2: Remove the Screw
- Pull the screw—EX Grade will come off cleanly, taking all the contamination with it.
- No tough scrubbing or scraping needed.
Step 3: Inspect & Reassemble
- The screw should be nearly spotless with minimal touch-up cleaning.
- Reinstall and restart production in record time.
What Processors Are Saying About Asaclean® EX
"With Asaclean® EX, pulling a screw is like peeling a banana."
— Production Manager, Film Extrusion, KY
"We cut our screw pull time from 12 hours to 4 hours. EX Grade saves us $25,000 a year."
— Wire Extruder, Midwest USA
"After purging with Asaclean®, the screw was spotless. Our screw supplier said he’d never seen one come out so clean."
— President, Custom Molder, Ohio
How Much Can You Save?
If you're spending hours on screw pulls, it’s time to rethink your process. With Asaclean® EX, you can:
- Save up to 92% of your screw pull time
- Reduce manual labor and maintenance costs
- Prevent future contamination and downtime
- Keep your production running smoothly and profitably
Take the Next Step: Try Asaclean® EX Today
You don’t have to suffer through long, difficult screw pulls anymore. Join the processors who are saving hours of labor and thousands of dollars by switching to Asaclean® EX Grade.
Ready to trial a new purge compound and experience the benefits for yourself? Get a free sample and schedule a meeting with an Asaclean purging expert to set up your onsite trial today. Our team is dedicated to helping you find the perfect purging solution for your needs, providing expert guidance and support every step of the way. Don't let another day go by without maximizing your efficiency and profitability – contact us now to get started on your journey to plastics processing excellence.
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