When a production planner is told that the injection screw needs to be taken down for cleaning, it’s more than just an inconvenience. It's a disruption to the carefully planned production schedule, often resulting in delays. For the production manager, the thought of delays is even more stressful. These delays directly impact delivery times, increasing the risk of missed deadlines and lowering overall production efficiency.
Meanwhile, the maintenance technician faces the frustration of having to abandon their pre-planned tasks to address this sudden cleaning requirement. What was once a smoothly organized workday is now interrupted by the need for hours of additional, unplanned labor.
On top of these challenges, human resources becomes involved when the risks associated with these disruptions become evident. The increased time spent on cleaning means additional labor costs and even the potential for safety risks as employees work longer hours or deal with the strenuous nature of mechanical cleaning.
In an aerospace plastics manufacturing plant, this issue was happening monthly. The plant was regularly taking down screws—around 25 times per month—due to contamination caused by the materials they processed. In most cases, these machines were processing plastics that melt at over 370°C (700°F), and when contamination occurred, it required mechanical cleaning to clear it up.
However, there was a bigger problem: the plant lacked the necessary infrastructure and tools to perform the cleaning efficiently, so they had to hire external contractors for the job. At more than $115 per event, these cleaning costs were adding up quickly, not to mention the additional downtime, labor, and resources spent on each cleaning event.
This all changed when a process engineer took action to optimize resources and minimize downtime. The engineer explored a solution that would streamline production and reduce the need for manual screw cleaning—purging compounds. After some research, the engineer discovered Asaclean® PF grade purging compound as the ideal solution for their needs.
By implementing Asaclean, the plant was able to eliminate the need for routine screw removals for cleaning, and now the only time screws are taken out is for measurements. The annual savings were significant—over $70,000—due to the reduction in machine downtime and the elimination of contractor fees.
The key advantages of using purging compounds like Asaclean are clear:
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Save time and resources: Eliminate the need for mechanical cleaning and reduce maintenance costs.
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Improve machine longevity: Avoid unnecessary wear and tear on machine components by minimizing manual cleaning.
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Enhance safety: Reduce the risk of accidents that can occur during prolonged or intensive cleaning processes.
For manufacturers, using purging compounds doesn’t just improve efficiency—it helps ensure a safer, more cost-effective, and reliable production process. By adopting this solution, manufacturers can ensure that their operations are optimized, with fewer disruptions and a stronger bottom line.
In conclusion, using purging compounds not only addresses the immediate concerns of contamination but also brings long-term benefits that ripple through every department—from production planning and management to maintenance and human resources. By switching to Asaclean, companies can streamline operations and achieve better, more predictable production outcomes, all while cutting costs and increasing safety.
Ready to see the difference Asaclean® can make in your production? Request a free sample today and experience how our purging compounds can enhance your color change efficiency, reduce waste, and improve your manufacturing process. Our team of experts is here to guide you through the process and help you achieve the best results. Contact us now to get started!
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