Degreasing machine cuts press shop solvent usage

A Pero degreasing machine has reduced solvent usage at a press shop to 2/3 barrel per year, representing a considerable financial saving.

Clamason Industries in Kenilworth, UK, presses technically complex metal parts in medium to high volumes using power presses of 50-2500kN (5-250 tonf).

90% of Clamason pressings are intricate and less than 2mm thick.

Annual order quantities per part can range from 25,000 up to 200 million, although an average call-off would lie between 50,000 and 250,000 per year.

The surfaces of all these pressings (stampings) require cleaning to remove lubricants deposited during the process.

Clamason's quality manager, Paul Edwards, said that the company used to use an open-top trichloroethylene tank.

He continued: "However, the recently tightened Solvent Emissions Directive (SED) regulations set us thinking about sourcing a different cleaning method." The company examined aqueous and hydrocarbon alternatives, but assessments of performance put solvent systems top of the list.

"We are well aware of the features and benefits of solvent cleaning and so were not surprised when other processes failed to match its performance," said Edwards.

"What is more, we discovered that closed-loop, low-emission solvent systems can be more environmentally friendly than aqueous units, which require high amounts of energy to heat the wash solution".

The Pero V2 solvent vapour degreasing system from UK distributor Kumi Solutions provided the answer.

V-Series machines work with the entire system under negative pressure: 'V' denoting vacuum.

Edwards said that the Pero V2's emissions were the lowest Clamason could find without any compromise with cycle time.

The machine also provided what Edwards regarded as the ideal basket size, 660 x 480 x 300mm.

Clamason can fit 15 large parts into a single V2 basket or as many as 50,000 smaller components.

Typical parts include airbag inflator housings, ladder platforms, set top boxes for digital TV, central heating boiler parts, vehicle engine control units, car radio housings, window hardware, tiny medical pressings and electrical contacts.

* Self-loading - having also purchased Pero's extended conveyor track, Clamason simply loads parts into a basket and lets the system do the rest.

The conveyor feeds the machine, which cycles automatically: there is no need to press a single button.

Clean parts emerge at the other end after a cycle of 5-6 min.

Now, 90% of Clamason's pressings are cleaned by the V2.

Only a small minority of customers request aqueous washing, said Clamason.

Edwards thought that the cleaning results with the Pero V2 were far superior and more consistent compared with the old open-top trichloroethylene tank.

He said: "We would previously find dirty parts in the middle of baskets that would require reprocessing.

This simply doesn't happen any more".

Working with the chemical service and solutions provider Safechem, Clamason was advised to use perchloroethylene as the cleaning solvent in its new Pero V2.

The solvent was delivered in specially designed safety containers, the Safe-Tainer system.

Safechem was then able to train Clamason on the necessary tests for their Dowper MC solvent that would need to undertaken, and to provide advice on safe handling and maintenance of the solvent.

* Solvent loss cut - Clamason said that solvent loss has also been cut significantly.

Using its open-top trichloroethylene tank, Clamason would lose approximately 14 tonnes of solvent every year.

Using the V2, solvent loss is estimated at less than 2/3 barrel per year, representing a considerable financial saving.

"We operate in a very competitive market with the highest quality requirements," concluded Edwards.

"Our customers expect clean parts, but unfortunately without incurring any price rise.

Hence we have to clean our components through a non value-added process in the most efficient and cost-effective manner possible without compromising quality.

The Pero V2 has provided this capability".

* About Clamason - established 60 years ago, Clamason Industries is a highly service-orientated, independent UK manufacturer and assembler of precision pressings (stampings) serving a broad spectrum of global customers from its manufacturing bases at Kingswinford (West Midlands) and Nitra (Slovakia).

Current turnover is spread over half-a-dozen key market sectors - automotive engineering and medical together comprising two-thirds, with the remaining third consisting of home entertainments, building products, electrical accessories and disparate niche markets.

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