--- title: Reduce Start-Up Scrap & Increase Profits with Purging Programs description: Discover how to reduce start-up scrap and boost profits with our effective purging programs for plastics processing. image: https://www.asaclean.com/hubfs/easystartup%20blog%202023.png --- [ 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/reduce-start-up-scrap-and-boost-profits-with-effective-purging-programs#subscribe-modal) ### Suscribirse Injection Molding / 4 min read / August 27, 2024 # Reduce Start-Up Scrap & Increase Profits with Purging Programs - [Facebook Share ](https://www.facebook.com/sharer/sharer.php?u=https%3A%2F%2Fwww.asaclean.com%2Fblog%2Freduce-start-up-scrap-and-boost-profits-with-effective-purging-programs) - 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A common question I encounter is, "How can we improve our start-ups?" The solution often begins not at the start-up but with refining your[ shutdown procedures](https://www.asaclean.com/solutions/shutdown-and-sealing). During the shutdown, processors frequently encounter several issues: failing to purge, leaving non-thermally stable resins, colorants, or additives in the barrel under heat, or leaving the barrels empty while banking the heat. These practices can lead to material degradation and the formation of black specs. For example, a non-stable white colorant might degrade under prolonged heat exposure, even if you use thermally stable polyethylene. We can tailor a purging program that minimizes these start-up challenges by identifying and addressing such issues. On average, a well-designed purge program can cut start-up scrap by 40-60%. **Success Story: Major Appliance Manufacturer** Consider a recent case with a major appliance manufacturer that produced white High-Impact Polystyrene (HIPS) sheets used to thermoform refrigerator liners. Their typical Monday start-up took up to four hours to eliminate black specs and meet quality standards for white sheets. Previously, they would end the week by leaving white HIPS in the [extruder](https://www.asaclean.com/process/sheet-extrusion) at a banked heat of 350°F, increasing to 420°F at start-up, without flushing the old resin. This approach was costly, with each Monday start-up averaging losses of $3,800 due to downtime and scrapped parts. However, with a new purging procedure using Asaclean U Grade, they changed their approach: 1. **Friday at 5 PM:** Purge out all white HIPS and [black specs](https://www.asaclean.com/solutions/carbon-contamination) at production temperature with [Asaclean U](https://www.asaclean.com/purging-products/u-grade) Grade. 2. **Shutdown:** Fill the screw and barrel system with Asaclean U Grade and turn off the heaters. 3. **Monday Start-Up:** Set temperatures to 420°F, use half a barrel of U Grade to purge the system, then flush with one barrel of HIPS before starting production. The impact was dramatic. Start-up time reduced to just 30 minutes with zero rejects. The cost for each Monday start-up dropped to $1,300—a 65% cost reduction, saving $2,500 weekly. Annually, this amounts to $120,000 in savings. **Beyond Financial Savings** Adopting a structured purging program with Asaclean saves money and reduces wear on your equipment. It also alleviates workforce stress, elevates product quality, and enhances overall production efficiency. Don't let start-up scrap erode your profits. [Contact Asaclean today ](https://www.asaclean.com/contact-us)for a customized purge program evaluation. Together, we can achieve significant savings and boost your profitability through optimized purging processes. Remember, effective purging leads to smoother start-ups and greater profitability. ![Jerry Weddell](https://www.asaclean.com/hs-fs/hubfs/1713568728231.jpg?width=150&name=1713568728231.jpg) #### [ Jerry Weddell ](https://www.asaclean.com/blog/author/jerry-weddell) With over 30 years in the field, Jerry Weddell is a Technical Sales Representative with a wealth of knowledge in mold-making and purging compounds. While his expertise spans injection molding, extrusion, and blow molding, he is particularly distinguished in injection molding. Jerry's profound understanding of these processes enables him to offer targeted, practical solutions, especially in the nuanced aspects of injection molding. His commitment to providing exceptional guidance and support to clients has made him a respected and trusted figure in the industry. - [Share On LinkedIn ](https://www.linkedin.com/in/jerry-weddell-b0747538) ## Related Posts [![](https://www.asaclean.com/hs-fs/hubfs/Process%20%26%20Industry%20Header%20Photo.jpg?width=450&height=250&name=Process%20%26%20Industry%20Header%20Photo.jpg) Faster Profile Extrusion Color Changes with Chemical Purging Troubleshooting / 2 min read / October 21, 2021 ](https://www.asaclean.com/blog/easier-profile-extrusion-color-changes-with-chemical-purges-concentrates) [![Clear resins are found in headlights and other lenses.](https://www.asaclean.com/hs-fs/hubfs/Clear%20headlights.png?width=450&height=250&name=Clear%20headlights.png) 2 Ways Purging Compounds Can Help With Processing Clear Resins Troubleshooting / 2 min read / September 08, 2020 ](https://www.asaclean.com/blog/2-ways-purging-compounds-can-help-with-processing-clear-resins) ## Comments Get Started ## Ready to start improving your efficiency and increasing your profitability? - [Request a Consultation](https://www.asaclean.com/blog/reduce-start-up-scrap-and-boost-profits-with-effective-purging-programs#) - [Contact Sales](https://www.asaclean.com/blog/reduce-start-up-scrap-and-boost-profits-with-effective-purging-programs#) ![](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/reduce-start-up-scrap-and-boost-profits-with-effective-purging-programs#top) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "Jerry Weddell", "url" : "https://www.asaclean.com/blog/author/jerry-weddell" }, "dateModified" : "2025-03-18T16:15:51.951Z", "datePublished" : "2024-08-27T13:15:00.000Z", "headline" : "Reduce Start-Up Scrap & Increase Profits with Purging Programs", "image" : [ "https://www.asaclean.com/hubfs/easystartup%20blog%202023.png" ], "mainEntityOfPage" : { "@id" : "https://www.asaclean.com/blog/reduce-start-up-scrap-and-boost-profits-with-effective-purging-programs", "@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" : "Jerry Weddell" }, "datePublished" : "August 27, 2024", "headline" : "Reduce Start-Up Scrap & Increase Profits with Purging Programs", "image" : "https://468726.fs1.hubspotusercontent-na1.net/hubfs/468726/easystartup%20blog%202023.png", "name" : "Reduce Start-Up Scrap & Increase Profits with Purging Programs", "url" : "https://www.asaclean.com/blog/reduce-start-up-scrap-and-boost-profits-with-effective-purging-programs" } ```