Our HDPE extrusion machine experienced a malfunction, causing approximately 80 pounds of molten plastic to spill onto the machine base. Removing the plastic is challenging due to limited access and the presence of cooling pipes. Currently, I am using a sawzall with a 10" long coarse blade to cut chunks of plastic, but the pile spans about 2 feet in diameter, making the process slow. After spending hours removing only a quarter of the plastic, I am seeking efficient methods to clear the remaining bulk without damaging the cooling lines. Any suggestions would be greatly appreciated. - Mike
Have you considered utilizing an air-operated jackhammer for breaking refractory linings, like I did in the past? What caused the unnecessary dumping of molten plastic?
I contemplated using a jackhammer, but I was concerned that the plastic would not be brittle enough to break apart like cement. Additionally, I was worried about causing damage to the machine. The standard procedure here is to turn on the extruder before positioning the molds. Typically, any excess plastic is caught on a sheet metal piece on the machine's frame. However, due to negligence or oversight, someone allowed the plastic to accumulate inside the machine, causing it to malfunction. Now, it is my responsibility to remove the built-up plastic. Quite the situation, isn't it?
If using a Jack Hammer seems excessive, consider using a drill as an alternative. However, using a drill may pose a risk of damaging the cooling pipes. Another option could be heating the plastic with a small torch or heating element. Additionally, partially disassembling the machine could provide better access for repairs.
I found it fascinating that you brought up using a drill. Just recently, I utilized a similar technique to remove a substantial amount of melted plastic from a 100HP shredder. The plastic had accumulated to about 2 inches in thickness in a circular recess measuring approximately 18 inches in diameter. Due to the tight space, I wasn't able to slide a pry bar underneath the edges. Instead, I opted to use a drill to create 'fault lines' by chain-drilling the plastic. With the help of a pry bar equipped with a spud (a pointed end), I leveraged the drill holes to break down the plastic, which proved to be highly effective. Although the process left some minor drill dents on the steel surface beneath the plastic, it wasn't a concern in this particular scenario. I'm now considering utilizing a 24-inch 'bell-hanger bit' to drill through a pile of plastic under the extruder. It's intriguing how similar our thought processes are, don't you think?
I was happy to offer assistance. Initially uncertain about the drill, I realized that in brainstorming, every idea holds potential until it is thoroughly examined and potentially rejected if deemed inadequate. The true failure lies in not putting forth any ideas at all. Remember: "No idea is a bad idea."
Hey Mike, sorry to hear about the mess. One method you might consider is using a heat gun. You can control where you're directing the heat and it will soften the HDPE making it pliable for removal with your sawzall. Remember to be careful not to damage the cooling pipes or overheat the surrounding components of the extruder. As always, make sure that proper safety precautions are being taken when applying the heat. Good luck!
Hey Mike, that sounds like a tough situation! Have you considered using a heat gun or hot air blower to soften the plastic before attempting to cut it? This might make it easier to remove larger chunks more quickly without damaging the cooling pipes. Just be careful with the temperature control, so you don’t overheat anything. Another option could be to use a combination of a putty knife or a metal scraper to chip away at the edges as you go. Good luck!
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Answer: - One effective method could be to use a heat gun or a blowtorch to soften the plastic, making it easier to remove without causing damage to the cooling lines. Another option is to use a heat-resistant scraper or spatula to carefully scrape off the molten plastic.
Answer: - While a sawzall with a long coarse blade can be useful for cutting chunks of plastic, it may not be the most efficient method for removing a large spill. Consider using specialized tools such as a heat gun, blowtorch, or a heat-resistant scraper for more effective removal.
Answer: - To speed up the process, you can consider using a combination of softening the plastic with heat and using a tool like a scraper to remove it in layers. It may also be helpful to work in sections, focusing on smaller areas at a time to make progress more efficiently.
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