Alkaline Cleaning

An overview of the alkaline Guide

cleaning process…

Article Post: 11/1/1999

GREGG SANKO
Senior Chemist, Oakite Products, Inc.

This guide provides finishers an overview of cleaners, the differences between them and discusses what to
look for in choosing an effective alkaline cleaner. Alkaline cleaning blends alkalinity sources with a balanced
amount of surfactants to constitute a highly effective metal cleaner. The concentrate is dissolved in water
and, in combination with mechanical action and temperature, generally removes most contaminants. This
method is cost effective, and disposal of the spent material is easy.

Alkaline cleaners
Cleaning is an essential part of the finishing process. The cleaning method can vary depending on the
contaminant to be removed, amount of material involved, possible need for an automated process and
overall effect on subsequent operations.

Alkaline cleaners are specifically formulated chemical blends consisting of alkaline salts, wetting agents and
sequestrant (chelating) agents. They owe their detergency, or cleaning ability, to the displacement of
contaminants by surface-active materials and alkaline builders. These constituents remove the contaminants
and allow them to be easily rinsed away.

The term "alkaline builders" covers a broad group of chemicals: caustic soda (NaOH), caustic potash (KOH),
phosphates, silicates and carbonates. These chemicals supply the alkalinity for the cleaner. High-alkalinity
products saponify fats and vegetable oils into soluble soaps. These alkaline salts also neutralize acidic
contaminants and aid in dispersing oils.

Caustics (KOH, NaOH), the most common type of alkalinity builders, are highly alkaline (pH 12 to 14). They
saponify fats and work with surfactants to disperse contaminants. This type of builder is not safe for use on
soft metals like aluminum and zinc.

Silicates provide medium alkalinity (pH 11 to 12.5) and contribute to detergency. They inhibit attack on soft
metals, but they become insoluble at a pH less than 10.

Phosphates have slightly lower alkalinity values (pH 9.5 to 11.5) and provide more detergency than the other
builders listed. They provide some protection for soft metals and tie up hard water ions, preventing them
from interfering in the cleaning process.

Mildly alkaline carbonates (pH 9 to 9.5) are mainly used to neutralize acidic contaminants. They also buffer
solutions to maintain a specific pH range.
Wetting agents (surfactants and synthetic detergents) aid in removing contaminants by lowering the surface
tension of the solution, allowing the cleaner to get under the contaminant and displace it from the metal
surface. Once the contaminant is in solution, the wetting agent creates an emulsion, preventing redeposition
onto the part being cleaned. Surfactants have one end that is soluble in water (hydrophilic) and one end that
is soluble in oil (hydrophobic). This allows the surfactant molecule to create an oil-water emulsion that is
easily rinsed away. Cleaning principles. Soil is defined as matter out of place. Regardless of the type or
category, all cleaners remove contaminants from a substrate by one or more of the following principles:

• solvent action - enables the cleaner to dissolve oils present on the metal surface;
• saponification - chemically converts drawing compounds (organic oils and fatty acids) into water-
soluble soaps that can add to cleaning efficiency;
• detergency - surface active agents, or surfactants, reduce the interfacial tension between solution and
contaminant, enabling cleaning solutions to better penetrate and displace contaminants from the metal
surface;
• emulsification - surfactants in the cleaning solution suspend contaminants in the aqueous phase for
easy rinsing; and
• deflocculation - disperses contaminants into very fine particles that are suspended in the cleaning
solution. Materials to be removed are classified into two general

categories: oil and particulate matter. Oil, by definition, is a petroleum-based product. However, for
discussion purposes, simple waxes, vegetable oils and animal fats, which may have been applied to
facilitate processing operations or rust prevention, may be included. Particulate matter is finely divided
contaminants present on the surface of the substrate to be cleaned, including smut, pigments, drawing
materials and shop dirt.

Cleaner selection
To select a cleaner it is important to consider which metal(s) will be processed to prevent attack of the
substrate. This is particularly important with aluminum, zinc and certain exotic metals.

The cleaner must be formulated to effectively remove the contaminants it will encounter. Simple, light-rust
preventive oils and water-soluble coolants are easily removed with mildly alkaline cleaners at moderate
temperatures. Waxes, heavy-oil rust inhibitors and other durable corrosion prevention compounds require a
more aggressive product. Typically, a high-alkaline product with a good oil-solubilizing surfactant package is
needed in conjunction with high temperatures.

The cleaner must also be suitable for the mechanics of the operating system. Immersion cleaners normally
require different surfactant systems than spray cleaners. Also, the use of chelates is often necessary to
counteract the undesirable effects of hard water salts.

Concentrate form also needs to be considered. Liquids are easy to use and can be automated. Powders are
usually added manually, but they are more cost effective for most operations.

Rinsing
An important part of the cleaning process is the rinse stage. As the substrate leaves the cleaner stage it
carries spent cleaner, emulsified soils and other contaminants. If not immediately rinsed, these contaminants
can redeposit on the part and become difficult to remove. The rinse must remove these unwanted materials
and not interfere with subsequent operations. Typically, a multi-stage rinse is used to ensure all
contaminants have been removed.

Caustics and silicates, two major ingredients of cleaners, are poor rinsers. On the other hand, phosphate
and phosphate blends along with blends of caustics and silicates are relatively easy to rinse. Hot water can
assist in rinsing; however, care must be exercised so that drying does not occur just before the rinse tank.
Double rinsing is common, using either deionized water for spot-free parts or adding a corrosion inhibitor to
the final rinse if rusting is a problem.

Single stage: clean only, no rinse. This method should contain inhibition if parts are ferrous steel. It should
be skimmed frequently to remove floating oils, extending cleaner life and preventing redeposition.

An immersion tank should be used for low-volume or batch work. An automated cabinet spray washer is
more efficient for low-volume batch work, while a conveyorized spray is more efficient for high-volume,
continuous production work. Another equipment option is ultrasonic.

Two stage: clean and rinse. With this method, frequent skimming to remove oils is needed in stage one. This
extends cleaner life and prevents redeposition. The rinse should also be skimmed and changed frequently,
and a rust inhibitor may be added as well.

An immersion tank, automated spray cabinet equipment with rinse cycle, conveyorized spray, auger washer
or ultrasonic equipment may be used.

Three stage: clean, rinse, rinse. This system can produce the cleanest part. Stage one should be skimmed,
while the stage two rinse should be kept clean by overflowing. Stage three can use deionized water for spot-
free parts and/or incorporate a water-soluble rust inhibitor if needed.

Equipment options include immersion tanks, automated cabinet spray equipment with three indexed cycles
(wash, rinse, and conditioned rinse), conveyorized spray, auger wash and ultrasonic.

Remember these basics about alkaline cleaning when you are researching your next cleaning system.