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KA Molded used to spend $282.53 per purge using in-house materials. They lowered their cost by 68% using Dyna-Purge® M.
Between the in-house purge and next production resin, KA Molded used to scrap 90 lbs of material during color or resin changeovers. Dyna-Purge® M lowered their scrap rate by 87%.
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Situation:
KA Molded Products, based in Mansfield, OH, is an ISO 9001 certified custom injection molder specializing in automotive, P.O.P.s and plumbing products. Operating out of a 9,000 sq. ft. manufacturing facility, KA Molded runs seven different injection molding machines with an average screw size of 2 inches in diameter.
The company noted that they process a variety of different resins, including Ultem and Acrylic SMMA. When transitioning from a
dark to light color, or from a high-temperature material to a low-temperature material, they would experience over 2½ hours of downtime. KA Molded stated that they were using in-house materials for purging, such as acrylic regrind, PC or PP. After consulting with Dyna-Purge®, a decision was made to run trials using Dyna-Purge® M, which is a versatile non-abrasive, non-chemical purging compound that can be used for purging a wide range of resins within the temperature range of 350°F to 600°F (177°C to 315°C).
Solution:
After conducting a series of purging trials, KA Molded approved Dyna-Purge® M, stating that it reduced downtime by 70% and lowered their purging scrap from 90 lbs to only 12 lbs.
Results:
- Reduced purging cost from $282.53 to only $90.35 per purge, a 68% improvement.
- Lowered scrap rate by 87%, using only 12 lbs to transition to next resin.
- Improved productivity by lowering purging time 70%.
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