Film extrusion—whether blown or cast—is one of the most demanding processes in plastics manufacturing. Precision, cleanliness, and efficiency are critical. Even minor contamination or extended changeover times can lead to scrap, customer complaints, and lost profits. Effective purging compounds offer a path out of this cycle, delivering faster turnaround, cleaner output, and reduced downtime.
Film processes often need to preserve a delicate bubble or maintain tight die clearances. These constraints make traditional cleaning methods impractical. Resin buildup in die edges, barrels, or screens can hide contamination that shows up as haze, streaks, or defects. Manually disassembling components or relying on virgin resin to purge often leaves residues that compromise the next production run.
Asaclean® purging compounds are designed to respect the nuances of film extrusion. Customers now purge while keeping the bubble intact, clean the edges of their dies, and improve color change speed—without resorting to teardowns or manual cleaning. One production manager reported that Asaclean® cut screw push time from 12 hours to 4 and slashed cost by 60 percent. And a master trainer in the medical extrusion space noted that downtime was literally halved.
Film extruders face diverse challenges. To address them, Asaclean® provides three core categories of compounds:
Chemical purging compounds and purging concentrates clean effectively in low‑flow and low‑pressure areas. These grades foam and expand, penetrating tight zones where streaking often begins. Purging concentrates, especially PLUS Grade, blend seamlessly with production resins, require no temperature change, and can be adjusted in concentration to match cleaning needs.
Mechanical purging compounds target high-pressure cleaning tasks and work well when die clearances and flow are less restrictive.
All grades are formulated to hold the bubble, clean die edges, and eliminate carbon or black specks—all while being displaced cleanly, without residue or haze.
First, after completing production of the current resin, operators feed approximately two barrel capacities of purge compound. The system runs at normal processing conditions until the purge is fully extruded. Once the extrusion appears clean, production resin resumes immediately.
When contamination is more stubborn, technicians can temporarily raise temperatures downstream of the extruder and pause screw rotation for short intervals. These simple adjustments enhance cleaning performance without disrupting production or risking equipment safety.
Adopting this purging strategy transforms film extrusion workflows. Scrap rates drop significantly, and defects that threaten customer satisfaction almost vanish. Mechanical issues related to buildup—such as screw pushes—become rare, and cleaning time becomes a scheduled, predictable activity. Film processors have reported up to 58 percent reduction in scrap and downtime.
Perhaps most impactful, technical support from Asaclean® is not sales-driven but operations-driven. Purging experts often began their careers as processors, and they guide customers through grade selection, setup, and long-term purging strategy. This hands‑on support helps teams become purging experts themselves.
Film extrusion demands both precision and agility. Cleaning cannot interrupt production, yet contamination cannot be tolerated. Purging compounds engineered for film serve as powerful allies in balancing these demands. They clean deeply, maintain the bubble, reduce scrap, and reclaim uptime. When paired with expert technical guidance, they turn purging into a strategic advantage, not a liability.
If changeover time, defects, or cleanliness are concerns in your film extrusion line, consider a customized purge evaluation. Request a free sample, consult with a purging expert, and see how smarter purging can transform your process.
If your team is dealing with tough resin transitions or temperature swings, we can support you with a customized purge protocol. Request a free sample or schedule a consultation with one of our purging experts today.