--- title: How This Molder Cut Startup Scrap from 100 to 3 in Minutes description: Discover how a medical molder reduced startup scrap by 97% and slashed downtime with a game-changing purging solution for rigid PVC and HDPE. image: https://www.asaclean.com/hubfs/medical%20pills%20industry%20%20factory%20and%20production%20indoor.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/from-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process#subscribe-modal) ### Suscribirse Injection Molding / 4 min read / October 08, 2024 # How This Molder Cut Startup Scrap from 100 to 3 in Minutes - [Facebook Share ](https://www.facebook.com/sharer/sharer.php?u=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Ffrom-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process) - [Twitter Tweet ](https://twitter.com/intent/tweet?url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Ffrom-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process&text=How+This+Molder+Cut+Startup+Scrap+from+100+to+3+in+Minutes) - [LinkedIn Share ](https://www.linkedin.com/shareArticle?mini=true&url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Ffrom-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process&title=How%20This%20Molder%20Cut%20Startup%20Scrap%20from%20100%20to%203%20in%20Minutes&summary=Discover+how+a+medical+molder+reduced+startup+scrap+by+97%25+and+slashed+downtime+with+a+game-changing+purging+solution+for+rigid+PVC+and+HDPE.&source=) - [Pinterest Pin ](https://pinterest.com/pin/create/button/?url=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Ffrom-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process) - [Email Email ](mailto:?subject=How%20This%20Molder%20Cut%20Startup%20Scrap%20from%20100%20to%203%20in%20Minutes&body=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Ffrom-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process) ![How This Molder Cut Startup Scrap from 100 to 3 in Minutes](https://www.asaclean.com/hs-fs/hubfs/medical%20pills%20industry%20%20factory%20and%20production%20indoor.jpeg?width=640&height=500&name=medical%20pills%20industry%20%20factory%20and%20production%20indoor.jpeg) ![OTF Color Change](https://www.asaclean.com/hs-fs/hubfs/OTF%20Color%20Change.jpg?width=414&name=OTF%20Color%20Change.jpg) When a [medical injection molder ](https://www.asaclean.com/industry/medical)in New England encountered persistent contamination issues, their production process was disrupted by excessive startup scrap. Running both rigid PVC and HDPE, they faced significant challenges in switching materials without carrying over contamination. This issue resulted in 100 scrapped parts at startup and 30 minutes of costly downtime. They needed an effective purging solution to thoroughly clean their screw and barrel—and fast. #### The Challenges of Injection Molding Rigid PVC and HDPE Both **rigid PVC** and **HDPE (high-density polyethylene)** are high-flow materials commonly used in injection molding. However, their high flow properties also make them prone to contamination during material changeovers. Contamination can impact **part quality** and **dimensional accuracy**, leading to startup scrap and downtime. Maintaining stringent **quality control** while minimizing production delays was critical for this molder's success. #### A Game-Changing Purging Solution for Injection Molding We recommended [the Asaclean U Grade Purging Compound](https://www.asaclean.com/purging-products/u-grade)to tackle these challenges, specifically designed for difficult [material transitions](https://www.asaclean.com/solutions/material-changeovers) like those between rigid PVC and HDPE. The U Grade effectively removes residual materials from the screw and barrel, preventing contamination between runs. It is also **non-toxic** and **non-flammable**, making it safe for **medical applications**. #### The Results: From 100 Scrapped Parts to Just 3 The molder conducted initial tests with [the U-grade](https://www.asaclean.com/purging-products/u-grade) and achieved impressive results. During their weekend [shutdowns](https://www.asaclean.com/solutions/shutdown-and-sealing), they used approximately 13 lbs of the purging compound—about 4.5 lbs per purge—on three different injection molding presses. Two of these presses ran rigid PVC, and one ran HDPE. These tests quickly showed the effectiveness of the solution. The molder reduced their startup scrap from 100 parts to just 3. Additionally, **downtime** dropped dramatically from 30 minutes to just 5 minutes. This marked a revolutionary improvement in their production efficiency, reducing waste and speeding up restarts. #### Conclusion This medical molder's success story illustrates the right purging compound's impact on [**injection molding**](https://www.asaclean.com/process/injection-molding)efficiency. By significantly reducing startup scrap and downtime, they were able to streamline operations, increase productivity, and improve overall part quality. ### If contamination issues are causing scrap and downtime in your operation, it's time to take action. Contact us today to learn how we can help optimize your process and deliver similar results. ![Ben Moore](https://www.asaclean.com/hs-fs/hubfs/Head_Shots/Ben%20Moore%20Headshot%20LinkedIn.jpg?width=150&name=Ben%20Moore%20Headshot%20LinkedIn.jpg) #### [ Ben Moore ](https://www.asaclean.com/blog/author/ben-moore) Ben Moore brings over 20 years of experience as a Purging Expert at Asaclean Purging Compounds, a leading manufacturer and distributor of purging compounds. As part of Asahi Kasei Plastics North America, Inc. (APNA), Ben has personally assisted hundreds of customers, helping them achieve significant cost savings. Based in Parsippany, NJ, Ben specializes in optimizing operations for thermoplastic injection molding, extrusion, compounding, and blow molding processes. His expertise lies in maximizing production efficiency by minimizing downtime and reducing scrap. For those interested in trying Asaclean products or seeking expert guidance, feel free to contact Ben directly. You can contact him at 800-787-4348, extension 227, or via email at bmoore@asaclean.com. - [Share On LinkedIn ](https://www.linkedin.com/in/ben-moore-84073131/) ## Related Posts [![Close-up of various plastic medical components including syringes, molded using clean, contaminant-free resins in a sterile manufacturing environment.](https://www.asaclean.com/hs-fs/hubfs/Ben%20Medical%20Blog%201-26.jpg?width=450&height=250&name=Ben%20Medical%20Blog%201-26.jpg) How a Medical Injection Molder Reduced Scrap by 97% Using ASACLEAN® U Grade Purging Tips / 6 min read / January 27, 2026 ](https://www.asaclean.com/blog/how-a-medical-injection-molder-reduced-scrap-by-97-using-asaclean-u-grade) [![3 Easy Tips to Determine Your Cost Per Purge](https://www.asaclean.com/hs-fs/hubfs/AI-Generated%20Media/Images/This%20image%20depicts%20someone%20stacking%20piles%20of%20gold%20coins-1.jpeg?width=450&height=250&name=This%20image%20depicts%20someone%20stacking%20piles%20of%20gold%20coins-1.jpeg) 3 Easy Tips to Determine Your Cost Per Purge Chemical... / 2 min read / April 25, 2017 ](https://www.asaclean.com/blog/3-easy-tips-to-determine-your-cost-per-purge) ## Comments Get Started ## Ready to start improving your efficiency and increasing your profitability? - [Request a Consultation](https://www.asaclean.com/blog/from-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process#) - [Contact Sales](https://www.asaclean.com/blog/from-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process#) ![](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/from-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process#top) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Ben Moore", "url" : "https://www.asaclean.com/blog/author/ben-moore" }, "dateModified" : "2025-03-18T17:50:56.496Z", "datePublished" : "2024-10-08T13:15:00.000Z", "headline" : "How This Molder Cut Startup Scrap from 100 to 3 in Minutes", "image" : [ "https://www.asaclean.com/hubfs/medical%20pills%20industry%20%20factory%20and%20production%20indoor.jpeg" ], "mainEntityOfPage" : { "@id" : "https://www.asaclean.com/blog/from-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process", "@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" : "", "author" : { "@type" : "Person", "name" : "Ben Moore" }, "datePublished" : "October 08, 2024", "headline" : "How This Molder Cut Startup Scrap from 100 to 3 in Minutes", "image" : "https://468726.fs1.hubspotusercontent-na1.net/hubfs/468726/medical%20pills%20industry%20%20factory%20and%20production%20indoor.jpeg", "name" : "How This Molder Cut Startup Scrap from 100 to 3 in Minutes", "url" : "https://www.asaclean.com/blog/from-100-to-3-the-contamination-fix-that-revolutionized-this-molders-startup-process" } ```