Purging for Electronics

The electronics industry relies on almost every manufacturing process to deliver us the quality products we depend on every day. The industry is evolving, and customers need smaller and more complicated parts with a wide range of properties. Asaclean® has safe, effective, dependable, and affordable purging compounds designed for the specific needs of electronics manufacturers. Whether you’re coating wires, making connectors using hot runners, extruding battery separators in blown film, or molding phone cases, we’ve helped people just like you achieve dramatic cost savings.

Here’s why Asaclean® Purging Compounds are the preferred choice for the best electronics companies worldwide.

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Why Asaclean® is the Best Choice for Electronics

When we hear from processors in the electronics industry, they usually are asking for help with a handful of different processing issues. If you’re reading this section, then you’ve probably experienced some of these struggles firsthand:

  • You have frequent material changeovers with engineering & super-engineering resins.
  • You’re fighting carbon contamination and black specks.
  • You use additives and pigments that seem to burn easily or streak in future parts.
  • You need fast and consistent color changeover times to keep on schedule.
  • Your start-ups are time-consuming and leave you with piles of scrap.

Electronic Vehicle Charger

There aren’t “easy” processes when you work in electronics.

You may have complicated setups with high cavitation molds or extruders with multiple layers.

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Many plants need to use difficult additives like flame retardants, and antistatic agents and may rely on conductive resins. Your products have zero tolerance for contamination but still run on tight deadlines. Most wire extruders have multiple color changeovers every day.

Many processors in the electronics market assume that these headaches are an inevitable part of the job.

We have good news. It doesn’t have to be that way.

Your products and technical service never cease to amaze us.”
Larry A., Purchasing, Electronics, Canada
58%

On average, Asaclean®’s electronics customers save 58% on reduced scrap & downtime.

1. Asaclean®’s Products Will Solve Your Issue

Processors in the electronics industry don’t need to experience contamination or lengthy changeovers.  We offer Mechanical Purging CompoundsChemical Purging Compounds, and Purging Concentrates designed to tackle your unique set of processing challenges.

I’m absolutely amazed with the performance of Asaclean®. The polymers/fillers that I’m mixing in our small compounder really stick to the equipment, and we can only get about 80 – 90% out of the mixer post-run, so it’s quite a mess. Put Asaclean® E in, mix for a few minutes, and the mixer body is immediately clean.”
Robert R. , Director of Material Development, Electronics, Extrusion, CA
Our Purging Compounds excel in your most difficult electrical applications.

Once we identify your needs, we will help you choose the best grade of Asaclean® for you.

For Electronics, Asaclean® Grades:

  • Excel in hot runner color changes and cleaning
  • Clean the screw & barrel thoroughly
  • Quickly clean out valve gates and nozzle tips
  • Shorten material and color changeover time
  • Are incredibly easy-to-use
  • Dramatically reduce scrap and defect rates
  • Clear the edges of the die quickly
  • Have low residue formulas for clear applications
  • Remove contamination & black specks
  • Prevent gels & non-melts
  • Holding a bubble in blown film
  • Perform on multilayer lines
  • Help facilitate easier screw pulls
  • Seal your machine during shutdowns to promote easier start-ups

Circuit boards and wires

I've been using Asaclean® for 6 years. I love it. I recently started a new job and insisted on my team using Asaclean®. It immediately reduced our changeover time from 4 hours down to 15 minutes. It's a great product and I recommend it to everyone.”
Zach Jolly, Eaton Corporation, Electrical, Ohio

large machinery connected to systems

For many electrical applications, we usually recommend Asaclean®’s N-Series line of Chemical Purging Compounds or PLUS Grade Purging Concentrate.
 

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Asaclean®’s Chemical Purging Compounds are blended products that also match your processing temperatures, your resins, your MFR’s, and your processing needs. But unlike Mechanical Purging Compounds, they clean using a heat-activated chemical reaction that performs best in low-flow and low-pressure environments. Chemical Grades are usually recommended for extrusion because they foam and expand to effectively clean dies or other areas where contamination can hang up. If you experience color streaking, these are a great option for you.

High-cavitation hot runners are better suited with a Purging Concentrate like Asaclean® PLUS Grade because PLUS supercharges your own processing resins and is easily displaced. This is a huge innovation in purging that’s made an immediate impact since PLUS was launched in June 2021. If you’re making connectors, PLUS might be the right choice.

PLUS Grade is the Holy Grail For hot runner color changes.”
Ray D., Plant Manager, Custom Molder, Southeast

2. Our Team Understands the Needs of Electronics Processors

Asaclean® Technical Service Representative offer a unique level of service not found in other areas of the industry.

up close view of microchips

Many of our Purging Experts used Asaclean® as customers themselves before joining our team.

Your point-of-contact isn’t a salesperson. They are a processor.

With over 200 years of combined processing experience, we understand your issue and can offer solutions. We’ve seen it all and are here to help you.

When you work with Asaclean®, you have access to free ongoing consultations with a electronics subject matter expert.

From a buying standpoint, one thing that really sticks out is that Asaclean® are solutions providers. They help us solve the problem. They have provided technical support, training, and product support followed.”
Ray R. , Supply Chain Manager, Washington

3. We Will Train Your Team to Be Asaclean® Purging Experts

large cords connecting into device

Asaclean® Purging Compounds are incredibly easy to use, but you will only see your best results when you follow our recommended purging procedures. When it comes to purging compounds, less is more.

We do not want you to use more Asaclean® than is necessary to achieve your best performance. If you use more than we recommend, your cost savings will drop.

We want you to get the absolute best performance using the least amount of Asaclean®. That is why we place such a premium on training your team.

All electrical processors deal with slightly different challenges, so it’s important that you follow the correct instructions. That’s where we come in.

When you select Asaclean®, we will diagnose your issues, build out a free Purge Program, and train your shifts on how to use Asaclean® to get the best results.

We will help you trial our product, provide in-person or virtual training, answer any questions, and be available however necessary to help your team succeed.

Sometimes keeping good labor can be difficult.

Don’t worry. As you find new hires, we’ll train them as well.

Asaclean® support goes over and above. Training is a part of that. it's great to have our rep in front of people giving training, because if five pounds works, ten pounds is not better. Training is key when you're using these products, and I feel that if I called my Asaclean® rep for help at midnight he would probably answer.”
John S. , Manufacturing Manager, Northwest

4. Simple Purging Tips for the Electronics Processors

EX Grade is an unbelievable product for pulling screws for our maintenance department. It helps us get back up and running in a matter of minutes.”
Vincent Zirkle, Plant Manager, Blue Ridge Molding, North Carolina
TIP 2. Plan Color Changes Going from Light to Dark

When setting up your production schedule, move from clear to light to dark colors whenever possible.

Darker color resins leave more visible residue than lighter colors, so moving from light to dark helps hide the effects of purge residue and residual color and decreases the total time spent purging.

If you’re coating wire, there’s a good chance you know what colors are coming. This tip can make a tremendous impact across all shifts.

TIP 3. Purge Preventatively & Don’t Run Until Failure

plastic electronic device

If you skip purging because you aren’t changing resins/materials or have a tight deadline, eventually you will have contamination issues that will bring production to a screeching halt. Production resins are not designed to clean machines and are not a substitute for commercial purging compounds. Purging in-between production runs will extend the time between teardowns. You should try to avoid teardowns at all costs. Although purging might take some time in the short-term, it will dramatically improve your product quality and output in the long-term.

TIP 4. Film Extruders Need a Grade of Asaclean® That’s Easily Displaced

If you’re a blown film processor in electronics, removing residue and cleaning multiple lines may be more important than holding a bubble. We offer several grades with a proven track record for clearing the edges of your die and removing contamination, that are also easily displaced by your next processing material.

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