Improving plastics production cycle-time and yield with custom gas blends from nexAir

The gas you use during plastics production affects how fast your line runs and how much scrap you generate. Custom nitrogen blends cool molten plastic faster than standard industrial nitrogen, which means shorter cycle times in injection molding and extrusion. Different plastic resins respond better to different gas compositions, and finding the right match can improve your output without changing equipment or processes.

How Gas Blends Speed Up Cooling

Injection molding heats plastic until it melts, injects it into a mold, then cools it until the part is solid enough to eject. Cooling takes up most of the cycle time. Nitrogen-based cooling systems work faster than water for some applications, and changing the gas composition affects how quickly heat moves out of the molded part. Adding small amounts of other gases to nitrogen changes how the blend transfers heat. Some mixtures cool plastic faster, which shortens cycle times. Others cool more gradually to reduce stress in thick parts. The right blend depends on what you’re molding and what the parts need to do.

Reducing Defects in Extrusion

Extrusion pushes molten plastic through a die to create pipes, sheets, or films. The plastic stays hot and can oxidize as it moves through the machine. Nitrogen blankets around the die keep oxygen away, which prevents discoloration and weak spots. Facilities running high line speeds or working with plastics that oxidize easily see better results from custom blends instead of standard nitrogen. These blends can include small amounts of other gases that improve how the plastic flows or cools. Less scrap means more usable product, which improves your bottom line.

Matching Gas to Your Product

Food packaging films need ultra-pure nitrogen to avoid contamination. Industrial parts like pipes can use lower-purity gas without problems. Medical components have specific regulatory requirements that fall somewhere in between. Using gas that’s purer than necessary wastes money. Using gas that’s not pure enough creates defects. The expert KnowHow™ we’ve developed working with plastics manufacturers helps match gas specifications to what your products require. We figure out what purity level your process needs, then deliver gas that meets those standards without paying for refinement you don’t need.

Finding the Right Blend

Getting the optimal gas blend usually requires testing different mixtures and measuring results. We work with your team to trial options and track cycle times, defect rates, surface finish, and dimensional consistency. The data shows which blend works best for your specific plastic, part design, and equipment setup.

Once we identify the right blend, we set up regular deliveries so your production runs consistently. Small variations in gas composition can affect part quality, so keeping the blend consistent removes one variable that might cause problems. We help you Forge Forward by making sure gas composition stays off your list of things that could create batch-to-batch quality issues.

Want to improve your plastics production? Contact nexAir to discuss custom gas blends for your manufacturing process.