In plastics manufacturing, contamination during start-up can lead to excessive scrap, increased downtime, and unnecessary cost. For medical processors, the stakes are even higher—requiring non-toxic, compliant materials that maintain part integrity and meet rigorous safety standards.
This is where ASACLEAN® U Grade purging compound proves its value. In a recent case study from one of our technical sales reps, a medical injection molder in New England was able to cut scrap by 97% and reduce downtime by over 80%—all by switching to U Grade.
The Challenge: Rigid PVC & HDPE Causing Costly Contamination
Medical molding operations often deal with difficult-to-process resins like rigid PVC and HDPE. These materials are prone to leaving behind residue, carbonized build-up, and contamination, especially during material or color changeovers. For this New England molder, every startup meant dealing with:
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Over 100 scrap parts per press
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Extended downtime of 30+ minutes
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Inconsistent part quality
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Increased labor and material costs
For a facility producing high-precision medical components, these problems directly impacted profitability and risked compromising part compliance.
The Solution: ASACLEAN® U Grade
Our sales rep recommended ASACLEAN® U Grade, a versatile, ready-to-use purging compound specifically designed for safe, effective cleaning in medical environments. Asaclean® U Grade is a high-performance mechanical purging compound designed to remove contamination using the shear force of your machine—without relying on chemical reactions or foaming agents.
After a quick trial using only 13 pounds of U Grade, the results were immediate.
The Results: Scrap and Downtime Slashed
✅ Start-up Scrap Reduced by 97%
The molder went from over 100 scrap parts to just 3 during startup—a dramatic improvement that meant less waste, less rework, and faster ramp-up.
✅ Downtime Cut by Over 80%
By thoroughly cleaning the screw and barrel, U Grade helped reduce changeover time from 30 minutes to just 5. That’s 25 extra minutes of productive uptime per shift—adding up fast over the course of a year.
✅ Improved Part Quality
With cleaner machinery, the team noticed improved part consistency, better dimensional accuracy, and fewer defects—especially critical when molding tight-tolerance medical components.
✅ Safe for Medical Environments
Because U Grade is free of toxic ingredients, foaming agents, and abrasives, it can be used with confidence in medical molding cells, where cleanliness and compliance are non-negotiable.
✅ Cost Savings Across the Board
Less downtime, fewer defects, reduced resin waste, and lower labor costs all contributed to improved profitability—and a much smoother workflow.
Why U Grade Is a Smart Investment for Medical Processors
Medical molders can't afford to waste time or material. Downtime can delay deliveries, and scrap can damage a company’s bottom line—or worse, its reputation. Purging with a dedicated compound like ASACLEAN® U Grade isn’t just about cleaning—it’s about production efficiency, quality assurance, and long-term savings.
Here’s what sets U Grade apart:
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No soak time required – Clean your machine and get back to production faster.
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Low-residue formulation – Avoid contamination during sensitive medical runs.
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Versatile performance – Works on a wide range of resins, including HDPE, PVC, TPE, and more.
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Safe and compliant – has a 3rd party letter or compliance.
Conclusion: A Simple Switch That Delivers Serious Results
In this case, a single trial of ASACLEAN® U Grade transformed a problematic process into a streamlined operation. With just 13 lbs. of purging compound, the customer eliminated nearly all start-up scrap, minimized downtime, and restored confidence in their production process.
If you’re in medical molding and facing contamination, black specks, or long startup times, U Grade could be the solution you’ve been looking for.
Reach out to our team to learn more, schedule a free trial, or request technical guidance tailored to your specific application.
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.
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