Optimally adapting component cleaning saves money and resources

The tasks in parts cleaning have become more diverse and must be solved more efficiently and in a more resource-friendly manner. This calls for solutions that are optimally adapted to the cleaning requirements.

The industrial transformation poses challenges for all areas of production, which also has an impact on component cleaning. Not only have the tasks become more diverse and demanding, they also need to be solved more efficiently and in a way that conserves resources. This requires effective and sustainable solutions that are optimally adapted to the cleaning requirements.

New products, changed production techniques and process chains mean that component cleaning has to meet an enormously diverse range of tasks. Stable compliance with very different cleanliness requirements - from grease and/or particle-free to the removal of very fine particulate contamination in the sub-micrometer range and nanolayers of residual film contamination - must be guaranteed, as must maximum cost-effectiveness. In order to keep the CO2 footprint as low as possible, cleaning must also be energy and resource efficient. These diverse requirements demand solutions that are optimally adapted to the cleaning task.

When selecting the most suitable solution, the key factors include the cleanliness to be achieved, the type and quantity of contamination to be removed as well as the material, geometry, dimensions and weight of the component. Company-specific criteria such as throughput requirements, automation and digitalization must also be taken into account. This complexity requires a partner who has mastered the entire range of cleaning technologies and has the relevant application expertise. As an experienced full-service provider of future-oriented and efficient solutions for industrial component cleaning, surface treatment and automation, Ecoclean has both. With module-based modular systems and individually designed special systems for water-based media, solvents and modified alcohols, the system manufacturer covers the entire spectrum of wet-chemical processes for batch and individual part cleaning in practically all industries. Various application-specific process technologies, for example for spray, high-pressure, immersion, ultrasonic and plasma cleaning, steam degreasing, injection flood washing, pulsed pressure cleaning (PPC) and ultrasonic plus, ensure that the required cleanliness specifications are achieved in a stable, reproducible and resource-efficient manner.

The module-based concept enables the quick and easy design of cleaning systems that are precisely adapted to the tasks and company-specific requirements. For large-volume components and high capacity requirements, for example, the EcoCstretch is ideal for operation with solvents and modified alcohols. The system, which operates under a full vacuum, is available in two system sizes, each with two different working chamber diameters. This type of system is used, among other things, for the production-integrated cleaning of aluminum contacts for cell contacting systems prior to welding. The parts are automatically placed in cleaning containers directly after punching. They are fed into the system via a two-lane loading device as a double batch with two sets of four baskets, each 600 x 400 x 125 mm, stacked next to each other. In order to guarantee the cleanliness specifications of "no particles larger than 500 µm and free surface energy ≥ 36 mN/m", Ultrasonic Plus is used in addition to the classic process technology such as dipping and injection flood washing. The pressure varies according to the component geometry so that impurities are also removed from hard-to-reach areas. After cleaning and vacuum drying, a robot removes the containers and places them in the unloading area equipped with filter fan units. From here, the parts are transported through a lifting door into a clean room.

The modular design also opens up a wide range of applications for the EcoCvela, which is designed for cleaning with water-based media. The system can be equipped with one or more closed work chambers in different sizes as well as several flood tanks. This flexibility has, for example, convinced a leading manufacturer of vacuum valves for high and ultra-high vacuum in the production of semiconductors, displays and digital technologies. The company uses a fully automated system of this type for the final cleaning of components made of various aluminum alloys, glass and quartz as well as different plastics prior to surface inspection and assembly, which are carried out in a clean room. This EcoCvela L is equipped with two work chambers for 800 x 500 x 600 mm batches and three flood tanks. After cleaning, which is carried out using spraying, flooding, high pressure, ultrasound and PPC - sometimes in parallel - depending on the components to be cleaned, drying is carried out using vacuum, hot air and infrared technology. The various drying technologies can also be used in combination, whereby the process air is treated with HEPA filters. After cleaning, rinsing and drying, the parts pass through a HEPA filter for component conditioning before being fed into the cleanroom (OM-9/25).