Post-consumer recycled (PCR) plastics offer a sustainable alternative to virgin resins. But contamination can require costly production line stops for cleaning. We worked closely with one customer to optimize their production process and reduce their downtime.
Our customer produces plastic sheets and bags via blown film. Typically, film producers don’t experience many contamination problems as their materials are highly stable and have few color/polymer changeovers. But they had recently begun to incorporate PCR material, which can process differently and degrade more easily.
Optimising production with purging compound expertise
During a visit to their site, our sales manager heard their machines were being contaminated and needed more frequent cleaning, often in the middle of a production run. The inherent variability of recycled materials can lead to occasional process inconsistencies, such as the appearance of black specks. These specks can accumulate on machinery. This was disrupting their timelines and costing them money.
In a case like this, there is no one-size-fits-all solution. It takes the customer’s experience in their own production processes plus expertise in handling PCR materials to find the right answer each time.
By joining forces, we were able to identify the right purging compound to clean their machines during regularly scheduled maintenance. We used our knowledge of the product, but also relied on their expertise with their machines to create a partnership driving towards a solution that could work within the perimeters they set out.
Results that save time and cost
The solution was a combination of providing the correct product and bespoke procedures for the customer. This option was best for them because it provided a straightforward, repeatable procedure which their teams could implement on their own and gain experience with.
Working together, we were able to eliminate mid-run stoppages completely and reduce their downtime by 75% — from 96 hours to 24 hours.
Our solution added nine full shifts of uptime to their yearly schedule by decreasing the need for long maintenance plans. This means more time for the machinery to produce sellable product.
“Like changing the oil in your car, PCR processors need to plan for routine maintenance to avoid larger, more costly issues later,” explained Austin Watkins, Global Principal Manager at IMCD. “A scheduled purging plan helps remove contamination before it accumulates and appears in the bubble. If you’re purging once you see specks appear, you’re already too late.”
Minimise your footprint, boost your efficiency
Variations in quality of PCR materials pose unique challenges. Recycled plastics often require the addition of stabilisers, compatibilisers, impact modifiers, and fillers to enhance their properties. They can also require different cleaning agents and purging compounds to help machinery adapt.
With European regulations demanding the incorporation of PCR material starting to take effect, these challenges will affect more and more manufacturers. At IMCD, we have long experience of these materials and their practical applications. And we pride ourselves on working in close partnership to find the right solution for every customer.
Together, we can reduce your reliance on virgin materials to shrink your environmental footprint without compromising on efficiency. To learn more, check out Enhancing Sustainability: A Guide to Choosing PIR and PCR Materials. Or give us a call anytime.