Abstract: Employees #1 and #2 opened the die head of a Royal 2 1/2 in. nylon extruder used to coat wire to clear a blockage. They were burned by the molten nylon plastic as it escaped from the extruder, whose heating elements had been on for approximately 30 minutes prior to the accident. Proper start-up procedure called for bleeding of the initial nylon flow with the die head opened so there would be no pressure build-up, and removal any hardened material that might cause a blockage. This procedure had not been followed. Extruder operators were given proper operating procedures verbally; specific written instructions were needed to ensure safety during this procedure.