Well, a washer works hard to ensure that parts come out clean and ready for the next production process. To keep the machine working at a high level, it must be cleaned on a regular basis. The contamination removed from the parts does not simply disappear; it builds up in the tank and greatly reduces performance. Performing a tank and system clean out can reduce the “peaks and valleys” in your cleaning processes.

To begin the process, turn off the automatic water fill supply and remove the nozzles and filters for cleaning. Pay attention to the direction spray angles of the nozzles in relation to the flow of the parts through the washer. Most nozzles will have an indication, either a slit or indented line, which shows the angle. It will be important to replace the nozzles in the correct position.

After the nozzles and filters have been removed, add a washer cleaning chemistry to the current wash solution. We recommend the use of our Renu Parts Washer Revitalizer. Heat the new solution to 160F, or the highest level attainable. Turn on the pumps and let them run for 30 minutes.

Clean the sludge that has been removed during this process and replace the nozzles. NOTE: If you run the pump for an extended period without the nozzles, then the pump motor will not sense the appropriate back pressure and the pump will burn up. After replacing the nozzles, turn the pumps back on and let them run undisturbed for 4 to 8 hours and allow the solution to work on the tank. Once the time is up, pump or drain the solution from the tank.

Use a power washer to completely clean the interior of the machine, beginning at the top and moving down. Make sure to clean the heater elements, auto-fill valve, wash headers, and blow-off headers. Check all corners or other areas that could catch dirt.

Completely clean any oil removal devices, and flush the tank of the remaining dirty solution. Then remove the clean pump inlet screen and chip basket for cleaning. Wipe down the outside of the machine. Take some time to inspect the interior and exterior components of the machine for damaged or missing parts. Make notes of any damages or problems for repair.

Replace the clean out doors, making sure that the doors are in good condition before doing so. Replace the doors in the reverse order from how they were removed, and then replace any other devices that were removed from the machine during cleaning. Place the nozzles back in their original position, making certain that they are at the correct angle and aim.

Refill the tank with a new solution of cleaning chemistry, and turn on the heat. Observe this process to make sure everything is running smoothly. Run the pumps and observe the gauge readings, making sure there are no more than 10-15PSI differences before filter and after filter. If there is, replace the filter. We offer a wide range of particulate filters ranging from 10-micron to 200-micron filtering capacity. Keep in mind that the tighter the filter element, the faster it will become plugged with contaminants. For most applications a 100-200 micron filter sock is adequate.

Once the solution has reached the correct temperature, check the spray pattern on parts moving through to ensure the machine is running correctly. Remove the wash door, using a piece of Lexan the size of the door, and observe. If it is correct, replace the door.

Performing this maintenance on your washer will help keep it running efficiently for a long time. Cleaning out the debris and inspecting the main parts of the washer allow you to head off major maintenance problems before they become too large of a problem to deal with. The shut down in production time that will take place during cleaning is more desirable than the extended shut down which will inevitably occur if cleaning is not performed and maintenance goes unchecked.

The time lapse between the photos was 3 minutes.

Low VOC Cleaner

After 3 mins the product could be wiped off or spray washed off easily.

Companies throughout the U.S. are in the process of eliminating their use of traditional solvents such as trichloroethane (TCA), trichloroethylene (TCE), perchloroethylene (PCE), chlorofluorocarbons (CFCs, e.g. Freon TF, Freon-113, CFC- 113), methyl ethyl ketone (MEK), acetone, toluene, xylene, and methylene chloride as these solvents become subject to more stringent regulations.

With all the attention focused on these solvents and efforts to reduce their use, it seems appropriate at this time to pause and take note of the accomplishments that have already been achieved by companies in the US to find alternatives. Over the past few years, numerous companies have been actively looking for cleaning and degreasing alternatives and many have made considerable progress, as reported in pollution prevention plans.

By sharing their successes, as well as providing some general guidance, we hope to help some of you in your efforts to find alternatives also.

As you conduct your search, however, realize that there are neither quick and easy solutions for your cleaning challenges nor “drop-in” replacements for your traditional solvents. As we all know, these traditional solvents have been widely used because of their excellent cleaning performance in diverse cleaning applications. Alternative cleaners or cleaning methods, by contrast, typically have limited applicability, and the following approach can be taken when searching for alternatives.

First, take a good, in-depth look at your current cleaning processes to understand what you are cleaning and why. Cleaning is the process of removing soils or contaminants from the surface of a substrate, and things to look at in your evaluation are:

• the substrate materials (e.g. metal, plastic),
• the specific soils to be removed (e.g. particulates, metal fines, oils, adhesives, waxes, rosins, greases, glycols, inorganic salts),
• how the soils are introduced onto the surface,
• the cleanliness requirements or standards, and
• the size and configuration of the parts.

Once you understand what you are cleaning and why, next, decide if there is really a need for cleaning. You may be surprised to find that you don’t need to clean as much or at all, as was the case with Hughes Missile Company, who conducted a thorough review of their microelectronics assembly cleaning processes and determined that a considerable amount of cleaning with TCA had no effect on product reliability and thus could be eliminated. Similarly, Intel Corporation found that cleaning with Freon in some operations could be eliminated.

Next, consider changes that will eliminate or minimize the need for cleaning, such as process changes equipment modifications, material substitutions, or product redesigns or reformulations. One company  installed an enclosed, automated casting machine and high efficiency gelcoat spray guns for manufacturing cultured marble, replacing a cement mixer, plastic buckets, and paint brushes, and as a result, significantly reduced the quantity of acetone used for equipment and tool cleaning.

Intel Corporation converted from ink markings of logos on some finished packages to laser marking, and eliminated the need for package pre-cleaning with Freon. One manufacturer of structural composite honeycomb core, found that by implementing improved materials handing procedures, such as wearing gloves and using plastic covering, a final cleaning of the core with TCA to remove particulates and body oils could be eliminated, while still meeting customer specifications.

McDonnell Douglas Helicopter switched to a water-soluble drawing and now uses our aqueous cleaner instead of TCA. Another company switched to a Kester water-soluble fluxes for solder assembly operations and now cleans with a water-based cleaner instead of Freon.

Once you have done everything to eliminate or minimize cleaning requirements, next consider using a less toxic material or cleaning method for each of your specific cleaning applications. In general, alternative cleaners or methods include aqueous, semi- aqueous, and nonaqueous cleaners, and mechanical and thermal cleaning methods.

Aqueous cleaners are waterborne solutions that typically contain rust inhibitors, surfactants, or emulsifiers, and include acid, alkaline or neutral cleaners. These cleaners are generally used for wipe cleaning, or in enclosed parts washers, spray tanks or immersion dip tanks, and are followed by a water rinse stage, and sometimes a drying stage.

Semi-aqueous cleaners consist of water-immiscible solutions used in conjunction with a water rinse and include terpenes, esters, petroleum hydrocarbons, and glycol ethers. Nonaqueous cleaners do not require the use of water in the cleaning process and include high flashpoint hydrocarbon or nonchlorinated cleaners, such as stoddard solvent, kerosene, or mineral spirits, as well as alcohols such as ethanol, isopropanol (IPA), and methanol and hydrochlorofluorocarbons (HCFCs). Mechanical and thermal cleaning methods include dry abrasive cleaning with plastic media or sandblasting, and bake-off ovens.

Overall, the use of alternative cleaners or cleaning methods seems to be the preferred option for many companies in the US. A printed circuit board company replaced TCA and Freon used for removing flux from printed circuit boards with an Alpha Metals saponified aqueous cleaner. A Plating company replaced TCA used for degreasing brass and steel parts with Industrial Metal Cleaner #10, an alkaline cleaner that can be used in spray or dip applications.