Universal solvent degreaser meets EU regulations

Degreasing machine has helped an second-tier automotive supplier to adhere to Solvent Emissions Directive regulations clean 2.5 tonnes of aluminium/day - 25% more than before.

East London-based Cold Formed Products CFP) has installed a Pero V1 universal degreasing machine from UK distributor Kumi Solutions.

Installed in October 2007 at the end of the production line at CFP's Plaistow manufacturing facility, the Pero is already cleaning approximately 1 million aluminium 'impact' extruded parts a month for a number of automotive and aerospace industry customers.

With over 45 years of history, CFP has grown to become a thriving, 40-employee second-tier automotive supplier to some of the biggest names.

Until recently, the company had relied on an ageing open-top solvent degreasing tank to clean the vast number and range of components it produces.

CFP had to change its degreasing system to conform with the EU's Solvent Emissions Directive (SED), which came into force at the end of October 2007.

CFP's technical director, David Binks, said: "We first heard about the impending SED legislation three years ago.

At first we thought the best approach would be to try and replace solvents altogether, so we looked at aqueous-based degreasing solutions.

But to be honest, the trials we conducted were far from convincing".

Consequently, the company looked again solvent cleaning, but this time Binks and his team considered hermetically sealed systems.

"We visited four of five suppliers of solvent-based sealed machines, but again the results were not impressive," said Binks.

"It was only when we spoke to our supplier of solvents that I heard about Pero machines.

We subsequently contacted Simon Graham at Kumi and he recommended the Pero V1 machine.

After trials in Germany we were relieved to find that it did the job very well".

CFP has developed its own in-house methods for measuring part cleanliness that replicate the procedures used by its customers, to determine whether or not components are sufficiently clean.

Binks said that one of the differentiating factors in favour of the Pero V1 was its vacuum system, which is used to evacuate the chamber of residue.

Many competitor systems use a 'regenerative carbon stack', which can be a time consuming alternative.

CFP also claimed that the V1 was priced more competitively.

* Universal degreasers - Pero machines represent a significant step forward in cleaning technology, said Kumi to manufacturingtalk.com, as the machines are 'universal'.

That is, they employ almost any type of solvent, from chlorinated hydrocarbons - such as trichloroethylene and perchloroethylene - through to methylene chloride, modified alcohols - such as Dowclene 1601 - and any standard hydrocarbons - for example, A3 category products with a flash point in excess of 55degC.

A V-Series system can be changed from one solvent type to another in as little as one day.

The V-Series machines are hermetically sealed to provide 'near zero' emissions and so comply with the new SED.

The machines are run under partial vacuum conditions, thus helping to lower the boiling point of the solvent.

This has many advantages such as the following.

* Improved energy efficiency.

* Reduced solvent consumption.

* Ability to clean more delicate materials such thermoplastics and coated parts.

Solvent condition is monitored automatically with solids, oil and water separated as part of the process.

Sophisticated drying using two or three vacuum pumps is also fully integrated.

The V-Series machines come in five sizes ranging from a basket-type system with 380 x 220 x 200mm capacity, up to a Euro pallet size capable of handling a 1500kg payload.

Installed in October 2007, the CFP Pero V1 was commissioned (using perchloroethylene) within two days without any interruption to the company's production.

"So far it has performed very, very well," said Binks.

"We manufacture around 1 million parts a month here and they all go through the Pero.

Cycle times are typically 6 minutes, but because of the machine's automatic basket loading system, which accommodates four baskets on the conveyor, the machine looks after itself for 24 minutes at a time.

It's a feature we really like." Depending on the size of component, CFP places between 150 and 2000 units in each basket.

The machine runs for 10 hours a day, five days a week.

"In total the Pero machines cleans 2.5 tonnes of aluminium a day, which is 25% more than we could do previously," said Binks, "Furthermore, the V1 only requires cleaning once every three weeks, whereas we had to clean our previous open top tank every week without fail - and the process was much more labour intensive".

CFP operates in what it describes as an intensely competitive automotive industry.

The advantage it offers its customers lies in its impact extrusion process, which can deliver up to 3000 parts/h.

The company also offers subsequent CNC machining to supply finished parts.

Back to top