Soils that are removed from the parts will build up in the cleaner solution over time.

Solid particles will settle to the bottom of the tank as sludge and oils, grease, and some
floating debris will float on the top of the solution. There is a limit to the amount of
contamination that a cleaner bath can tolerate before it will cease to clean and need
to be dumped and recharged. Overflowing the solution can help to reduce the accumulation
of floating debris, but solids can still cause a problem and overflowing the
solution will create a need for more chemical. Oil skimming and sludge removal can
extend the life of the cleaner and techniques for this are explained in the section of
this book on washer design.
Certain operating parameters need to be controlled for good performance. The
control parameters that affect the performance of the cleaner include contact time,
chemical concentration, temperature, spray pressure, drain time, and the volume of
contaminants in the solution. These are the items that must be monitored, recorded,
and maintained within proper ranges in order to achieve predictable cleaning
performance.
1.1.7.3 Time
It is important to have enough contact time to provide complete wetting breakdown
of soils. The longer the contact time, the more the reaction will be. The control of
contact time is usually equipment related. If the cleaning method is manually operated,
the time can be adjusted for different soil loads. If the cleaning system is automated
the time will depend on the conveyor line speed.
1.1.7.4T emperature
As a rule of thumb, cleaning chemical processes can be accomplished more quickly
with higher temperatures. The chemical supplier will recommend a temperature range
needed to provide satisfactory performance with their product. With some cleaners,
elevated temperatures can adversely affect substrates and chemical compounds.
Improper temperature may also cause excess foaming with some cleaner products.
Managing the temperature requires a properly maintained thermostat and heating
source (boiler, heating elements, burners, etc.).
1.1.7.5 Spray Pressure
The physical force of solution under pressure, agitation in a chemical solution,
or scrubbing will enhance the performance of a cleaning solution. This factor is
Part Preparation Processes and Equipment 21
extremely important in removing tough soils such as particulate matter and heavy
buildup of grease and oil.
Controlling the scrubbing force in a system depends on the method of application
used. In the case of spray systems, it is important to keep the nozzle orifices clear of
scale and shop debris to help maintain the proper pressure. Immersion systems or dip
tanks can use air agitation, solution circulation systems, or a mixer blade.
1.1.7.6 Concentration
Chemical concentration is related to the particular product being used. Concentrations
should be consistent with the suppliers’ recommendations. Too much cleaner may
cause poor rinsing or excess carryover. If the concentration is too low, the parts may
not get adequately cleaned.
The substrate, types of soils, and the equipment used all influence chemical selection
and solution strengths. Certain blends of chemicals work well for immersion
systems but not in other applications. Problems may occur in the degree of reaction,
flash rusting, or foaming. Concentration control is very important. Cleaning solutions
should be monitored regularly and controlled. Simple titration is typical, using either
dropper or burette techniques.
The effectiveness of a cleaner solution gradually decreases as the soil load
builds up. The effective life varies depending on hours of operation, the volume
of metal processed per hour, the type of metals processed, the amount of carry out,
the use of filtration, and the types of soils removed.
1.1.8 METHODS USED TO MEASURE