Introduction: The Cost of Contamination in Film Extrusion
If you're in blown film or cast film extrusion, you know that contamination isn't just an annoyance—it’s a major source of lost productivity and profit. Black specks, gels, and color streaks lead to scrapped product, increased downtime, and costly teardowns.
Many processors accept these issues as inevitable, but the reality is that most contamination problems are completely preventable with the right approach.
This blog will break down the true cost of contamination and how Asaclean® Purging Compounds help leading film extruders:
What Is Contamination Really Costing You?
Contamination affects more than just product quality—it impacts your entire operation.
Production Scrap: Wasted Resin and Lost Profits
Every time contamination ruins a run, you’re losing product, material, and time. Color streaks and haze lead to downgraded or scrapped film. Black specks and gels result in customer complaints and wasted rolls. Layer contamination in multi-layer extrusion can create structural issues, leading to even more rejected material.
Even when resin prices are low, lost production time is costly. If a changeover takes eight hours instead of two, that’s six hours of lost production that could have been prevented. Using an effective purging compound like Asaclean® PLUS Grade or Asaclean® N-Series Chemical Purging Compounds can help remove contamination efficiently while minimizing scrap.
Unnecessary Teardowns and Manual Cleaning
If your plant frequently pulls dies, screws, and melt pumps for deep cleaning, your team is spending valuable time on maintenance instead of production. Labor-intensive cleaning adds to operating costs, and excessive wear and tear on equipment increases long-term expenses. Every unnecessary teardown results in extended downtime, which means lost revenue.
Instead of waiting for contamination to force a teardown, using Asaclean® as part of a preventative purging program keeps equipment clean without requiring costly disassembly.
Lengthy Changeovers Hurting Your Output
Switching from one color or resin to another is one of the biggest challenges in blown and cast film extrusion. Many processors still rely on running virgin resin or regrind to flush out the previous material, but this method is slow, ineffective, and costly.
Changeovers take longer than necessary, residual contamination leads to scrap after startup, and increased downtime means fewer good parts produced. Using Asaclean® during changeovers reduces scrap and speeds up the transition between materials and colors, getting production lines back up and running faster.
How to Prevent Contamination Before It Costs You
Contamination-related downtime can be significantly reduced or eliminated with a few key strategies.
Purge Between Runs to Prevent Layering
Running one resin or color for too long without purging causes material layering inside the screw, barrel, and die. Over time, these layers lead to carbon buildup and contamination. Using Asaclean® before material changeovers prevents layers from forming and reduces the risk of carbon contamination.
Use Chemical Purging Compounds for Low-Flow Areas
Many contamination issues originate in low-pressure areas such as dies, melt pumps, and static mixers. These areas allow material to accumulate, degrade, and create defects in finished products. A chemical purging compound like Asaclean® N-Series or PLUS Grade expands to reach these hard-to-clean areas and effectively removes stubborn residue.
Seal the Machine During Shutdowns
When equipment sits idle over weekends or holidays, oxidation and contamination build up inside the system. If a machine is not properly sealed, startup contamination can cause extended downtime and additional scrap. Sealing with a heat-stable purge like Asaclean® NCR Grade prevents oxidation and ensures a cleaner startup.
Use EX Grade for Easy Screw Pushes and Faster Teardowns
For processors who must pull screws, choosing the right purging compound can make a significant difference in downtime and labor costs. Asaclean® EX Grade is designed for easy screw pulls, peeling off like a banana skin and eliminating the need for manual scrubbing. Many film extruders have reduced their screw pull times from 12 hours to just four hours by switching to EX Grade.
Conclusion: Prevent Contamination, Increase Profitability
Contamination in film extrusion isn’t inevitable—it’s preventable. By purging at the right times with the right Asaclean® grades, processors can reduce scrap, eliminate unnecessary teardowns, speed up color and material changes, and extend equipment life.
If your plant is struggling with contamination, there’s a better way—and Asaclean® can help.
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.