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Deluxe Plastics runs a natural ABS with various colorants on its 720-ton Toshiba hot/cold runner system approximately 5,000 hours per year for a major customer. By introducing Dyna-Purge M
to purge for color changes, the company has cut downtime substantially, freeing up about 15 production shifts per month for its most in-demand press.
Purging with Dyna-Purge M has enabled Deluxe Plastics to save 240 labor hours annually and open up 104 hours of production time for its two 500-ton presses.
The ability to provide short-runs with JIT delivery for a variety of customer parts and products was enhanced when Deluxe Plastics began using Dyna-Purge M, cutting purging costs 47% and downtime 67% on average.
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Situation:
Deluxe Plastics, Inc., Clintonville, Wisconsin specializes in short-run custom injection molding with JIT
delivery. The company uses virtually every type of resin available in producing dispensers, automotive
products, packaging, office and outdoor furniture, and other consumer goods.
In order to meet customer requirements, Deluxe Plastics runs 15 hot and cold runner molding
machines, including Toshiba, JSW, Toyo, and UBE models, with barrel capacities ranging from 6 to 36 ounces
and temperatures from 380°F to 600°F.
The variety of work and pressing deadlines present
many purging challenges, such as 25 color changes in 30 days for one customer, and a weekly changeover
from white ABS to smoke acrylic for another.
Having found other commercial purging products ineffective or too expensive, Deluxe Plastics would use a
glass-filled polypropylene regrind, or the next resin to purge. These in-house remedies also proved to be
time-consuming and unproductive when trying to purge colors and materials effectively.
Solution:
Use Dyna-Purge M, a versatile purging compound designed for purging a wide range of resins at 350°F to 600°F (177°C to 315°C).
Results:
- Downtime for changeovers was reduced by 67% on average as typical purging time decreased from 45 minutes to 15 minutes using Dyna-Purge M. As a result, 240 labor hours are saved annually, and 104 hours of additional production time is now available.
- The average cost to purge using Dyna-Purge M is only $38.90 for Deluxe Plastics, compared to an average of $73.70 using carrier resins and regrinds. As a result, the company lowered its cost to purge by 47%.
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