This article was originally drafted by Sandro Siminovich and published as a blog post at https://ecoclean-group.us/news/blog#11. Images and text are the exclusive property of Ecoclean, Inc.
16 Tips for Cleaning Manufactured Parts
Some simple tweaks to your parts cleaning process can make a significant improvement in your parts cleaning results. In this article, we offer some basic actions you can take which may help in one or more of the following ways: improve your cleanliness results, increase your washer’s efficiency, reduce cleaning costs, and protect your washer against issues related to misuse, time and wear. Ecoclean recommends the following sixteen tips. While parts cleaning equipment is paramount in determining cleanliness quality for a given manufacturing process, external factors, both upstream and downstream, also play a role.
Following these actions and precautions can significantly improve cleaning results. These are general guidelines and may not necessarily apply to all parts cleaning situations.
Tip 1: Production-to-cleaning (avoid storage)
Move parts directly from the production line into the cleaning process. Avoid storing of parts, especially those parts manufactured with coolants. The coolant can dry on the parts making them more difficult to clean, resulting in longer cycle times, potential spotting on the parts and increased manufacturing costs.
Tip 2: Deburr parts prior to cleaning
Burrs will probably not be removed with a regular cleaning washer. Special applications for deburring (brush or high pressure) must be used prior to cleaning. Burrs left on parts can interfere with downstream processes and even get loose once parts are delivered to end customer. Another option is to consider if the application is a fit for a washer that offers a combination of processes, such as deburring, cleaning and drying.
Tip 3: Consider if changes or circumstances in the manufacturing process are compromising the cleaning results
Sometimes undesired cleaning results are not the caused by failures in the cleaning process. For example, a change in the coolant used in the machining process can interfere with the cleaning operation. Another variable that can affect cleaning results is dull tooling. Dull tooling can generate chips that are hard to remove. New tooling or a chip breaker can easily resolve the problem.
Tip 4: Reduce the quantity of parts in each batch
If cleaning is unsatisfactory with a basket-style washer, try loading fewer parts into the basket. While this will decrease throughput slightly, it can improve cleanliness by allowing more cleaning media (solution) to access the parts. Higher throughputs or faster cycle times are of little value if the parts aren’t getting clean.
Tip 5: Use the correct type of baskets
Use baskets made of stainless steel round wire. Avoid baskets made of galvanized perforated sheet metal. The perforated metal basket has a reduced open area, and therefore allows less cleaning media to access the parts. Additionally, perforated baskets deflect ultrasonic waves and can result in an ineffective cleaning.
Tip 6: Like cleans like
The composition of contaminants on the parts can determine the cleaning process that is selected. If the contaminants are oil-based cutting fluids, then use a hydrocarbon (isoparaffin) cleaning process. If contaminants are water-based, such as emulsions or lapping compounds, aqueous parts cleaners should be considered. If production has a mix of oil and water-based coolants, a process with a modified alcohol might be indicated. This general rule can influence cycle times, cleanliness levels, and repeatability.
Tip 7: Spotting is a consequence of mineral residue left on parts
Salts and minerals from the water might not be removed and can dry on the parts. Wiping with a clean cloth after washing might resolve the problem but certainly is not desirable. Using demineralized water in water-based machines can eliminate the problem. If cleaning with a vapor degreaser, water free parts are the best solution.
Tip 8: Pre-dip wet parts before cleaning with hydrocarbons
If parts have water or coolant on them, as may occur after different machining operations, dip the basket of parts into a hydrocarbon bath immediately after machining and prior to loading the basket into the cleaning machine. This can remove unwanted water.
Tip 9: Intermediate cleaning between manufacturing phases
In multi-stage production processes, different media, cutting fluids, or coolants are sometimes used at different stages. The mixture of these media can have unpredictable effects on the cleaning process. If cleaning results are unsatisfactory, try cleaning the parts between these manufacturing phases, rather than just at the end of the line. This may improve the results. In any case, always make sure the contaminants being removed are chemically compatible with the selected parts cleaning machine.
Tip 10: Fine cleaning machines must be dedicated to fine cleaning
Never use a fine cleaning machine for general purpose cleaning applications, even in a pinch. Fine cleaning may include the final wash stage or parts having tight cleanliness specifications. If the fine cleaning machine is misused, dirt can accumulate inside and eventually make its way onto parts. This will degrade the fine cleaner’s effectiveness and affect contaminant loading in filtration systems. It can ultimately result in part rejects.
Tip 11: A dirty environment jeopardizes cleanliness
It may be that when parts come out of the washer, they are clean. But after one hour in a plant with atmospheric particulates, they may get dirty again. There are times when a clean room is necessary. In such cases, parts may be transported via conveyor directly from the machine into a dedicated clean room.
Tip 12: Avoid human contact with clean parts
Like debris and contaminants in the manufacturing environment, humans can unknowingly transfer contaminants onto the parts, such as oils from their hands, or strands of hair. Handlers should wear lint-free gloves, hair nets, and work coats or body suits whenever possible.
Tip 13: Avoid dirty shipping packaging
After all the preparations, the last phase (packing and shipping) must introduce no new contaminants. It is best to wrap the parts in protective plastic. Make sure packaging crates or boxes are free of debris and particles that might spoil the cleaning unexpectedly.
Tip 14: Educate operators, handlers, and maintenance personnel
Although cleaning is a necessary evil, basic training about cleaning principles and best practices can go a long way toward improved production overall. Optimally, maintenance personnel should also be trained on how to get the most out of the cleaning machines they service.
Tip 15: Perform washer equipment maintenance
Cleaning machines are particularly influenced by changes in external processes. Likewise, their performance can be adversely affected by poor or inconsistent maintenance. This is especially the case with aqueous parts washers. Unlike cutting equipment, where poor maintenance results in an eventual breakdown or gauged part failure, on a washer, poor maintenance can result in less visible issues that go undetected far downstream. Regularly scheduled maintenance can reduce the likelihood of unseen issues and rejected parts or batches.
Tip 16: Watch for regulatory impacts
Some cleaning chemicals are being phased out by the EPA, making cleaning equipment that relies on those chemicals costlier to maintain. Washer manufacturers have been known to quote machines that rely on chemicals subject to pending or future environmental regulations. This may occur because a washer company’s equipment design is not compatible with newer cleaning agents or degreasers. When purchasing a parts washer, it is recommended to involve the supplier of the cleaning media about the chemicals to be used in the machine. There are parts washers and solvent degreasers that meet EPA and OSHA standards and some are classified as BACT (Best Available Control Technology) and pre-approved for use in California. It is recommended that manufacturers seek assurances about known regulatory impacts for their regions.
This article was originally drafted by Sandro Siminovich and published as a blog post athttps://ecoclean-group.us/news/blog#11. Images and text are the exclusive property of Ecoclean, Inc.