How To Minimize Scrap Rates By Using Preventive Purging Practices

By Author: Subash Ellath
Total Articles: 40
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People who work in the plastic processing industry should know that waiting and reacting to color or carbon contamination only result in increased expenses and reduced profit.
How you approach purging actually impacts your capability to produce proficiently. For instance, if you wait to clean your machine until you see contamination in your finished product, you are surely going to experience longer production runs & excess machine downtime.
Plastics processing firms working to decrease scrap rates can consider preventive purging as a best practice to attain their goal. To reduce scrap rates, listed below are 3 preventive purging practices that you would like to follow:

Use proper amount of purging material
One of the most common causes of high scrap rates is inadequate purging during downtime & changeovers. Defect rates increase when plastic processors don’t make use of the adequate purging compound for plastic.
Some firms ask machine operators to use an exact quantity of purging material, promoting ...
... a one-size-fits-all outlook.
However, how much purging compound will be needed for each changeover differs by circumstances. Such as the more time that has passed since a screw pull & manual cleaning, the more impurities you will find in your machine.
Your purging compound supplier should educate operators to purge until cleaning is finished, within a specific tolerance range, before contacting a manager. Putting a machine back into production after employing a fixed quantity of purging material isn’t recommended.
Overuse of purging compounds can also be a possible concern here. You want your operator to use the appropriate amount of purging compound, as wastage of your resources can’t add to your profitability by any means.

Seal your machines during system shutdowns
To avoid contamination, it is recommended to use thermally stable purging material to seal your machine during system shutdowns and extreme downtime events, for example, PMs. Leftover polymer decay can hinder machine startup and prompt excess material waste. Whether at the time of a temporary or prolonged shutdown, sealing your machine is the most vital step toward reducing scrap rates.

Purge at the time of startups
At startup, expel the sealing purge and follow up with 1 or 2 barrels of fresh purging material prior to starting production. This is an aggressive technique to get rid of carbon buildup and contamination that was isolated from metal surfaces at the time of sealing. Executing this purge as part of your startup practices helps minimize the time needed to get up and running.
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