The cleanliness of industrial components is a key factor for product quality, assembly reliability, and downstream surface treatments. Choosing the right cleaning method and the appropriate parts cleaning machine directly impacts efficiency, repeatability, and production costs.
We offer here a lot of technical and practical information on the various systems used to effectively wash, degrease and clean the different types of parts that are manufactured or handled in industries. These solutions range from basic manual operations to automated systems designed for high production volumes and demanding technical requirements.
The systems used in these cleaning actions are as follows:
This method uses the chemical action of various cleaning agents, solvents, alcohols, petroleum, and alkalis, combined with the mechanical action of rubbing or scraping the parts to be cleaned with different tools such as brushes, polishers, sanders, scrapers, and abrasive cloths. This method is now obsolete and is only used for non-critical or low-production parts due to its high cost, limited effectiveness, and the significant environmental impact it has on operators.
This method involves immersing the dirty parts in tanks filled with different types of liquids, such as cleaners, soapy water, solvents, petroleum, and alcohols. When the parts are submerged, the liquids impregnate their entire surface, including hidden areas like through or blind holes, grooves, and threads. This, along with the additional aid of moving the parts or agitating the liquids using various means such as turners, turbines, or ultrasound, ensures thorough cleaning. Afterward, the parts must undergo a drying and protection phase.
Spray cleaning with final drying:
This can be done by spraying cold or hot cleaning liquids at high or medium pressure onto the parts to be treated manually using conventional steam-water pressure washers mixed with detergents. This system is suitable for large-format or low-production parts. Either with automatic washing machines in special static booths, or in continuous tunnels for large productions, in this case the parts circulate inside the washers directly supported or inside appropriate baskets on linear conveyor belts, carousels, rotary drums, or the parts are hung on frames mounted on overhead conveyors that circulate inside tunnels passing between tubular ramps equipped with different types of special nozzles that project at certain pressures and at a controlled temperature, the cleaning liquids onto the surface of the parts to be treated carrying away the greases, oils and all kinds of dirt that they contain towards the bottom of the tanks from where the booster pumps that work in a closed circuit filter all the impurities, dose and control the levels of the cleaning liquids to be able to work efficiently and continuously. At the end of this process or processes, since there may be several intermediate or final stages of treatment and finishing (rinsing, phosphating, oiling, etc.), the pieces are given a final drying to ensure proper surface treatment and prevent oxidation.
Cleaning using automated industrial systems:
Because surface treatment of all products is currently a key factor in all industries, some manufacturers have specialized in supplying turnkey, fully automated machines and systems designed according to the needs of each type of part. In fact, these systems result from combining all or part of the previously listed cleaning systems into a single unit or treatment line: immersion tanks, agitators, conveyors, heaters, and all controlled by control panels with programmable logic controllers (PLCs) for the automatic control of all the motors, sensors, solenoid valves, pneumatic, hydraulic, and electric cylinders, etc., that make up this type of machine.
Cleaning and degreasing using chlorinated solvent and hydrocarbon vapors:
This process involves heating and vaporizing the liquid cleaning agent (solvents) in a tank within an open chamber with adequate suction or in a vacuum chamber. The expanding vapor condenses onto the surface of the parts to be cleaned, carrying away all grease, oil, and dirt. Most solvents are recovered through condensation and filtration until they are clean enough for reuse. At the beginning or end of the vaporization process, the parts to be cleaned can be immersed in the solvent, or the cleaning solvent can be projected directly onto their surface in automated, properly sealed systems. This prevents environmental contamination and protects operators from direct contact with the toxicity of these solvents, which are released in their vapor phase. For this reason, some of these solvents are prohibited or obsolete. Currently, there are other types of alcohols and special solvents that do not have these drawbacks and offer certain advantages if handled properly.
Besides these cleaning methods, there are other “Surface Treatment” systems for performing specialized work with specific materials that cannot be treated with the traditional methods we have described:
Biological Cleaning and Degreasing:
These are water-based bioenzymatic products capable of loosening and removing fats, oils, and organic contaminants through the action of certain microorganisms and enzymes (lipases). Once removed, these substances are readily biodegradable. Recommended for the food industry, although the cleaning process is very slow.
This method removes dirt by directing a laser beam onto the material being treated, vaporizing rust, paint, oil, grease, etc. While this technique is high-quality, it is slow and expensive to apply since only surfaces directly exposed to the laser beam can be cleaned.
Plasma cleaning (atmospheric or pressurized):
This is a relatively new technique that creates a chemical reaction that oxidizes organic contaminants, causing them to volatilize. Similar to laser cleaning, it can be an ideal tool for specific treatments of plastics, electronic components, textiles, and medical devices, although it is impractical and expensive for metallurgical treatments.
Abrasive blasting (shot blasting):
This process involves projecting small abrasive particles at adjustable pressure using compressed air, either inside suitable booths or continuously. The specific abrasive particles used depend on the type of material being treated and can include sand, glass microspheres, steel, plastic, corundum, etc. The surfaces to be cleaned are bombarded with these particles at high speed (50-110 m/s) to remove dirt, paint, oxides, mill scale, etc. Parts impregnated with grease or oil require prior degreasing.
Based on the above, to choose the best cleaning system, according to the specific needs of each product or component to be treated, it is necessary to carry out an adequate study by a company that is highly specialized.