Preventive Maintenance & Sealing

Purge plus Sealing
Stop specks, save at once

Purge and seal with ASACLEAN to stop black specks returning — less carbonized burn, downtime and real hidden line costs.

See savings figures See the sealing method See the burn mechanism
26,555฿saved / month / machine
7 stepsSealing steps
~95%Hidden-cost cut
10 minFast full purge
0 defectClean startup
Value saved26,555฿/ month / machine
40 min/monthTotal purge time
No screw pullLess downtime
Hidden Costs

Deep dive into hidden costs (Hidden Costs)

Why do low-grade compounds or unfinished purges cost more than you think?

No seal / low-power purging compound

*Assumptions: 200-ton injection machine, 9 purges per month, 1,000 THB per hour opportunity cost.

  • Compound plus scrap (12.5 kg x 80 THB x 9 times)9,000 THB
  • Speck defects (45 pcs x 25 THB x 9 times)10,125 THB
  • Machine-stop time (5.25 hrs x 1,000 THB)5,250 THB
  • Screw-pull opportunity loss (3.5 hrs x 1,000 THB)3,500 THB

Total hidden cost per month

27,875 THB

With ASACLEAN plus sealing

*Only 4 purges per month, total purge time under 1 hour, no screw pull.

  • ASACLEAN compound (1 kg purge plus 0.5 kg seal)1,320 THB
  • Speck defects (0 pcs)0 THB
  • Machine-stop time (slashed)-
  • Screw-pull opportunity loss (none needed)0 THB

Total cost per month

1,320 THB
ASACLEAN mascot saving costs

Savings per machine

0
THB per year

Instant savings 26,555 THB per month (over 95 percent hidden-cost cut).

Short picture

200-ton injection machine uses 1 kg ASACLEAN purge plus 0.5 kg seal, averaging just 330 THB per time.

  • 4 purges per month totals only 1,320 THB per month.
  • Total purge time under 1 hour.
  • Jobs open with zero black-speck defects.
Hard truth

Old-method purging may look low cost per kilo But adding defects, scrap, stoppage and screw pulls, true cost can hit 27,875 THB per month versus ASACLEAN saving over 26,555 THB per month per machine.

Savings in every production dimension

A good compound saves not just material cost but time, scrap, labor and production opportunity — ASACLEAN returns machines to good parts faster, cuts specks and unseen line costs.

Standard Procedure

ASACLEAN shutdown sealing procedure

Sealing means holding ASACLEAN in the barrel during stops after old resin is purged — cutting leftover-resin contact with oxygen and heat, the key carbonization-and-burn mechanism.

Standard procedure

  1. 1
    Discharge old material fullyAfter production, discharge molding materials first for effective purging.
  2. 2
    Feed ASACLEAN and rotate the screw to purgePurge across until old resin is displaced with no old color or material bleeding.
  3. 3
    Visual checkConfirm old material is out, then enter sealing.
  4. 4
    Feed ASACLEAN to sealHold ASACLEAN in barrel and nozzle during the stop as a barrier layer against oxygen reaching leftover resin.
  5. 5
    Meter full shot volumeMeter full shot volume per machine terms to hold ASACLEAN in position.
  6. 6
    Stop the machine / switch off heatersSwitch off or lower temperature at stops to cut stored-heat and resin-degradation risk.
  7. 7
    New start: heat up and discharge before productionDischarge ASACLEAN clean, then feed next material and verify part quality.
Note: Pick the sealing grade as the purging grade or a fitting sealing grade, and avoid Glass Fiber grades for sealing — see Grade helper
No sealO2 plus heat plus leftover resin leads to carbonize and burn marks
ASACLEAN acts as the sealing layer
O₂
Oxygen
Heat
Leftover resin
C
Carbonize
Burn marks
Screw with carbon burn from no sealing
Mechanism arrows and icons slide toward screw, showing burn-formation mechanism
Screw with carbon burnNo seal: burn stuck on screw
Clean screw and barrel sealed with ASACLEANSealed: ASACLEAN leaves no gaps
Conceptual View

Routine purging and sealing versus resin degradation

Without purging and sealing, resin degradation climbs until burnt residue flakes as specks — routine purging holds degradation low; sealing keeps it inside ASACLEAN-purgeable bounds.

ASACLEAN-purgeable zone with no part contamination Very high degradation High degradation Significant degradation Less degradation Degradation level Time lapse 3. Purge residue out Do nothing ② Routine purging ① Sealing
No purge and no seal — degrades fast to specks 2. Routine purging — holds degradation low 1. Sealing — holds lowest 3. Purge residue out with ASACLEAN
If you do nothing

Resin degradation climbs to very high, baked-on burn flakes as specks — major strip-down (overhaul) needed.

Routine purging

Purge on schedule while residue still releases easily; degradation stays low, never accumulating to quality problems.

Sealing

Hold ASACLEAN during stops against oxygen; degradation stays inside ASACLEAN-purgeable bounds, near-zero screw residue.

Concept adapted from the Asahi Kasei document Conceptual view of contamination generation mechanism in the barrel — conceptual illustration, not values measured on every machine.

Results

Outcomes production teams want

Cut residue before trouble

Run ASACLEAN on PM (preventive maintenance) rhythm to cut burn and holdup before quality problems.

Cleaner screws

Concept from documents — cleaner screws after purging, less flaked contamination next jobs.

Oxygen protection

After purging, hold ASACLEAN in the barrel against oxygen, slowing leftover-resin degradation.

Worked example

Purge with just 1 kg ASACLEAN and 0.5 kg seal, within 10 minutes, fewer specks from job start, fewer mid-week repeat purges. Core idea: never judge purging-compound price per kilo — total scrap, stoppage and screw-pull risk too.

Technical data and fitting grades should be checked against the Technical Data Sheet and ASACLEAN specialists per real machine terms before use. Example figures are estimates under specific assumptions, not guaranteed results for every machine.

Want your machine to open jobs with zero specks?

Send machine, resin, temperature and stop rhythm for CSC technicians to plan purging and sealing for your real site.

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