--- title: 10 Tips to Remove Carbon From Hanger Dies in Cast Film Applications description: Dealing with carbon buildup in cast film dies? Follow these 10 proven tips to clean hanger dies effectively and avoid manual die-splitting downtime. image: https://www.asaclean.com/hubfs/Cast%20Sheet%20Extrusion.jpg --- [ Order Online ](https://asaclean.my.site.com/b2bstore) [ Free Sample ](https://offers.asaclean.com/free-sample) ## [ Asaclean Blog ](https://www.asaclean.com/blog) Browse by Topic " aerospace asaclean asaclean news Asaclean® benefits asahi kasei automotive Best Practices black specks blisters blow molding blown-film extrusion buyers caps and closures carbon contamination cast-film extrusion Chemical Purging Compounds clear applications Color Changeovers Company News compounding consumer products contamination Cost savings custom molders Customer Success Story decreasing scrap defects electronics Energy Efficiency EX Grade extruder cleaning Extrusion fillament glass filled Glitter Grade Selection HDPE High and Low Temp Changeovers hold a bubble Hot Runners Injection Molding Injection Molding Tips LDPE Lightweight automotive components LLDPE low residue maintenance Material Changeovers Mechanical Purging Compounds medical Melt Flow Index NPE 24 nylons on the fly packaging PCR PEEK Polypropylene Post Consumer Resins preventative preventative purging processing tips profile extrusion Purge Program purge programs Purge Training Purge Trial purging purging compounds purging concentrates purging procedures Purging Tips quality recycled resins residue issues scrap reduction Screw Pulls sheet extrusion shutdown and sealing start-up super engineering resins Sustainability Tech Day technical support training trials Troubleshooting Twin Screw twin screw extrusion two step purging U Grade ULTEM venting Viscosity webinars wire extrusion - 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They produce this film for thermoforming machines producing flower pots. The repro PP they run has different loadings of PCR and this causes inconsistent process conditions from lot to lot, carbon contamination causing flow/die lines and other quality issues, etc. I recommended these 10 tips to help them  alleviate these problems. 1. **Use the correct chemical purge compound for the resin. In this case it was a 2-4 melt flow index repro PP. For this particular application, I chose [Asaclean NCT grade.](https://www.asaclean.com/purging-products/asaclean-chemical-purging-grades/nct-grade-purging-compound-formerly-supernova-ht/)** 2. **All screen packs should be removed before trying to clean machine.** 3. **Raise heats to 550ºf or a bit higher.** 4. **Flush out production resin and in this case, it was black PP with a similar natural resin to remove the bulk of the color.** 5. **Plug any vents on the barrel if necessary.** 6. **Introduce the [NCT](https://www.asaclean.com/purging-products/asaclean-chemical-purging-grades/nct-grade-purging-compound-formerly-supernova-ht/) to the extruder using a high screw speed to ensure the NCT fills out to the edges of the die. In this case, it was a hangar die of 32” wide.** 7. **Once even flow is accomplished, slow the RPMs of the screw to a point that the screw is just turning with no chatter. This allows fresh purge to be introduced to the die during the soak period of 30 minutes.** 8. **Soak for 30 minutes with screw slowly turning.** 9. **At this point the machine was not going into production until the following morning. Leave the NCT in the barrel and shut the heats off.** 10. **Upon start up, soak the heats as normal. Once at proper production temp, remove remaining purge in barrel and start production.** The next day, I followed up with my contact and he reported the machine came right back into production with no carbon or die lines causing rejects. He was very happy not to have to split the die and clean manually. While this is a very specific example, I've dealt with hundreds of different processing issues through the years and am happy to conduct a free consultation with anyone who might be having an issue.  **Learn about the importance of implementing proper purging procedures by downloading this free industry guide.** **** ** [![](https://no-cache.hubspot.com/cta/default/468726/interactive-161630774182.png) ](https://www.asaclean.com/hs/cta/wi/redirect?encryptedPayload=AVxigLIY8PYVHYDvyAI66GAf%2Fo%2B40OhonzU4ah1Tw29t9mc717BOzTL4L0OI%2FA5Kf5ahuoBFk1i4cRkGyA2lnHpu1BzhVVNyReuKZzH0UbThqNTBcLllO0g1NLAm7YfjqpYsLQYAsTByWYk1XwoCXfnhumY1GszMuAv0z99AP9ZsbovzD4ZPuzyP2xd0qfNPSutE%2Fa4dd0gJ%2BRk9gc%2B97Bbn5yJ%2FoLY5Ueca5qzP6C2zVi7Tt2eJXEAbOw1r&webInteractiveContentId=161630774182&portalId=468726) ** ** ** ![Eric Despotovich](https://www.asaclean.com/hs-fs/hubfs/Eric%20Despotovich%20LinkedIn%20Headshot%202%20-%20Copy.jpg?width=150&name=Eric%20Despotovich%20LinkedIn%20Headshot%202%20-%20Copy.jpg) #### [ Eric Despotovich ](https://www.asaclean.com/blog/author/eric-despotovich) Eric Despotovich, an esteemed Asaclean Purging Expert and Technical Sales Representative, brings over 40 years of processing experience to his role. With over 18 years of dedication to our company, Eric has become a cornerstone of our sales team, renowned for his commitment to client success. His extensive industry knowledge and genuine passion for helping clients make him a trusted advisor in optimizing their operations. Eric's approach is characterized by deeply understanding each client's unique challenges, ensuring tailored solutions that drive efficiency and profitability. - [Share On LinkedIn ](https://www.linkedin.com/in/eric-despotovich-5449682b) ## Related Posts [![How to Prevent Splitting Hanger Dies for Color or Material Changes for Cast Film Extrusion](https://www.asaclean.com/hs-fs/hubfs/Avoid%20Die%20Teardowns%20Blog%20Header-1.jpg?width=450&height=250&name=Avoid%20Die%20Teardowns%20Blog%20Header-1.jpg) How to Avoid Splitting Hanger Dies in Cast Film Extrusion Troubleshooting / 3 min read / December 18, 2018 ](https://www.asaclean.com/blog/how-to-prevent-splitting-hangar-dies-for-color-or-material-changes-for-cast-film-extrusion) [![Color Changes on the Fly for Blown Film Applications](https://www.asaclean.com/hs-fs/hubfs/Blown%20film%20blog.jpg?width=450&height=250&name=Blown%20film%20blog.jpg) Color Changes on the Fly for Blown Film Applications Best Practices / 3 min read / June 25, 2024 ](https://www.asaclean.com/blog/color-changes-on-the-fly-for-blown-film-applications) ## Comments Get Started ## Ready to start improving your efficiency and increasing your profitability? - [Request a Consultation](https://www.asaclean.com/blog/10-tips-to-remove-carbon-from-hanger-dies-in-cast-film-applications#) - [Contact Sales](https://www.asaclean.com/blog/10-tips-to-remove-carbon-from-hanger-dies-in-cast-film-applications#) ![](https://www.asaclean.com/hubfs/assets/images/icons/icon-layers.svg) #### Free Sample Request a free sample of Asaclean® Purging Compounds for your plant and start saving today. 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[See your savings](https://www.asaclean.com/cost-savings-calculator) [ Back to Top ](https://www.asaclean.com/blog/10-tips-to-remove-carbon-from-hanger-dies-in-cast-film-applications#top) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Eric Despotovich", "url" : "https://www.asaclean.com/blog/author/eric-despotovich" }, "dateModified" : "2025-05-06T13:46:32.853Z", "datePublished" : "2018-09-18T13:41:00.000Z", "headline" : "10 Tips to Remove Carbon From Hanger Dies in Cast Film Applications", "image" : [ "https://www.asaclean.com/hubfs/Cast%20Sheet%20Extrusion.jpg" ], "mainEntityOfPage" : { "@id" : "https://www.asaclean.com/blog/10-tips-to-remove-carbon-from-hanger-dies-in-cast-film-applications", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://www.asaclean.com/hubfs/Asaclean%20Logo%20TM.jpg" }, "name" : "Asahi Kasei Plastics North America" } } ``` ```json { "@context" : "http://schema.org", "@type" : "Article", "articleBody" : "Recently I was speaking with a processor I met at NPE 2018 who was having trouble with their cast film application. They had a problem when extruding re-pro PP with post consumer resin (PCR) content for cast film. They produce this film for thermoforming machines producing flower pots. The repro PP they run has different loadings of PCR and this causes inconsistent process conditions from lot to lot, carbon contamination causing flow/die lines and other quality issues, etc.", "author" : { "@type" : "Person", "name" : "Eric Despotovich" }, "datePublished" : "September 18, 2018", "headline" : "10 Tips to Remove Carbon From Hanger Dies in Cast Film Applications", "image" : "https://cdn2.hubspot.net/hubfs/468726/Cast%20Sheet%20Extrusion.jpg", "name" : "10 Tips to Remove Carbon From Hanger Dies in Cast Film Applications", "url" : "https://www.asaclean.com/blog/10-tips-to-remove-carbon-from-hanger-dies-in-cast-film-applications" } ```