Contents
1Why extrusion differs from injection
Injection machines rest on Hold and Cooling beats that open fast-purge chances, while extrusion runs Continuous. Color streaks or tiny carbon ride whole rolls tens or hundreds of meters long, making scrap per problem far higher than injection.
Extra extrusion parts:
- Die Dies with resin-holding lands and lips
- Screen Pack / Breaker Plate Screen packs filtering resin pre-die
- Adapter / Connector Adapters between barrel and die
- Twin Screw s with harder inter-mesh zones than single screw
2Hidden costs in color and material change
Changeover cost scatters across purged resin, not-yet-passing machine time, labor and energy. Logging the baseline before trials beats generic estimates.
Calculate your plant ROI at Calculator page
3ASACLEAN grades fitting extrusion
| Grade | Fits | Temperature | Notes |
|---|---|---|---|
| newEX | Color and material change plus high-cleaning-power residue jobs | 200-330°C | Glass fiber. Verify flow path and equipment first. |
| RU | General purging and non-glass-fiber-formula processes | 160-300°C | Non-GF. Pick by resin and system structure. |
| RE | Low-residue-priority jobs | 160-300°C | Non-GF. Verify fitness to parts. |
| RX | Heavy residue and engineering plastics per job terms | 180-330°C | Glass fiber. Check die and screen pack first. |
| PF | High-temp engineering and super engineering plastics | 280-420°C | Non-GF. Assess resin and system before trials. |
Take the 1-minute grade quiz at Grade-selection page
4Single-screw purging
- Cut old-resin feed rate, leaving the throat clear
- Verify temperature range from the picked grade TDS and old-resin limits
- Set starting amounts from barrel capacity, die volume and contamination level
- Tune screw speed per approved SOP, watching pressure, current and die discharge
- When color returns to pure ASACLEAN, feed new resin to rinse
- Run until pure new resin exits the die, then start production
5Twin-screw purging
Twin screws add hard inter-mesh zones plus side feeders and liquid injection ports:
- Cut old-material feed rate plus close unneeded side feeders
- Set amounts from machine free volume and target components
- Tune screw speed and feed rate to torque, pressure and machine limits
- Fix vacuum-vent and side-feeder states in the SOP before starting, never adjusting without control criteria
- On clean pellets at the die, feed new resin to rinse
6Professional die and screen-pack changes
Die changes spike costs hardest, requiring:
- Machine stops
- Hand die purging (brass brushes, chemicals)
- New die assembly plus parameter setup
- Trial runs to quality
Planning ASACLEAN before die removal aims to:
- Cut old resin held in barrel, adapter and die before teardown
- Systematize post-removal residue and die-state checks
- Fix post-reassembly steps before feeding production resin
Want machine-specific SOPs?
Send machine model, die and resin. CSC technicians design SOPs free.
7Controlled-trial planning and measurement
Extrusion outcomes hinge on system volume, die, screen pack, resin, old and new color and product pass gates. Never use another machine percentages as your machine result guarantee.
Baseline
Log the old purge formula, time, material amounts, labor and failing-product counts
Trial Plan
Fix grade, amounts, temperature, screw speed, sampling points and trial-stop terms
Acceptance
Fix color, speck, clarity or related property gates before starting, judging results identically
Review
Compare total cost and risk, never per-kilo purge-material price alone
8Blown Film & Cast Film
Film jobs demand extreme cleanliness since tiny residue shows in thin sheets:
- Blown Film LDPE/LLDPE/HDPE: Use RU For general purging RE For fine jobs
- Cast Film PP/CPP: Use RU Or RE
- Multi-layer Co-Extrusion: Purge layers separately. Order high-to-low temperature.
- Barrier Film (EVOH, PA): Use RX (Not yet available in Thailand) or consult technicians to optimize
9FAQ
Can ASACLEAN run extruders?
Yes, matching grade and steps to Single Screw or Twin Screw type, resin, temperature range, die, screen pack, vent and feed points. Assess the real system before trials.
How to handle extruder die changes with ASACLEAN?
Plan purging before die removal to cut in-system old resin, then inspect and clean dies per equipment-maker terms. After reassembly run material per approved SOP before production.
What scrap percent does ASACLEAN cut in extrusion?
Depends on machine, resin, old and new color, temperature, system volume and quality gates. Log the baseline, then controlled-trial comparing time, discarded material and actually passing parts.
Does ASACLEAN damage dies?
Match grade and procedure to die type, clearance, screen pack and equipment-maker advice. Non-GF formulas are not automatically right for every die. GF grades should not run Hot Runner or unverified fine flow paths.
Which grade for twin-screw compounding?
Weigh resin, temperature range, free volume, screw elements, side feeders, vent and die first. Glass-fiber grades may fit some jobs but assess every flow-path and equipment point.
Can ASACLEAN run PVC pipe extrusion?
PVC is thermally sensitive, so never pick grades or steps from general tables. Send formulation, temperature and machine data for technician assessment before trials.
Send system data for technician assessment
Data enters the team Google Sheet for owner assignment and callback, and builds your preliminary Trial Plan
- Single or Twin Screw type and barrel size
- Resin, old-new color and temperature range
- Die, screen pack, vent and target problems