Purging Compound High Cleanability Type – Free samples of plastic purging compounds for injection molding machines are available for improving black dot defects.

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Evaluation Method for Purging Compounds – Carbide Removal Edition

When considering purging compounds, each customer has various challenges. When evaluating different purging compounds, it is important to first use them according to the manufacturer’s recommended instructions to confirm their effectiveness, and then adapt the usage method to suit your own environment.

Even if the usage method of the purging compound is appropriate, the effect may not be visible unless the “evaluation method” is aligned with the specific challenges. Therefore, we introduce the method to evaluate the “carbide removal effectiveness” of the purging compound ecomaru.

Evaluation Procedure for Carbide Defect Challenges

When expecting a purging compound to have carbide removal effectiveness, it should fundamentally be judged by comparing the frequency of carbide contamination (defect rate). For evaluating this challenge, we recommend the following procedure:

黒点不良に高洗浄パージ剤
Evaluation Procedure for Carbide Defect Challenges

First, before the evaluation, check the usual occurrence of black dots during mass production. If you are not constantly measuring the defect rate, approximate it beforehand. This allows for a more realistic comparison of quantitative defect data. At this time, also check the usual cleaning time and purging compound usage to enable a more comprehensive evaluation.

The important thing here is to “not judge based on the amount used during purging and the amount discarded during purging.” While the amount discarded during purging is a crucial cost factor, the goal this time is to observe changes in the defect rate. Therefore, do not conclude “it’s no good because the discard amount is large,” and try using it as is. Our cleaning agent Ecomaru often takes longer for purging when it effectively removes foreign matter from inside the machine. This is because the dirt accumulated by previous cleaning agents is being expelled all at once, which is a natural phenomenon when the agent is working effectively. During the initial cleaning, more cleaning agent is used, which may create the illusion of “not being clean” if evaluated by the number of pellets. Please continue cleaning until the purge color appears and evaluate based on the change in defect rate after starting molding.
Rather than drawing conclusions after a single use, we recommend setting a period for evaluation. Depending on the usual frequency of machine disassembly and purging, a period of one week to one month is suggested. Contaminants accumulated inside the machine form layers and adhere firmly, and it is rare for them to be discharged all at once, not just with ecomaru. Additionally, at this stage, it is crucial to “monitor the trend of the defect rate.” When a large amount of accumulated dirt is expelled, the defect rate will temporarily increase. Do not judge that “the purging is ineffective because defective products have increased”; instead, observe the progress and use the point when the fluctuation in the defect rate becomes minimal as the evaluation endpoint for an accurate assessment.
This is the most important stage, but comparing results while managing various tasks can be challenging. You may find it difficult to identify the elements to compare or to gauge the impact of changes in defect rates. To assist you, we offer an Excel-based cost estimation sheet where you can simply input the numbers for an easy comparison. Please make use of this tool.

Case-Specific Points and Additional Notes

During the initial use, defects may frequently occur, and the amount of purging material may be high. If you are considering ecomaru, please inform your representative that you typically do not use purging compounds.

Generally, filler-containing (high cleaning power) cleaning agents may take longer to replace with subsequent materials. Although ecomaru is designed with consideration for replaceability with subsequent materials, please consult our customer service if you have any concerns.
Even after using it two or three times, it may be difficult to see a noticeable difference. For machines that undergo disassembly cleaning, we recommend regularly using the purging agent after disassembly to monitor the increase in defect rates. If you are testing on machines that do not undergo disassembly cleaning, it is fine to purge at the usual frequency. However, if possible, increasing the frequency of purging agent use may make the effects more apparent.

By using a purging compound before dismantling and cleaning, you can visually check the amount of carbides adhering to the machine and make a visual comparison with and without the use of the purging compound. It is recommended to use the purging compound regularly for a few days before dismantling and cleaning. Once the removal effect of carbides is confirmed visually, you can optimize the usage amount by regularly using the purging compound and observing the trend of the defect rate.

Summary

For the evaluation of foreign matter and black dot defect issues, please be mindful of “continuous evaluation” and “quantification of evaluation contents” to conduct a more meaningful review. If you have any questions, please contact us.

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