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Rouen Plastics was using in-house resins and regrinds to purge when changing colours and materials, but now uses Dyna-Purge, as shown above by Jack Turcotte, Production Supervisor. As a
result, Rouen has decreased its average cost to purge by 93% and reduced scrap by eliminating the need to use 189 kgs (417 lbs.) of in-house materials to purge.
Cleaning on the first pass, Dyna-Purge eliminates streaking for Rouen Plastics in approximately 15 minutes compared to up to two hours with previous methods. The before-and-after
difference is shown between in-house resins/regrinds and Dyna-Purge for a selection of Rouen's products including retriever cups, golf tees and phone covers.
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Situation:
Rouen Plastics, Inc. produces automotive, medical and recreational plastic products at its plant in Ajax, Ontario, operating nine injection moulding machines
including Toshiba, Sumitomo and Arburg models. With tonnage ranging from 28 to 250 tons and operating temperatures of 149°C to 310°C (300°F to 590°F), the company processes ABS, nylon, acetal,
polypropylene, polycarbonate and PVC.
Using polypropylene virgin or regrind natural material, Rouen would purge 5 to 10 times daily when changing colours or switching from high-melt
to low-melt materials.
The greatest challenge was changing from platinum to charcoal gray and back. Streaking would continue for one to two hours and consume about 189 kg
(417 lbs.) of usable resin. The cost-per-purge for Rouen Plastics was C$360.00.
Solution:
Use Dyna-Purge M, a versatile grade, to purge a wide range of resins from the barrel and screw at 177°C to 315°C (350°F to 600°F).
Results:
- Streaking was eliminated in approximately 15 minutes compared to taking 1 to 2 hours using in-house resins when changing colours. This represents an 83% reduction in downtime.
- The average cost to purge decreased by 93% to C$26.49.
- Instead of using, on average, 189 kgs (417 lbs.) of in-house material for each purge, Rouen Plastics uses only 1 kg (2.2 lbs.) of Dyna-Purge. This is a significant reduction in scrap.
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