With laboratory analysis for optimum component cleaning

Laboratory tests and cleaning tests help to find the best solution for every component cleaning task. This enables parts cleaning experts to determine the optimum cleaning medium and the most effective cleaning system in the laboratory.

The effectiveness and efficiency of parts cleaning in the production process sometimes depends on the choice of cleaning medium used. Particularly in the case of non-polar contaminants such as grease, oil and lubricants, the use of hydrocarbons or modified alcohols is usually weighed up. The cleaning experts at Vapic GmbH rely on extensive and project-related cleaning tests. Their findings: hydrocarbons offer an alternative and often superior solution for cleaning tasks that are otherwise attributed to modified alcohols.

In view of the current high energy and material costs, companies are once again being called upon to set up industrial parts cleaning as a resource-saving and economical process. The contract cleaner and system and chemical manufacturer Vapic GmbH from Neubulach in the Black Forest specializes in designing individually tailored cleaning systems. Extensive laboratory tests and test procedures play a fundamental role in this: "We determine the process-optimized chemistry for each cleaning task in advance in our in-house laboratory, because no two applications are the same," explains Samuel Wolf, Managing Director of Vapic GmbH. This is done using a series of solubility tests and has already led to results that no one would have expected beforehand. "Many of our customers are convinced at the start of system planning that they are cleaning with modified alcohols. In our laboratory tests, however, hydrocarbons often prove to be the more effective and economical choice. That's why we are not guided by blanket recommendations when it comes to cleaning chemicals, but examine and decide on a case-by-case basis," continues Samuel Wolf.

One example of this is the project planning of the cleaning system for V-Zug AG. The manufacturer of high-quality premium household appliances from Zug in Switzerland replaced its previous through-feed degreasing system with a two-chamber system from Vapic. Its planning and installation was part of a comprehensive redesign of the process landscape and the cleaning process with automated component transfer between the high-bay warehouse and assembly. Since March 2024, the new system has been used to clean chrome steel, chrome-nickel steel, galvanized sheet and aluminium that have machining residues such as punching and drawing oils after the punching and forming process. Some of the cleaned parts are later installed inside the appliance, while others are used for coating and must meet the highest cleanliness standards or have a visually perfect surface as visible parts. These varying and constantly increasing cleanliness standards could only be met with the previous system, which was time-consuming and energy-intensive.

To ensure that this can be done more economically in the future and that the cleaning process is also securely positioned for growing requirements, the company wanted to invest in a new system with a wet-chemical process. At the beginning of the system planning, the project managers had already agreed on the medium "modified alcohols": "We sought advice from various cleaning agent suppliers in advance. After various trial cleanings, we came to the unanimous recommendation that guided us. Modified alcohols are also known for their polar and non-polar properties and are usually used in demanding cleaning applications. That's why we hadn't considered hydrocarbons before," reports Christoph Fässler, Project Manager Plant Planning at V-Zug. However, the results of the extensive test cleaning in the Vapic laboratory disproved the previously obtained recommendations.

There, the cleaning performance of hydrocarbons and modified alcohols was determined and compared using extensive solubility tests. For this purpose, stainless steel plates were contaminated with three different lubricants and cleaned at 50°C. The evaluation of the surface energy achieved in each case made it clear that better values could be achieved with the hydrocarbon cleaning medium for two of the lubricants tested. Subsequent simulation tests confirmed these test results. They also proved that no acids, solids or other substances were produced in the process. This demonstrated the process safety of the hydrocarbons. "With our precise analysis process, we try to determine the requirements for component cleanliness on a factual basis and, in accordance with the principle of 'as clean as necessary', find a solution for the cleaning task that is both needs-based and economical," explains Julian Köpplin, Head of Chemistry at Vapic. Another reason why V-Zug opted for hydrocarbons was that they are cheaper to purchase and maintain. As they demonstrably did not form any acid in the simulation tests and ensured better phase separation and low odor pollution, they also proved to be easier to handle overall.

"In addition to the very good cleaning results and lower costs, it was the better handling and easier quality maintenance that ultimately convinced us to use hydrocarbons in the cleaning system," says Christoph Fässler. He also appreciates the adaptability of hydrocarbons, which allows the medium to be adapted to any changes in contamination or cleanliness requirements. "Hydrocarbons can be used in a mixture with modified alcohol. This allows their polarization properties to be changed, which is why they are able to effectively dissolve many other contaminants. This property is often given too little attention at the start of a plant project, which is why we always advocate extensive test analyses. It is worth questioning and thinking outside the box when choosing a medium," Julian Köpplin is convinced. The stable cleaning process and the high quality of the results confirm this approach. (OM-3/25)