Quick Tips To Reduce Scrap During Material Changes

Understanding Scrap in Material ChangesWhat is Scrap?

Scrap is basically the leftover material after you’ve done molding or manufacturing. It can come from improper color changes, faulty products, or just operations that didn’t go as planned. High scrap rates can drive up production costs and add to environmental waste,which is a challenge for everyone.

Common Causes of Scrap

There are plenty of reasons why scrap happens during material changes, but here are a few key ones:

• Material Incompatibility: When switching materials, sometimes the new stuff just doesn’t bond right. If it’s not matched up properly, it can lead to scrapped products.
  
• Release Properties: Poor mold release agents can leave pieces stuck in the molds, resulting in damage or scrap.

• Process Variables: Inappropriate settings for temperature variation and injection speed, along with inconsistent maintenance, can adversely affect the material.
  
  
  

  Why Should Scrap Be Reduced

• Reducing scrap allows manufacturers to anticipate higher profitability, as scrap is avoided and sustainability in production is attained. With even one gram of waste, there’s not only wasted material but also labor, energy, and resources that went into generating that gram. In this regard, reducing scrap positively impacts both the company’s bottom line and the environment.
  
  
  

  What Are Mold Release Agents?
  

  Mold release agents are lubricants that get applied to molds to make it easier to remove the formed parts. important for preventing damage to both the mold and the product, which helps keep the quality of the finished part as high as possible.
  
  

  Here are some common examples of mold release agents:

• Water-Based Release Agents: These are essentially the go-to option because they’re easy to use and good for the environment. A lot of manufacturers really like how user-friendly they are across different applications.

• Solvent-Based Release Agents: The team does a great job helping molded parts pop out. But, there are some environmental concerns with them, which is something manufacturers usually think about when picking their materials.

Silicone Mold Release Agents:

These have become super popular for their fantastic performance in composite molding. They offer a smooth release and can handle high temperatures without breaking a sweat. It’s no surprise they’re a favorite among many in the industry!

Effect of Mold Release Agents on Scrap

When applied properly, mold release agents can dramatically lower scrap rates. Quality agents help reduce defects, boost the overall quality of the final product, and make cleanup a breeze. Silicone-based agents, like those from ChemTrend, really step up the release efficiency and are perfect for producers looking to cut down on scrap.

Quick Tips to Reduce Scrap While Changing Materials

Tip 1: Be Sure to Select the Right Mold Release Agent
Choosing the right mold release agent is key to cutting down on scrap during material changes. ChemTrend’s Silicone Mold Release Agents are flexible, meaning they can work with a bunch of different materials and processes. When you match the right material to the right agent, you can see some big reductions in defects and waste.

Tip 2: Surface Preparation
Before slapping on the mold release agent, make sure the mold surface is clean and ready to go. Any leftover stuff from previous materials can mess with the release. A good cleaning will get rid of those contaminants and make adhesion and release way better.

Tip 3: Thickness of Application
How thick you apply the mold release can also affect how well it works. Too thick can lead to uneven releases, while too thin might not cover enough. So, it’s important to find that sweet spot for reliable release.

Tip 4: Uniform Temperature Control
Material properties can be sensitive to temperature changes, so mold release performance can take a hit too. Keeping things at uniform temperatures throughout production can help catch defects and ensure high-quality molded parts. Make sure all your machines and materials are warmed up before you start.

Tip 5: Optimization of Injection Speed and Pressure
Lowering injection speed and pressure can really help avoid defects and keep scrap rates down. Slower injection speed lets the material flow nicely without trapping air pockets or leaving gaps. Keep a close eye on this and calibrate for the best production conditions.

Tip 6: Maintenance Equipment
Regularly maintaining your molds and processing equipment can help you steer clear of issues that lead to scrap. Set up a schedule for checking your machines, cleaning and lubricating parts, and replacing anything that’s worn out. This proactive approach boosts efficiency and cuts down on scrap.

Tip 7: Training of Operators to Best Practices
Training your team on the best practices for running operations can make a huge difference. Educate your employees on how to handle production to minimize waste as much as possible.

Case Study: Transformative Purging Solution

A global plastic packaging manufacturer was dealing with big scrap problems and found their solution with ChemTrend, a top specialty chemical company in India. They were struggling with incomplete color changes that left residual particles in the barrel and head of their extrusion blow molding equipment. This led to contamination through color, unusable products, and tons of extra scrap, not to mention a lot of frustrating downtime.

The Challenge

This company was dealing with some serious color contamination issues, which led to way too much scrap and a lot of downtime. They tried several purging compounds, but nothing really worked for them. They even whipped up their own liquid purge blend, but it didn’t cut it either.

Our Solution

Then ChemTrend came in with Ultra Purge 3615—a ready-to-use, self-draining purging compound made from top-notch thermoplastic polymers. This new material tackled the tricky green-to-white color changes, plus the whole startup and shutdown process.

Result Obtained
Ultra Purge 3615 delivered some amazing benefits, including:

• 85% scrap reduction: Those color variations from light to dark slashed scrap from thousands of kilograms down to nearly nothing.

• 87% cost savings: When switching from green to white, efficiency shot up and resulted in far more effective in-house purging compared to conventional methods.

• 69% Downtime Reduction: Ultra Purge™ 3615 significantly decreased downtime caused by the cleaning of machine lines and blenders.
• Scrap was reduced to as low as 100 kg, compared to 400-800 kg previously, during the processing of HDPE using Ultra Purge™ 3615.
  
  The production quality improved significantly, with a reduction in downtime and overall waste through the implementation of Ultra Purge™ 3615’s self-emptying technology. Scrap and material waste were eliminated during color changes. The manufacturer looks forward to expanding this to its facilities.
  
  
  

  Conclusion
  

  The key benefits in increasing manufacturing efficiency, cost savings, and improving sustainability are the scrap reductions resulting from material changes. Significant scrap reductions can be achieved through effective mold release agents, process optimization, and investment in training.
  
  With Ultra Purge™ 3615, ChemTrend clearly illustrates its great ability to innovate the best solutions for mold release. This will allow producers to boost production levels. Let’s explore the silicone mold release agents and purging compounds within ChemTrend’s product range and understand how scrap can be kept at its minimum while also increasing the productivity of your operations. Let’s start optimizing your production process and reducing waste!