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Bob Williams is the Injection Molding Manager at Aakron Rule responsible for reducing the company’s annual purging costs $4,000 by switching from in–house resins to Dyna–Purge purging compounds.
The elimination of a difficult color, such as blue, is made easier and more efficient by running Dyna–Purge P through the entire system, including the mold.
Dyna–Purge P reduced downtime 75% and the cost to purge by more than 50% for Aakron Rule. The company makes the Flyer® in nine different colors, so total savings are significant.
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Problem:
Aakron Rule produces approximately 2,000 Flyer® aerodynamic toy discs per day in nine different colors.
There is an extensive amount of downtime and wasted material associated with each color change.
In order to purge the old color out, roughly 110 lbs. of polypropylene would be run through the mold plate of a 375–ton Cincinnati Milacron, two–cavity hot runner system.
The barrel temperature operates at 450°F to 500°F, and the mold plate at 90°F to 100°F.
Purging with the resident resin would take at least two hours per color change and result in 400 to 500 defective parts produced.
The calculated cost to purge for every color change is $150.00 in lost production, material and labor.
On an annualized basis, it was costing the company nearly $8,000.00 to purge using in-house resins.
Solution:
Use 15 lbs. of Dyna–Purge P, a grade specifically designed for purging hot runner (and hot manifold) systems at 320°F to 575°F.
Results:
- Machine downtime is reduced 75% as both the barrel and hot runner system are purged and cleaned in 30 minutes.
- Since the cost to purge a color change using Dyna–Purge P is $70.00, Aakron Rule reduced its purging costs more than 50%.
On an annualized basis, this represents a savings of more than $4,000.00 with Dyna–Purge compared to using an in–house resin to purge.
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