--- title: Cutting Scrap By 73.3% By Using The Right Purging Compound description: You can’t maximize your bottom line with inefficiencies and wasted materials. Learn how one manufacturer cut scrap by 73.3% percent with help from ASACLEAN image: https://www.asaclean.com/hubfs/AI-Generated%20Media/Images/This%20image%20depicts%20a%20bar%20graph%20steadily%20going%20down%20with%20an%20arrow%20tracing%20the%20reduction-2.jpeg --- [ 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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[Twin Screw](https://www.asaclean.com/blog/topic/twin-screw) - [twin screw extrusion](https://www.asaclean.com/blog/topic/twin-screw-extrusion) - [two step purging](https://www.asaclean.com/blog/topic/two-step-purging) - [U Grade](https://www.asaclean.com/blog/topic/u-grade) - [ULTEM](https://www.asaclean.com/blog/topic/ultem) - [venting](https://www.asaclean.com/blog/topic/venting) - [Viscosity](https://www.asaclean.com/blog/topic/viscosity) - [webinars](https://www.asaclean.com/blog/topic/webinars) - [wire extrusion](https://www.asaclean.com/blog/topic/wire-extrusion) [ Subscribe ](https://www.asaclean.com/blog/cutting-scrap-by-73.3-by-using-the-right-purging-compound#subscribe-modal) ### Suscribirse Troubleshooting / 5 min read / June 07, 2016 # Cutting Scrap By 73.3% By Using The Right Purging Compound - [Facebook Share ](https://www.facebook.com/sharer/sharer.php?u=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fcutting-scrap-by-73.3-by-using-the-right-purging-compound) - [Twitter Tweet ](https://twitter.com/intent/tweet?url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fcutting-scrap-by-73.3-by-using-the-right-purging-compound&text=Cutting+Scrap+By+73.3%25+By+Using+The+Right+Purging+Compound) - [LinkedIn Share ](https://www.linkedin.com/shareArticle?mini=true&url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fcutting-scrap-by-73.3-by-using-the-right-purging-compound&title=Cutting%20Scrap%20By%2073.3%25%20By%20Using%20The%20Right%20Purging%20Compound&summary=You+can%E2%80%99t+maximize+your+bottom+line+with+inefficiencies+and+wasted+materials.+Learn+how+one+manufacturer+cut+scrap+by+73.3%25+percent+with+help+from+ASACLEAN&source=) - [Pinterest Pin ](https://pinterest.com/pin/create/button/?url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fcutting-scrap-by-73.3-by-using-the-right-purging-compound) - [Email Email ](mailto:?subject=Cutting%20Scrap%20By%2073.3%25%20By%20Using%20The%20Right%20Purging%20Compound&body=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Fcutting-scrap-by-73.3-by-using-the-right-purging-compound) ![Cutting Scrap By 73.3% By Using The Right Purging Compound](https://www.asaclean.com/hs-fs/hubfs/AI-Generated%20Media/Images/This%20image%20depicts%20a%20bar%20graph%20steadily%20going%20down%20with%20an%20arrow%20tracing%20the%20reduction-2.jpeg?width=640&height=500&name=This%20image%20depicts%20a%20bar%20graph%20steadily%20going%20down%20with%20an%20arrow%20tracing%20the%20reduction-2.jpeg) Scrap and wasted materials are an aspect of manufacturing that every company wants to minimize. One automotive parts supplier was suffering from an alarming 15 percent reject rate, and significant material waste. The manufacturer was processing Ultem at a temperature range of 680 to 700 degrees Fahrenheit. It was recommended that their operators use a high-temperature grade purging compound with advanced thermal stability at elevated temperatures.![Cutting_Scrap_By_73.3_By_Using_The_Right_Purging_Compound.jpg](https://www.asaclean.com/hubfs/Cutting_Scrap_By_73.3_By_Using_The_Right_Purging_Compound.jpg) The processor had been using a [PF Grade compound](https://www.asaclean.com/purging-products) to clean their machine, in line with the aforementioned recommendations. They were also following the purging instructions that their supplier provided them. Their machines were successfully purged at the end of each run, however, they were experiencing an odd problem. The next morning, upon starting up their machine, the processor’s initial run would produce a black, tar-like substance. It appeared as though degraded purging compound was coming out of the barrel. ### **Getting To The Bottom Of An Unusual Issue** Clearly, the manufacturer was experiencing an abnormal problem that warranted investigation. To get to the bottom of the issue, we asked the processor several important questions: **“Did you purge until there was no further resin or contamination seen in the outcoming purge?”** *“Yes. The purge was examined and NO contamination could be seen.”* **“Did you turn your heat off?” **(High-temperature PF grade purging compounds should not be left idle in your barrel above 700 degrees Fahrenheit for any period of time.) “*Yes. Machines are always turned off each night.”* **“Were your barrels completely full, to ensure that *****no***** oxygen could enter?”** **“***No. The barrel was left empty.”* ### **Solving A Costly Issue** Although the processor had been following the purging procedure, without sealing measures in place upon shutdown, oxygen was entering the barrel and causing carbon contamination. With the machine at an elevated temperature before shutdown, the combination of heat and oxygen created degradation of the purging compound residue, which produced buildup of the black, tar-like substance on the screw. Even after a purge and emptying of the machine, there would always be some traces of purge or resin left on the screw because of the presence of oxygen. **Oxygen + Heat = Degradation** We recommended that the processor use a purging compound upon shutdown to seal their barrel. **Sealing For Significant Savings** As a best practice, always seal your machine – whether it’s being shut down for the night, weekend or even just taking a few hours off between runs. This practice saves you hours on startup, and has a huge impact on your scrap rates and material waste. To seal your equipment, ensure the barrel is full of a thermally stable sealing-grade [purging compound](http://dev.asaclean.com/purging-products/) from the hopper through to the die head and/or hot runners (if required). This ensures that there are no openings, and thus, no way for oxygen to enter the machine. In the case of this manufacturer, adopting a sealing process and preventing oxygen from entering the machine cut their reject rate upon startup from 15 percent to 4 percent, a  73.3 percent reduction in wasted materials. Overall, the automotive parts supplier is  reaping the benefits to their bottom line. **Learn how the right purging compounds and procedures impact your process efficiency.** **** ** [![](https://no-cache.hubspot.com/cta/default/468726/interactive-161630774182.png) ](https://www.asaclean.com/hs/cta/wi/redirect?encryptedPayload=AVxigLINtj9pCUwwAflqfjkdgkYq4Samx1NhABh56%2Ff6i8Mnzgb4qjK9RqiabvcM8iekJNdry0KymSDp%2BTNF2Tft7FV9xMMzRPlVmWvgm0NUKQbfnRTQorTv%2BA6bFMp2NothKfAZX6J5zRe7J%2F194wv0jRgC%2F0ppzS5bHPlbRqodvIaV4Yvj6hRMHVx5mqSlnyK3ychJjj5aKZvmhpI%2Brj8rDrnVkYci09oSRMJt1rh%2BTmCDlEDRc0Qkb8V6&webInteractiveContentId=161630774182&portalId=468726) ** ** ** ![Tom Hanvey](https://www.asaclean.com/hs-fs/hubfs/Tom%20Headshot.jpg?width=150&name=Tom%20Headshot.jpg) #### [ Tom Hanvey ](https://www.asaclean.com/blog/author/tom-hanvey) Tom Hanvey is the Associate Director of Marketing & Sustainability at Asahi Kasei Plastics North America. Before joining APNA, he worked as the Senior Marketing Manager for Asaclean Purging Compounds. He's worked in the plastics industry for over 10 years and focuses on recyclable resins and on the inbound marketing side, providing easy-to-digest content to processors looking for an edge on their competition. - [Share On LinkedIn ](https://www.linkedin.com/in/thomashanvey/) ## Related Posts [![3 Ideas for Your Holiday Shutdown](https://www.asaclean.com/hs-fs/hubfs/AI-Generated%20Media/Images/this%20image%20depicts%20a%20sign%20that%20says%20Happy%20New%20Year%20with%20confetti-1.jpeg?width=450&height=250&name=this%20image%20depicts%20a%20sign%20that%20says%20Happy%20New%20Year%20with%20confetti-1.jpeg) 3 Ideas for Your Holiday Shutdown Injection... / 2 min read / November 29, 2018 ](https://www.asaclean.com/blog/3-ideas-for-your-holiday-shutdown) [![](https://www.asaclean.com/hs-fs/hubfs/IMG_1730.jpg?width=450&height=250&name=IMG_1730.jpg) 3 Tips for Your 2020 Thanksgiving Shutdown Injection... / 3 min read / November 17, 2020 ](https://www.asaclean.com/blog/3-tips-for-your-2020-thanksgiving-shutdown) ## Comments Get Started ## Ready to start improving your efficiency and increasing your profitability? - [Request a Consultation](https://www.asaclean.com/blog/cutting-scrap-by-73.3-by-using-the-right-purging-compound#) - [Contact Sales](https://www.asaclean.com/blog/cutting-scrap-by-73.3-by-using-the-right-purging-compound#) ![](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. [Request your free sample](https://offers.asaclean.com/en/free-sample?hsLang=en) ![](https://www.asaclean.com/hubfs/assets/images/icons/icon-calculator.svg) #### Cost Savings Calculator Use our free calculator to see how much you could be saving with Asaclean® Purging Compounds. [See your savings](https://www.asaclean.com/cost-savings-calculator) [ Back to Top ](https://www.asaclean.com/blog/cutting-scrap-by-73.3-by-using-the-right-purging-compound#top) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Tom Hanvey", "url" : "https://www.asaclean.com/blog/author/tom-hanvey" }, "dateModified" : "2025-07-08T18:29:08.800Z", "datePublished" : "2016-06-07T12:00:00.000Z", "headline" : "Cutting Scrap By 73.3% By Using The Right Purging Compound", "image" : [ "https://www.asaclean.com/hubfs/AI-Generated%20Media/Images/This%20image%20depicts%20a%20bar%20graph%20steadily%20going%20down%20with%20an%20arrow%20tracing%20the%20reduction-2.jpeg" ], "mainEntityOfPage" : { "@id" : "https://www.asaclean.com/blog/cutting-scrap-by-73.3-by-using-the-right-purging-compound", "@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" : "Scrap and wasted materials are an aspect of manufacturing that every company wants to minimize. One automotive parts supplier was suffering from an alarming 15 percent reject rate, and significant material waste.", "author" : { "@type" : "Person", "name" : "Tom Hanvey" }, "datePublished" : "June 07, 2016", "headline" : "Cutting Scrap By 73.3% By Using The Right Purging Compound", "image" : "https://468726.fs1.hubspotusercontent-na1.net/hubfs/468726/AI-Generated%20Media/Images/This%20image%20depicts%20a%20bar%20graph%20steadily%20going%20down%20with%20an%20arrow%20tracing%20the%20reduction-2.jpeg", "name" : "Cutting Scrap By 73.3% By Using The Right Purging Compound", "url" : "https://www.asaclean.com/blog/cutting-scrap-by-73.3-by-using-the-right-purging-compound" } ```