Product category:
Cleaning media and cleaning systems
News Release from: MecWash Systems | Subject: Aqueous-based component cleaning technology
Edited by the Manufacturingtalk Editorial
Team on 24 May 2006
Aqueous cleaning systems have high
quality
The aqueous-based component cleaning technology has been shown to deliver extremely high quality results, whilst avoiding many potential environmental issues associated with alternative methods.
The aqueous-based component cleaning technology, for which MecWash Systems has gained a leading international reputation, has been shown to deliver extremely high quality results, whilst avoiding many of the potential environmental issues associated with alternative methods Today, the company offers a range of stand-alone machines - all based on rotational spray and flood washing with components secured in a front loading drum either lose in baskets or in purpose-designed fixtures - to meet varying application needs
This article was originally published on Manufacturingtalk on 11 Jul 2005 at 8.00am (UK)
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The spirit of innovation, to which MecWash owes its origins, is now much in evidence with a choice of complimentary technologies that extend the benefits offered into even more market sectors.
Dedicated jetting, is the basis of MecWash's 'Ultimate Wash' process and is now available on a growing number of machines in the range - a direct reflection of the increasing development and use of complex components.
Machined products that contain numerous blind holes, oil ways and recesses are becoming relatively commonplace, particularly in industries such as aerospace, automotive and medical engineering.
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Machining of such components unavoidably creates numerous areas where swarf and other contamination can become trapped.
The combination of MecWash Systems' rotational washing technology coupled with highly focused jetting action helps to maximise the cleaning performance and, significantly, can be achieved within the same frame and footprint of the existing equipment.
"Components of this type are almost always washed in our equipment in purpose-designed fixtures," commented sales director at MecWash Systems, Paul Young.
"These hold the component firmly in position inside the rotating drum where it is subject to a powerful spray washing, rinsing and drying process." He said: "The addition of dedicated jetting involves the supply of pressurised solution to nozzles directed at specific areas - where the contamination is hidden in the deeper recesses of the component.
Once removed, the contamination is flushed away by the general wash process and collected via two-stage filtration.
Very high standards of component cleanliness are consistently achieved using the dedicated jetting method, with particle sizes of less than 100 microns common on complex engineering components." Running parallel to this development of the MecWash approach to component cleaning is the option to include ultrasonic cleaning into a number of the company's units.
By combining the two technologies, MecWash Systems is able to extend the high quality of its cleaning processes into all areas of the manufacturing industry.
From companies producing simple pressed parts to designers of highly complex and bespoke aerospace or medical componentry - all can now gain from the optimum choice of cleaning processes in the single chamber MecWash Systems equipment.
The well-established use of ultrasonic cleaning processes have long been a regular feature of manufacturing industry with, conventionally, components lowered into a tank whereby the action of the ultrasonic waves loosens ingrained and adhered contaminants into the wash solution to meet predefined cleanliness targets.
However, as Young explained, this approach can have notable drawbacks that are now eradicated when it is used in conjunction with the company's technology.
Young said: "Whilst ultrasonics are highly effective in loosening a wide range of ingrained and adhered contaminants - from casting sand, graphite and lapping paste to polishing compounds and even heavy greases - the removed material can simply fall onto another component surface or to the bottom of the small wash tank.
Here, it will build up very quickly in the wash solution to cause rapid contamination of both the solution itself and of further components." He continued: "This contamination inevitably reduces the effectiveness of the ultrasonics process.
Regular costly and time-consuming changes of wash solution are therefore required.
The combination of ultrasonics with our powerful rotational washing action immediately removes the contaminants released by the ultrasonic process".
"The filtering systems that are built into our units then return clean wash solution, thus eliminating the risk of cross contamination for subsequent components.
In a growing number of cases, this is proving to be the optimum process to maintain the highest quality results." To date, MecWash Systems has focused on adding an ultrasonics capability to two units within its range - the 'Midi 400' and the larger 'Millennium' system.
In both cases, the technology is built into the existing framework so no increase in footprint on the shop floor is required.
However, a third area of innovation with which the company is achieving notable success, can be enjoyed either within an existing machine frame or as a separate mobile unit.
The MecWash 'Aqua-Save' waste water recycling unit works in conjunction with the aqueous technology and allows users to maximise dramatically the effectiveness of their environmental performance.
Young highlighted the thinking behind the Aqua-Save concept: "The system continuously recovers and reuses the wash water, virtually removing the need for disposal." He said: "At the same time, water quality is maintained throughout the production process helping to ensure that parts exit the system in a clean condition without contamination from oily residues.
The only effluent resulting from the system," he pointed out, "Is a concentrated oily waste which, typically, represents only 2-3% of the tank volume.
It is surprising how often the quality of wash solution can be neglected by manufacturers," he continued, "But this can now be addressed directly and automatically by the Aqua-Save system." He pointed out that in a typical 500 litre aqueous washing machine savings of some GBP 7500/year can be realised - which means the Aqua-Save can fully pay for itself in around 12 months.
Add to this 100% tax allowances available against investment in equipment that is designed to maximise energy saving and water quality and the proposition becomes thoroughly compelling.
An excellent example of this capability can be seen at subcontract turned parts manufacturer, MSP, where the installation of a MecWash Solo 400 component washing system linked to an Aqua-Save is not only helping the company maintain its success but is also enhancing the service it offers to its customers.
The company produces some 15 million parts/year to meet sale successes world-wide with the focus on manufacturing an extensive range of brass, steel and aluminium parts between 1mm and 110mm in diameter.
"MSP's customers include many of the leading names in the automotive, electrical, hydraulic and white goods sectors so the demand for quality is paramount," explained Young.
Stringent cleanliness levels at the site can translate to contaminant of no more than 15 mgs/kg of parts - levels which the Solo 400 can readily accommodate.
"The decision to link the Solo 400 to an Aqua-Save water recycling unit is also very significant," continued Young, "Because it enhances the company's commitment to environmental care.
The Aqua-Save permits the re-circulation of the wash solution producing only the minimal amount of waste oil for removal off site.
At a time when many of MSP's customers are calling for production techniques to meet the highest environmental standards, this is seen as an important addition." Maximising equipment performance and meeting ever more stringent environmental standards are clearly the watch words of manufacturing industry today.
Proven MecWash technology and the ongoing innovation as illustrated by the options described, are set to provide customers with the optimum range of choices and to play a key part in engineering and industrial processing in a growing number of sectors.
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