Merits of an Aqueous Parts Cleaning System

Aqueous Based Systems

The alternative to Solvents is aqueous based systems, which use water or emulsions as a cleaning media. Emulsions are relatively simpler to handle, wash and recycle. But there are issues that are faced during the disposal of the emulsion waste when the media is to be cleaned.

All emulsions are categorised as water in oil or oil in water types. 

The emulsions are made of emulsifiers which have hydrophobic and hydrophilic ends.  When they are brought in contact with water, the hydrophobic end attaches itself to water molecule and the hydrophilic end is free and can easily attach itself to any oil, grease or similar contaminant. This helps in removal of the contaminant from the media or the substrate.

Emulsions are made by mixing water and the emulsifier under immense shear and pressure to create a colloidal solution that has a dispersion of emulsifiers in water. Emulsifiers have the same property as any hydrocarbon making it an ideal compound to be used in the cleaning. The emulsions are  also made of stabilisers, buffers and other chelating agents.

There are many advantages of using Emulsions. Temperature of washing can be increased and it can also be operated in an open system. It’s also compatible with most metals, non-metals, plastics and alloys. Most emulsions are stable over a wide range of ph, temperatures and can accommodate additives needed in the washing process.

However emulsions need a process of rinsing and subsequent drying. The rinsing is compulsory as we need to remove the detergents and soap remains from the component. This process is not required when dealing with a solvent based system.

A typical aqueous cleaner is 3 stage:  

1) Washing

2) Rinsing

3) Drying.

Most aqueous cleaning agents are made of various compounds to accommodate different processes.  They can incorporate Chelating agents, sequestering agents, anti-rust compounds, anticoagulants, buffers, stabilizers and other such compounds. These Chemistries are detailed in a different book.

 In summation it can be said that most metals clean and dry faster in solvent based systems, but we need to study the economics of using the solvent must be studied in detail. Aqueous technologies are safer, healthier and less expensive too.

Both Methods have disposal issues.  There is a change in the mind-set of existing users who are moving towards thee aqueous based solutions. Class 1 level of washing needs be augmented with a newer generation of chemicals.

Industrial Ultrasonic Cleaning - Advantages and Limitations

Ultrasonic Cleaning: Handicaps and Limitations

Hi…

Thanks for dropping by!

This is Chandrakant from ESP Ultrasonic .

Last week, while I was visiting an Auto Component manufacturer, I was asked by their production manager Mr. Thirumuragan, what was exposure that i considered most valuable , as a Sales Professional.

Without hesitation I blurted out, “We don’t have a solution for every need.”

It’s true, we don’t!

We deal with various Industry verticals and each one of which are so well tuned with their expectations of process fit, budget considerations, Safety standards and Production . No two experiences are the same.

More often than not, we have to devise solutions. By networking with like minded professionals, process experts and by reviewing resources online , we work out a fitting solution. The internet has changed the outlook to successful marketing personnel to that of a marketing consultant. We source popular solutions and work with industry defined norms of acceptance and economy.

Our ability to offer solutions is important because we can offer technical options, which generally are not available to an outsider or on the internet. 

The Limitations of Ultrasonic Cleaning

Industrial Cleaning is evolving and so is technology, process and metallurgy . 

As salesmen, we have the most exciting occupation . Each client has a different challenge.

After about six months of follow up, I met the Senior Vice President of a company and he put forth his requirements .

“Can you dry clean a component”, he asked me.

In my head, I was thinking, ‘Obviously, NOT!

Since I could not offer them any of the wet cleaning options, I took time off to check alternatives. Finally,we arrived at a solution that could give them the ‘dry cleaning’ that they required.  

Ultrasonics do have their limitations. There are two obvious challenges: 

a) The Montreal protocol has prohibited the use of various solvents by restricting the use of the most compatible ones.

This was a body blow to the industry. After working on development of alternatives, the result was the emergence of water soluble solvents and aqueous based systems. The trends are emerging that this seems to be the best way out for most component cleaning challenges.

b) The other limitations of Ultrasonic Cleaning is that it doesn’t work in moving (flowing) media (be it water or solvents).

Yet considering the general methods of cleaning, Static media can’t flush out contaminants in deep recess parts or inside the intricate designed component.

In order to bridge the gap between these two challenges, Ultrasonic technology emerged by using slow flowing media or intermittent pressure jets or rotating component basket. Equipment designs have arisen where media is subjected to sudden turbulence created by blade propelled movement.

Another technique is to gently rock the component back n forth to dislodge deep set contaminant.

Hybrid technologies have also developed.

The good news is that cleanliness levels of 0.04 mg have been achieved using aqueous equipment.

The application of creativity and plethora of chemicals has ensured that almost every requirement for cleaning systems are addressed using Ultrasonic in total or in conjugation with other technologies. This has prompted most professions to adopt a solution based approach rather than a technology based approach.

Strengths of Ultrasonic Cleaning

Well, I think we should also look at the bright side of using Ultrasonic in cleaning.

The ideal system is built on using the combination of the technologies that mask the handicaps and limitations of the other.

Let’s take  another example - Cleaning Materials Exposed to Radioactive Particles.

This has traditionally been a stronghold of Vapour degreaser and High Pressure jets. However the flushing of beta and gamma radiations have been a very closely guarded technology as exposure is fatal and the contaminant cannot be disposed off.

With the challenge for recycling the irreplaceable resource, it was decided to develop a nano-filtration system that works to collect the particulate matter and remove the metal or non-radioactive substances.

Now 99.999% of the required can be achieved with beta filtration using multiple Ultrasonic tanks and jet spray arrangement.  This system is well set to increase the profitability of the cleaning process.

Also, new designs have emerged in the stainless steel tank construction, micro polishing of inner surfaces and use of acoustic technology like resonance, etc.

Ultrasonic Cleaning has emerged as a modern, flexible and dynamic cleaning technology. The technology can be tuned to adapt strengths from water blasting, to that of vapor based cleaning.

In washing, ultrasonic has ceased to exist as a technology.  Its now a solution based to a specific challenge.