Single and multi-step aqueous washing with Standard Industrial.

 

For consistently high levels of cleanliness utilising aqueous formats a secure process control is essential.  Whether in-line or batch format, single or multi-step, Standard Industrial offers systems ranging from heavy maintenance and re-manufacture to precision cleaning in high integrity engineering production.  

With so many companies offering aqueous spray wash systems what distinguishes Standard Industrial technology?  Apart from exceptional build quality and wash efficiency, the assurance of repeatable cleaning performance is of paramount importance.  There are many companies who can manufacture a spray wash system specification.  Almost all will demonstrate how well their specification will perform using clean water and chemicals - the true test of performance is how well component cleanliness is maintained days, weeks or even months after system refilling with clean solutions and how efficiently waste residues are removed from the installation.  Disposal costs of contaminated waste water are set to rise and control of ongoing costs will be critical when considering a new installation.

 

 

Most wash systems rapidly suffer a deterioration in cleaning performance due to "cross contamination" of various wash and rinse waters.  This is unavoidable without the advanced features of intermediate rinse and counter refill.  It must be remembered that components will (nearly) always be washed with "dirty" water -  the final cleanliness achieved is a function of the quality of the final rinse water which, in high integrity applications can be provided from mains supply (de-mineralised if requirements dictate). 
Standard Industrial has met many industrial cleaning tasks throughout the world ranging from high integrity manufacture in aerospace, medical and general precision engineering including Flexible Manufacturing Systems (FMS) to automotive remanufacture and heavy maintenance railway applications.

 

 

Typical applications include:

Removal of press and punch oils

Cleaning of cutting fluids following machining operations

Pre-treatment including iron or zinc phosphating prior to powder coating or painting
Removal of lubricating fluids and compounds

Surface cleaning prior to media blasting operations

Removal of heavy road/rail contamination

For optimum performance it is also essential that the right choice of fluid(s) is made to meet each task.  Whether a general degreasing application based on alkaline technology or an acid process such as phosphating, the correct selection and application of chemistry is critical.  However this is just the beginning - as fluids are lost through consumption and evaporation and contamination levels within the system increase, the process would deteriorate if imbalances were not corrected.  Automatic chemical dosing ensures that chemical concentrations are maintained.  In addition, a variety of mechanical filtration options for particulate matter and oil separation  techniques are available to increase solution life expectancy far beyond other processes. 

 

 

Top Loading Systems

For simple washing in a single stage format, the Standard Industrial top loading systems offer the perfect solution. Parts are loaded into the basket and are washed by a powerful combination of spray from all sides utilising an environmentally friendly detergent from the EcoSpray range.

Robust manufacture with chamber in stainless steel.

Front Loading Systems

Front loading cabinet wash systems are available in a wide range on standard sizes in single or multi step format.  Gross contamination can be removed with a single step process in areas such as re-manufacture and heavy maintenance whilst precision manufacturing will require higher levels of surface cleanliness which can only be met with a multi step operation. 

Counter refill, automatic chemical dosing and a range of oil removal techniques ensure wash and rinse water integrity is maximised giving consistent cleanliness and economy in both chemical consumption and disposal costs.  

Efficient washing requires water to continuously flow over the component surfaces in order to remove surface oils and grease by solvation.  High volume is generally more important than extreme pressure.  The high kinetic energy of spray washing along with higher surface tension of water is beneficial when considering high levels of particulate matter such as swarf and machining debris. However, in components with complex geometries such as cross machining or deep drilling the contamination has to be actively flushed out for removal from the liquid by mechanical filtration.  In many cases this will require component manipulation such as rotating baskets or jigs.

In Line Washing

  

Many continuous manufacturing processes will require components to be cleaned “in line”.  Standard Industrial tunnel wash installations are designed and manufactured specifically to meet to requirements of the particular process.

Adopting similar “counter refill” techniques as the cabinet wash systems, in line systems again greatly reduce the problems of cross contamination of various wash and rinse liquids.  A variety of drying technologies including hot air recirculation, infra red and air knife mean that parts can be made immediately available for onward processing.  

Waste Water Treatment

Contaminated water produced as a result of cleaning and degreasing operations will, of course, be classed as industrial waste and will have to be disposed of in accordance with local and national legislation.  Whilst many cleaning chemicals and detergents are often sold as “environmentally friendly” and “biodegradable”, most certainly the residues removed will not.

As costs of waste disposal rise and more manufacturing facilities rely upon metered water, many installations will benefit from a dedicated or central water treatment plant to re-use water and compact waste into smaller volumes.