Luckily Purgex delivers versatile purging compounds for extruders designed for performance and engineeredto combat these challenges extrusion molders face. We always recommend stepping down as you change into a resin with a lower processing-temperature range. CPC suppliers should be able to provide estimates on how much purge to use based on the screw diameter and how severe the purging application. Plot No-451, Old Market Lesliganj, Palamau Dist. None of them want to deal with an awful shift starting up on Monday.. Additionally, we will hear first-hand experiencefrom machinery maker LeistritzExtrusionand Asaclean sister company Asahi Kasei Plastics of North Americaone of the largest compounders in North America. You will be redirected to the ChemTrend Global website where youll find your requested content in English. E Grade is a purging compound for thermoplastic injection molding and extruder machines. Learn why purging compounds are so important and see how Asaclean helps your entire team succeed. In order to build up pressure, in many cases it helps to leave in place screen packs and breaker plates (if used). E Grade is ideal for shutdown and sealing applications to ensure fast and clean machine start-ups. But when it comes to cleaning twin-screw extrusion equipment, there isnt a one-size-fits-all process or purging-compound solution. min read. Tip 4: Make sure you are optimizing your screw pushes for easier teardowns: If changeovers are the biggest challenge that compounders face, screw pushes are a close second. It is also advisable to change the screen pack after purging is complete so that no purged contaminants break loose or bleed into the process. Sealing with a heat-stable material ensures that no further degradation occurs and also provides further cleaning. He says, Watch for degradation and contamination when processing heat-sensitive resins like PVC or EVOH. Then increase the screw speed to the maximum safe rpm once the purge starts to come out of the machine. Sometimes a change in product requires you to swap out a screw element, and this can be time-consuming if the screws are not in an ideal condition for removal. With these recommendations in mind, purging procedures for the extrusion process vary according tothe grade youre using. Most of my guys reach out to me a few weeks before the July 4 or Christmas holidays to make sure they have stock before they take a break. When transitioning between two incompatible polymers, two differing MFI ranges, or two different matrices, it is best to use a specialized purge compound. Various factors such as temperature and application time have an influence on the cleaning result. These applications include: What issues are you currently experiencing? The most efficient way is to use purging compounds in a preventative maintenance program. Do not increase temperature inside the barrel until you are certain all the PVC has been removed. But if you proactively clean your systems, non-glass-filled grades are perfectly acceptable. AG Grade is one of our best cleaning purge compounds for thermoplastic injection molding and extrusion machines. Compounders push screws for three main reasons: They may be required by the compounder to ensure 100% no polymer cross-blending; Changeovers require a different screw design; Severe contamination cannot be removed by normal purging. Asaclean's CP Grade purging compound is also suitable for fast and effective purging of hot runner systems. Maintenance departments often clean screws wrongly, causing serious and expensive damage. Always check with the CPC supplier for screen-pack and die clearance requirements. No items currently match your filtering criteria. Chem-Trends Ultra Purge purge compounds have been formulated to provide high performance with a lower the cost of cleaning. Pass through dies as small as .030 (.755mm) in diameter. Neutrex, Inc. For example, a periodic purging regimen should be established to prevent contamination build-up, which could lead to more complicated purging scenarios requiring greater time and effort. Plastics Purging Compounds | Plastics Technology Our singular focus is saving your facility save time and money. C Grade is a cost-effective mechanical purging compound suited for basic color and material changes for thermoplastic injection molding and extrusion molding machines. Feed two-barrel capacity of purging compound into the extruder. Asaclean has several large compounding customers who run several resins or the same resin with different additives. Historically, CPCs have been used less frequently in extrusion than injection molding because of equipment design and the fact that extrusion is a continuous process whereas injection molding is a cyclic process. Mechanical Purging Compounds depend on your machines power to do the work. Our singular focus is saving your facility save time and money. Using the right purging compound helps you maximize your operational efficiency by effectively eliminating all contamination and increasing up-time and productivity. These resins inevitably break down and form a lot of carbon deposits. Start by assessing the status quo, as well as defining future needs. A solution that liquefies polycarbonates and doesnt allow them to solidify during the temperature change By doing so, severe buildup on the screw, barrel, hot runners and extrusion dies can be avoided, resulting in less production stoppages, machine downtime, and material waste. There are grades that go up to 790 F but that isnt everything. This often happens when processors are running on tight deadlines or when they have limited budgets for purge. Dyna-Purge Purging Compounds: A New Level of Purging Homepage They both work with all resins processing between 340F and 610F. Clean Xpress - Purging compound for extrusion & injection molding Purging Benefits for Cast & Blown Film Extrusion | Asaclean Depending on your specific needs, the Unitemp team has various Pekutherm products that work for different machine sizes, processing temperatures, colors, and assorted plastics.This chart can help you navigate through our different formulations.However, you are always welcome to call our office at (888) 864 8367 for friendly assistance. A Chem-Trend purging compound can purge all of your biggest frustrations and keep you moving forward. We are here to Help. }, false ); document.getElementById( "ak_js_1" ).setAttribute( "value", ( new Date() ).getTime() ); With a vast distribution network set up across the globe, getting the Purgex you need is easier than you might think. location = 'https://purgexonline.com/contact-us-at-purgex-quality-purging-compounds/thank-you/'; Taking a narrow view may lead you to choose the wrong purging compound. David Krueger, a process engineer at Asahi Kasei Plastics North America (APNA) has spent his career in compounding and knows how this seemingly cost-saving decision can backfire. Not all purging compounds are safe for use in hot runner systems, screen packs, melt pumps and extrusion dies. With operating temperatures of 330 - 610F, this formulation also works on hot runners and thoroughly purges manifolds with gates as small as 30 thousandths. Error occurred during login. Because they are safer for the equipment, they are also more suitable for using as part of a preventative maintenance program as opposed to only as a problem-solving product. More recently, hybrid purging compounds, combining the efficiency of a mechanical cleaning with the thoroughness of chemical cleaning, have been developed. Although screw pushes might be necessary in your plant, that doesnt mean they need to be time-consuming, profit-sucking headaches. Tip 1:Dont use production resin, regrind, or additives to purge your extruder:Production resins are not designed to clean machines and are not a substitute for commercial purging compounds. Just fill out this form to get started. Purging Compounds for Extruders - Purging Compounds Extrusion Molding | Purgex. Ultra Purge specialized purge compounds improve operational efficiency by reducing setup/change-over times and reducing both the time to purge as well as the amount of material required to complete a purge. Preventative maintenance of screws, barrels, and hot runner systems, through regularly scheduled and consistent purging, makes sure that they stay in clean condition, reducing carbon buildup. Purging products can be used for several different cleaning applications, and each of them may require a different grade of purging compound. State-of-the-art technology helps drive results under pressure. There are two major classes of purging compounds in the market. Pekutherm EX is a soft-scrub physical action Purging Compound designed for Extruders, that stridently yet gently scours away outgoing plastic, built up previous material, burnt on residues, expels color and off spec.contaminants including gas residues. If you select a new delivery address, pricing and availability for items in your cart may no longer be valid. Gutierrez explains, a general understanding of how material travels through specific screw types, while also identifying high- and low-pressure flow paths, can help a processor decide which type of purge would be best for their specific twin-screw setup.. This often leads to frustrating production challenges for operators who use traditional methods to clean their thermoplastic processing equipment. ASACLEAN Purging Compound Extrusion Procedures - YouTube Click here and allow all cookies or skip this step and click here to view the video directly on Vimeo. The first and easiest method of extrusion cleaning is "disco purging." This is done by ramping the extruder speed (rpm) up and down at a relatively high interval using the normal production material formulation. Whether youre struggling with hot runner color changeovers, costly screw pulls, or holding a bubble in blown-film extrusion, we have the solution to your problems. Weddell agrees, adding thatbuilt-up material on the screw flights is very difficult to remove. Youll want to go with grades that make it unnecessary to clean the screw by baking it in an oven, wire brushing, torching, etc. Asaclean Purging Compounds are engineered to tackle your hardest processing challenges and make an incredible difference in your process efficiency. Mechanical Purging Compounds | Asaclean Purging Compounds Remember, you can manage cookies in your browsers settings. Twin-screw extruders (TSEs) have long been the machine of choice for compounders due to their superior performance and customizability. A CPC can be used for a wide array of extrusion processes: pipe, profile, tubing, sheet, film, compounding, and extrusion blow molding. In most cases, one to three full barrels worth of CPC are sufficient to clean an extruder. All rights reserved. They process almost all resins and allow for different additives and fillers to be combined to achieve different pellet sizes and shapes with an impressive array ofpossible properties. Adopting preventive purging practices not only saves your facility from machine downtime, but it also reduces scrap rates, customer rejects and line shutdowns. It is essential to use the right product and process for purging screws for extrusion. All things to avoid. Asacleans Gutierrez said its not uncommon to deal with extruders struggling with 8-12 hr screw pushes. John Pizzo, Technical Service & Development Engineer, Sun Plastech, Inc. 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With other resins such as styrenics and nylon, increased carbon deposits may lead to prolonged cleaning time. You have chosen to remove your account. Twin screws interact with each other, but dont confuse their self-wiping characteristics with self-cleaning. It is also recommended to do a shutdown and sealing with non-glass-filled grades during a temporary or extended shutdown. Taking a holistic approach will help you improve efficiency and profitability. Are purging compounds available for use when transitioning between materials with very different processing temperatures? There are three main benefits to implementing a preventive maintenance program and purging process at your facility: Preventing buildup of color and carbon contamination; Reducing excessive purging time and material waste at the end of production runs; Limiting the frequency of screw pushes and minimizing the time and effort required to pull and manually clean your screw. CPCs can prevent the need for screw-pulls; or, if they are required, can drastically reduce the time and effort required to overhaul the machine. Purge compounds for extrusion are generally more viscous compared to polymers used in injection molding. This is done until the purge is visibly free from any contamination. Are purging compounds easy to use and easy to evacuate from transparent polymers? It is one hundred percent pure. Once your machine returns to production, carbonized materials eventually break free and contaminate your product. Learn more about how to optimize your thermoplastic processing with Lusin purging compound products. Jerry Weddell, Asaclean business manager,saysthat one of his common challenges with compounders involves changeovers with temperature swings. Pekutherm HLT has no chemical reactant, hybrid lubricant, carrier resin, or abrasive additive. But engaging in this type of purging policy leads to reduced profitability and efficiency. Frequently Asked Questions About Purging | Plastics Technology Be aware of these zones and pay close attention to your processing numbers.. It helps in purging all of the resin from the die, barrel, and screw. Items in your cart might be affected by address change. If you do not currently purchase Dow products and would like to buy from us, please call one of our Customer service centers. . Ultra Purge provides a broad spectrum of solutions across the Thermoplastics Industry. It consists of high quality thermo-plastic polymers as well as highly efficient cleaning additives. Using the right settings will activate your chemical purge for optimal cleaning power. For extrusion purging, operators should ensure that all zones are in the proper temperature range for the type and grade purging compound being used. The value of switching to a high-performance purging compound is clear. There is a wide range of problems your extruder. These processes dont have the same options to manipulate pressures and turbulence the way an injection molding process does. Yes, this typically happens when a heavily contaminated machine is purged with a specialized purging compound, especially when the machine has a lot of carbon residue trapped in it. COMMON PROBLEMS SOLVED WITH THIS SOLUTION, at color or material changeover than traditional solutions. Tip 7: Seal your machine with heat-stable compound during every shutdown: Aside from regular and preventative-maintenance purging, use a heat-stable purging compound for temporary or extended shutdowns and sealing, especially over weekends or holidays. {{ user.selectedShipTo }} {{ user.defaultDeliveryAddress.companyName }}, {{ user.defaultDeliveryAddress.formattedAddress }}. To access videos on the Chem-Trend website, please accept all user cookies. Do universal purging compounds work with all applications and polymers? What is your range of operating temperatures? Although screw pushes might be a necessary in your plant, that doesnt mean they need to be time-consuming, profit-sucking headaches. APNAs Krueger said that screw pulls using Asacleans EX Grade can save processors 75-90% on downtime. Is the use of virgin material a cheaper alternative than a purge compound? Purging Compounds for Sheet Extrusion . Whether youre struggling with hot runner color changeovers, costly screw pulls, or holding a bubble in blown-film extrusion, we have the solution to your problems. PF Grade purging compound is specifically formulated for super-engineering resins at processing temperatures of up to 420C (790F). Purging Compounds for General Extrusion Profile extrusion is a continuous process where contamination issues can lead to large amounts of scrap and necessitate time-consuming teardowns. PX2 Grade purging compound excels in purging super-engineering resins at processing temperatures of up to 420C (790F). Carbon builds up in your machines dead spots: mixing sections, dies, downstream equipment, etc. UNIPURGE DFDB-0964 Natural 7 provides a practical method of rapidly and economically cleaning plastic processing equipment, such as extruders and injection molders. Purge Right works great with extruders. 5 While most CPCs are not expressly die cleaners, they often clean the die sufficiently or even completely. Inspect the purge lumps manually to see whether the lumps are free of contamination or not. min read. Whether you're making the bed . Distributed Worldwide. Can machine parameters influence the cleaning result of a purge compound? Purge Right is very cost-effective because of its cleaning power and affordable price per pound. Determining how to clean your systems is dependent on whether youre using high-temperature resins such as PEEK, PEI or LCP versus PC, ABS or Acetal. Cost efficiency is an important consideration for your process. But if you are dealing with frequent teardowns, a strong cleaner might be needed as well. Taking a narrow view may lead you to choose the wrong purging compound, which ultimately wastes resources and affects profitability. If no contamination is found, then start your resin at safe screw speed. A purging compound is a plastic resin compound designed to clean all primary plastic machinery ( extruders, injection and blow molding machines) when changing color, resin or simply to remove black specks or contaminations. Purging Compounds are an easy-to-use and affordable way to dramatically reduce scrap & downtime in plastics manufacturing. Purge Compounds for Thermoplastics | Chem-Trend These contribute to an overall saving of money and resources. Even if you take the contamination issues out of the conversation, the changeover time will vary wildly if you are using resins or regrind. These materials can be particularly hard to clean from a machine. Need to figure out your mold-cooling energy requirements for the various polymers you run? They are universally usable in hot runner systems and can be injected in cavities when a purge compound with an appropriately suitable MFI is selected. Designed by Elegant Themes | Powered by WordPress, Popular Applications for Purging Compounds, Purging Compound Procedures and Safety Precautions, Purging Procedures: Hot Runner/ Open Mold, Comparing Commercial Purging Formulas For Effective Purging of Thermoplastic Molds. [Log On], Tom Hanvey, Asahi Kasei Asaclean Americas, Follow These Tips to Power Up Your Purging Process, Molder Cuts Post-Purge Costs and Downtime in Half, How to Achieve Simulation Success, Part 1: Model Accuracy and Mesh Decisions, Tracing the History of Polymeric Materials, Part 28: Making LCP's Melt Processable, National Survey Reveals Surprising Opinions About Recycling Plastic, Solve Venting Problems on Twin-Screw Compounding Extruders, Solve PP Molding Problems with Nucleating Agents. Using a specialized purging compound on machines typically purged with virgin polymer often evacuates several previously processed colors. If shutdowns are performed, purge should be used during every shutdown. With some solutions MORE INFOS ABOUT PURGING COMPOUNDS SOLVING PURGING ISSUES Use a purging compound for : This powerful purging compound helps to remove old resin and color residue in extrusion, injection, and blow molding operations. Request a Free Sample today and Learn why over 2,000 customers are currently using Asaclean. Pekutherm EX does not melt, upon use is reaches the soft-scrub consistency of a common pencil eraser, and this is what provides the elastic-like scrub action. Changeover time will vary wildly if you are using resins or regrind for purging., However, to administer proper cleaning in low-pressure areas (like near vents) or in hard-to-reach areas (found on more complex screw mixing elements), a chemical purge gives the better result. The die is typically the most difficult area of the extrusion line to clean. This chemically reactive compound is safe to purge through the mold and helps to . Leistritz Extrusion has performed extensive testing to determine the best purging options for their customers, notes Charlie Martin, president and general manager. 716.685.2121. . Learn how to reduce machine downtime with five quick purging compound tips. Start-up with the screw in an empty material position for cleaning the hopper and feed throat! There are different grades for operating temperatures as low as 320 degrees Fahrenheit to as high as 790 degrees Fahrenheit. The edges of your die may seem impossible to clean, and melt pumps and static mixers make changeovers and contamination issues even more challenging. Get Free Sample However, they also can provide the same benefits to extrusion processors. A general rule of thumb is one purge per week. Purging your extruder with the next resin or regrind is time consuming, wasteful and ineffective at removing color and carbon contamination. What is the intended application (s) of the purging compound? UNIPURGE DFDB-0964 NT 7 Purging Compound - Dow This guarantees your machine will be running clean in no time. What are the respective advantages and disadvantages of the different types of purging compounds? Improved Product Quality Reduced Downtime Reduced Scrap Rate Value The value of switching to a high-performance purging compound is clear. Tip 5: Understand your screw-design & mixing areas & pay close attention to machine settings: TSEs are modular and offer limitless combinations of screw segments and different mixing regions that also exacerbate some of these purging challenges. You can clean the extruders with a die attached by using our highly efficient purging compound. High-temperature resins often require PF or PX2 Grade. This may result in higher scrap rates, more downtime, and lower quality of finished products. What is the intended application(s) of the purging compound? They can also solve contamination issues when the polymer is transparent, and when changing colors especially when hot runner molds are used in injection molding facilities. In most cases, one to three full barrels' worth of CPC are sufficient to clean an extruder. UNICLEANPLUS purging compound acts fast and ensures thorough cleaning. Once your plant has buy-in and your line workers understand that its much more beneficial to be proactive than reactive, you will start to see immediate savings. When compared to traditional cleaning methods, our purging products provide better cleaning, prevent unwanted stoppages, and save you money. When you use regrind or virgin resins to purge, the material creates another layer over any existing resins, color deposits or carbonized material within the barrel and on the screw. However, it is important to keep in mind that the more contamination, or dirt, there is in the machine the longer it will take to evacuate. UP Grade is an olefinic-based purging compound designed for polypropylene and polyethylene color/resin changes for thermoplastic injection molding and extrusion machines. We provide Purging Compounds for Extruders and to clean extruders we recommend using Purge Right PR-5000 and Purge Right PR-6000. smooth transition between PC and PMMA. One of the most commonproblem areas when purging extrusion molding machines is streaking. Use our free calculator to see how much you could be saving with Asaclean Purging Compounds. [Log On]. 2023 Asahi Kasei Plastics North America. This is because they rely on pressure and agitation to clean out the previous resin or any contamination within your machine. Purging in extrusion tends to be more challenging than in other processes, and TSEs face these challenges on a much larger scale because the systems are much more complex than their single-screw brethren. If you find the presence of contamination, then repeat the purging process. E Grade leaves very little residue behind while facilitating color and material changes. The barrel should be run empty, and the hopper . Learn more about the technique needed for preparing and filling purging compounds in your operation. Your account has a credit block in place. In a continuous process like extrusion, contamination has a detrimental effect on the bottom line. We request that you confirm your website account is valid and verify your email address. Purging the screw and barrel of an extruder is typically straightforward and easy, though it tends to become more difficult when more mixing/kneading elements are used. Purge with the purging compound grade for cleaning the screw and barrel. Universal purging compounds are effective only on polymers compatible with their matrix and MFI and less effective on incompatible polymers and/ or with very different matrices. Purgex is a registered trademark of Neutrex, Inc. Check your barrel temp that matches the UNICLEANPLUS purging compound grade. Screw design does not have any significant impact on removing contamination, even though a twin-screw is designed to be self-wiping.. Our in-depth guide tells you everything you need to know about purging compounds. The easiest way to diagnose the actual cause of a molders streaking problem is to see when the streaking initially occurs. Short-term solutions very often prove to be more expensive and less satisfactory after a period of time. Pick the Best Purging Compound for Your Extrusion Process: 2 - Asaclean These vents can contribute lower pressures in those specific mixing zones and may lead to more difficulty in proper removal of product, Gutierrez notes. Some of these questions include: What are your processing temperatures? When you reach out to a purging expert for a free consultation, they will look at several key things to consider in order to select the right grade and quantities necessary to choose the best purging compound for your system. What positive effects on production do purging compounds provide? Please try again later. Proper purging procedures can help keep compounding twin screws up and running. Download our thermoplastic processing product brochure to find out which of our LusinBrand release agents will work for your application. Polymer contamination/carbonization, additives, encrustations, degraded material, or color residue from dirty equipment can be released by utilizing one of our highly specialized Ultra Purge purging compounds. Krueger elaborates, Screw design does not have any significant impact on removing contamination, even though a twin-screw is designed to be self-wiping. Substantial heat is generated due to shear, and contamination will occur regardless. If your plant is dealing with either of these scenarios, consider working with a purging expert to conduct a cost-savings analysis so you can show management just how costly this decision is. The wide range of resins and additives in profile increases the likelihood that problems might occur. 3 A typical compounder may pull a screw four to five times a week. Learn more about purging compounds for thermoplastics applications and get answers to frequently asked questions. document.addEventListener( 'wpcf7mailsent', function( event ) { When it comes to heat-sensitive materials, extra steps do need to be taken, but they can be cleaned very effectively when using this approach. CPCs are more commonly used in profile extrusion and compounding because changeovers are more frequent and the resins, colors, and additives are more varied. Tip 2: Ask yourself these questions to select the best purging compound for your needs: Introducing a purge program can easily help compounders cut downtime by 50-75%. Resin or standard purging compounds for extruders can have trouble reaching and cleaning key problem areas that cause streaking such as the far ends of the die head. Beyond using a purge compound when transitioning from one color or material to another, using a specialized purge compound could also be beneficial in the case of unexpected production events.
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