October 1, 2010 - Buffalo, NY - The Dyna-Purge® Division of Shuman Plastics, Inc. announces that the company recently helped save one of its clients $78,749 annually by switching to New & Improved Dyna-Purge® K engineered purging compound. This global Tier I injection molder, specializing in automotive interiors, supplies large panels to an automotive manufacturer at a rate of 345 vehicles per day. The Ontario, Canada based injection molder called on Dyna-Purge® after they encountered a problem changing over from black to a lighter color.
"We operate four different machines, ranging in size from 1100 to 1550 tons, and the interior parts in question are usually run on a UBE 1550T machine, where we use four different molds on a daily basis," explained a member of the injection molding company's management team. "The production runs can be as short as 72 parts and are offered in three basic colors: black, ivory and gray. When we changed from black to a lighter color, swirls would often form on the lower end of the panels."
All of the panels are made from PP and the processing temperatures range from 428°F to 440°F (220°C to 226°C). The UBE 1550T is purged an average of four times per day. To resolve the swirl problem, the operators would raise the temperatures by 100°F (38°C), closing off some gates, and then run straight PP through the remaining gates. On average, they would use 101 pounds of PP per purge at a cost of $151.50. When operating expenses were factored in, the overall cost per purge was $170.
The technical staff at Dyna-Purge worked with the Tier 1 supplier to identify the cause of the swirls as bleeding from gate hang-ups. A decision was made to sample New and Improved Dyna-Purge® K, a mechanical, non-abrasive purging compound designed for purging PP and other low-temperature resins.
"New & Improved Dyna-Purge® K is specially formulated to flow naturally through the machine and provide for a 'dual power' cleaning technology," said Tim Cutler, Dyna-Purge® Business Manager. "A non-melting but softening thermoplastic scrubs while a proprietary ingredient expands to clean hard to reach areas on the first purge, without leaving residue."
Using New & Improved Dyna-Purge K on just one machine lowered the Tier 1 supplier's overall purging costs by 44% for the annual savings of $78,749. In less than 11 minutes, and with no temperature adjustments, they were able to transition from black to ivory colored panels. In addition, the supplier lowered its scrap rates by 51% to less than 50 pounds per purge.
Developed as part of the company’s continuous product innovation program, Dyna-Purge® K is ideal for processing temperatures ranging from 290°F to 550°F (143°C to 287°C). Furthermore, like the company's other products, New & Improved Dyna-Purge® K utilizes FDA-compliant ingredients. It is easy to use, with no mixing, soaking or machine adjustments required.
For additional information, including a Case Study on the Tier 1 supplier's use of New & Improved Dyna-Purge® K, contact Shuman Plastics, Inc., Dyna-Purge Division, 35 Neoga Street, Depew (Buffalo), NY 14043; Phone: (716) 685-2121; Fax: (716) 685-3236; E-mail: info@dynapurge.com; Website: www.dynapurge.com
