When a Southeastern blown-film processor specializing in polyethylene bin bags faced frequent color changeovers—from black to clear—they were spending up to four hours per transition. These changeovers weren’t just slow—they were expensive, wasteful, and disruptive to production.
The company ran multiple black-to-clear changes each week, and each one meant full stops, heavy scrap rates, and long startup delays. The process relied on virgin resin for purging, which had little effect on removing stubborn black resin remnants. Contamination often appeared in the early part of clear runs, leading to even more rejected product.
A Simple Change with a Big Impact
After reaching out to Asaclean®, the processor agreed to trial UF2 Grade, a mechanical purge compound developed specifically for blown-film extrusion. Unlike traditional methods, UF2 is designed to run directly behind production resin—while holding the bubble.
The results were immediate. In just 30 minutes, the changeover was complete. The purge cleaned the screw and die head thoroughly, the bubble remained stable throughout the process, and the plant was back to running clear product faster than ever before.
No additional training was needed. Operators from all three shifts followed a simple protocol, replacing old purge practices with UF2 and reducing downtime dramatically.
Measurable Time and Cost Savings
Before using Asaclean®, each changeover cost the operation roughly $2,200 in material, labor, and lost production time. With UF2, that number dropped to around $760.
Over the course of a year, those savings added up—more than $200,000 on a single line.
But the benefits weren’t just financial. The plant also saw:
- A drastic reduction in scrap during changeovers
- Fewer quality complaints caused by color contamination
- Improved safety by eliminating manual cleaning and screw pulls
- More predictable scheduling across weekly production plans
Why UF2 Works
UF2 is ideal for blown-film extrusion because it balances strong cleaning power with low-disruption operation. It’s compatible with a wide range of PE-based resins and designed to purge without requiring the processor to stop the bubble.
That means operators don’t need to break down equipment, introduce excessive dwell time, or reset the entire line. It’s a fast, stable solution that fits seamlessly into existing production processes.
The Takeaway
Frequent color changes don’t have to come with high downtime or excessive scrap. For this film extruder, switching to Asaclean® UF2 transformed a routine bottleneck into a fast, efficient, and cost-effective procedure—cutting changeover time from 4 hours to just 30 minutes.
If you’re running a blown-film line and struggling with long changeovers or contamination, it may be time to rethink your purge process. Request a free UF2 sample and see the difference for yourself.
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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