A Guide to component cleaning

How to plan and prepare

prepare for the right component cleaning process and equipment
What is parts cleaning ? Parts’ cleaning has the following functions; examination by electron microscope or
mass spectrometric techniques.
1. To clean and prepare the surface of a 3. Standards may have levels of
part prior to a subsequent process such acceptance on a pass / fail criteria
Almost every manufacturing process has a
as coating or treating. based on the measurement of what is
need for cleaning. This normally involves a
2. Cosmetic cleaning to remove unsightly acceptable by the customer. These will
stage in the manufacturing process when the
or unwanted surface soiling. usually be based on the application and
part needs to be cleaned before
before the next 3. As a process to remove contaminants use of the part and the role cleanliness
activity or for a final clean to ensure that the
which may ultimately affect the quality, plays in its performance.
part is in an acceptable condition for the
operation or function of a product. 4. In certain medical applications further
customer.
4. A process to remove soiling or to tests to measure bio-cleanliness may be
In most manufacturing operations ‘intermediate’ disinfect parts after use or before first used.
cleaning can often be repeated after various use.
stages.
Essentially therefore, parts cleaning can range
What are Cleaning Specifications ?
Parts cleaning can be a relative simple
simple from simple cosmetic cleaning to critical
cleaning.

Cleaning
specifications help to
What is meant by ‘clean’?
establish the process
by which cleaning
The answer to this may differ widely. Cleaning
standards are met.
standards and specifications vary.
These specifications
1. Cleaning standards can mean a will detail the method
subjective, visual test. and process of
2. It can mean measured scientific tests to cleaning, providing
establish pass-fail levels of cleanliness. information on the
operation depending on the type of soiling or These can range from a simple filtration chemistry, cleaning
contamination and the level of cleanliness method to sophisticated surface and drying steps, process times and use of
required agitation or cleaning actions.
What
What are the factors that affect selection ? First steps – what’s available? Broad Considerations – the task itself

There are a number of drivers or reasons to The first thing to recognise is that there is likely The task of cleaning usually involves the
introduce or to change a component cleaning to be more than one option and that there is no removal of a soil or contamination from the
process. one size fits all. Every application is different surfaces of a substrate.
and there are many combinations of cleaning
1. New products or changes in the chemistry and types of component cleaning This is where a number of variables can occur
products being manufactured equipment. as both the material of the substrate and the
2. Customer demand or higher customer nature of the contamination will inform what
expectations cleaning options are available. Considerations
3. Replacing old or ineffective cleaning will include;
equipment Broad Considerations – what do you
4. Changes in raw materials necessitating The material of the substrate
need to achieve?
cleaning prior to production
The design of the component, such as shape or
5. Business strategy to improve production Being clear about why you need to clean, what holes and crevices that may present challenges
efficiency aspects need to be addressed and who, such to cleaning.
6. Business requirement to improve quality as your customer, needs to be satisfied with the
or to manage cost final result. The nature of the contamination, such as
7. Environmental impact polar/non-polar, new/aged, particulate or
8. Health & safety reasons It is useful to meet with all stakeholders in the soluble contamination, volume and extent of
9. Regulation or legal requirements process to list the objectives and agree the soiling.
10. Company policies desired outcome. This might include;
There are also considerations about the residue
Each of these reasons for change will have 1. Different or higher cleaning standard of cleaning. Is there a need to remove any
implications for the selection of cleaning 2. Higher through-put (Productivity) moisture or to ensure corrosion resistance or to
chemistry and investment in appropriate 3. More consistent cleaning provide another surface finish.
cleaning equipment. 4. Lower cost
5. Compliance and safety
6. Use of an acceptable chemistry
7. Customer acceptability
8. Reduced risk of product failure /
improved quality
How to select cleaning chemistry It is usually advisable to be as open as possible Several chemistries can be tested.
about chemistry and not to exclude without
reason. Some solvent chemistries will be effective in
removing more than one type of soiling and
Deciding which chemistry to use will depend Reasons to choose one chemistry over another from more than one type of substrate. Some
upon; will depend on a number of factors solvents are effective in a fairly wide range of
applications.
Its ability to remove the contamination (assisted Its cost and availability
by other factors) Aqueous chemistries may be limited in their
Its capacity to clean effectively effectiveness across more than one type of
The chemistry’s compatibility with the substrate
material or contamination and may need
or other materials in the process Any special handling requirements
dedicated chemistry to each application.
Environmental and health considerations There is no reason to exclude any solvent
Cleaning performance can be significantly
unless its use is prevented by law. Most
Regulation improved by;
solvents can be managed in enclosed
processes to prevent loss or exposure. Temperature
Corporate policy
Aqueous choices can offer distinct benefits as Duration of cleaning exposure
Customer requirements
well as add further complications, such as
Generally there are two broad options, solvent drying and effluent disposal. Agitation – spray, rotation etc
or aqueous. Both offer many choices and both
Ultrasonics
have benefits, but also drawbacks.
Selection of a cleaning chemistry

What are the Advantages and disadvantages

General information on cleaning performance
Methods of selecting cleaning chemistry can be obtained from chemical suppliers.
However the only way to ensure suitability is to To some cleaning using aqueous chemistry has
test the chemistry with actual contaminated a clear advantage in terms of health and safety.
parts. Testing can be arranged with Layton However it is not always clear cut. There are
Technologies (usually free of charge) implications of aqueous cleaning that can
www.laytontechnologies.com increase environmental impact for example an
increase in energy and water consumption (a
To test clean, a range of test parameters are resource that also has to be managed). Then
established and results recorded. These results there is the problem of managing the inevitable
can be evaluated.
waste which has to be disposed of. This means What containment and management is Depending on the size of the project and the
further environmental impact and cost. necessary? type of cleaning process, this team may vary in
size and composition. It is essential however to
Similarly solvent cleaning has an environmental 1. Are there any regulations or laws to consider the wider interests of stakeholders to
impact. The use of solvents, produced from consider? avoid what can be basic but costly errors.
finite natural resources, have the potential to 2. Can it be easily sourced and how is
damage the environment if not properly supplied? It would also be advisable to ask potential
managed and controlled. There are also 3. Is the solvent affordable? vendors and chemistry companies to present to
possible health and safety risks with certain this stakeholder group and after vendors have
solvents, again requiring careful containment been selected to get them to attend meetings of
measures. Stakeholder interests the group.

On balance both offer advantages and both

It is advisable to meet with everyone who has
have potential disadvantages. It is important to
an interest in the cleaning project. There are
remain objective and consider what works best
likely to be a number of people who will need to Budget considerations
considerations
for your business in terms of cleaning
be involved in the selection, implementation
effectiveness. When working with Layton we
and on-going operation who will need to be
can advise you on the most effective way to As cleaning has become more demanding in
consulted.
manage the process to ensure that terms of automation, solvent management,
environmental and safety matters are properly Typically the project team might involve; environmental compliance and process
managed. complexity, inevitably the cost of cleaning plant
1. Budget holder has also risen to reflect this higher
For aqueous cleaning these are some of the 2. Process or production representative specification.
issues to look out for; 3. Site or facilities representative
4. Environmental and H&S representative There are ways to ensure that the equipment
1. How effectively will the chemistry and
5. Cleaning specialist or someone to you eventually buy is both value-for-money and
process clean?
approve cleaning standards fit for purpose, these include;
2. What are the likely costs of energy,
6. Quality representative
water and effluent disposal? 1. Understand the reason for cleaning and
7. Operator representative and/or
3. Do I need to dry the parts and if so how the standard you want to achieve
maintenance
efficiently can this be achieved? 2. Clearly specify your needs
8. Plant installation engineering
representative 3. Ensure that the equipment is designed
For solvent cleaning, these are some tips to
9. A representative or internal ‘champion’ to meet your specific needs and can be
consider;
for your external customer modified if necessary
 4. Ensure that the costs of consumables, You will have considered which option health and safety and environmental
including solvents are accounted within will give you the best result and meet compliance.
the costs other environmental objectives.
5. Calculate other operating costs 5. Space limitations
including energy, water, waste costs 2. Future proof Any height, weight and footprint
and manning levels There is no certainty to planning what constraints will need to be factored into
6. Consider the degree of automation might happen in the future, but choosing the machine selection. As will access to
required. Can increased automation equipment that allows some flexibility in the location and any special limitations
increase productivity and lower costs? terms of cleaning media, will help you to on services. Where space is limited
7. Maintenance costs hedge against chemicals that may fall there are systems available which can
8. What additional services might be into tighter regulation, become less offer compact design with high work
needed and have these been factored available or more expensive in the capacity. It should also be noted that
into the cost future. It is also worth considering what multistage systems will obviously
9. Are there installation costs, such as might happen to the pattern of your require more space.
removal of old plant and new work to business that might impact upon the
install a replacement productivity of your cleaning system. Do 6. Location limitations
10. What ancillary equipment is required you need a cleaning provision that Where locations offer additional
such as chillers or compressors allows extra capacity later? challenges including accessibility,
11. What addition equipment is necessary additional engineering or modification,
to handle the installation 3. Cleaning media these factors need to be considered
Conversations with both chemistry within the scope and cost of the project.
suppliers and equipment manufacturers
Specifying your machine
should provide the advice you need and 7. Process time / throughput
this together with access to trials will The calculation of what throughput you
Having identified the reasons why you need help you to prove your cleaning process. need and therefore the batch size and
clean parts and what you want to achieve, the It is important to recognise that unless cycle time is a key element of the
choice and specification of the cleaning plant, you have a specific agreement with the project. This will form a central part of
chemistry and process is the next logical step. equipment manufacturer the the machine specification and its cost. It
Providing potential machine vendors with a responsibility for the process rests with is possible to manage the variables of
clear statement of your requirements will help to you. time and volume by improving the
ensure that you purchase a fit-for-purpose cleaning process through various
system and eliminate any excessive cost. This 4. Environmental and safety constraints means such as adding ultrasonics for
is a simple step-by-step guide; Your machine and chemistry choice will example. See also Process Details and
need to reflect all requirements to meet Cleaning Standard below.
1. Solvent or aqueous
 10. Process details – steps required in
8. Operating duty – continuous or shifts, cleaning Vendor selection
regular or occasional The process is designed to provide a
This will also influence the size and consistent cleaning result over a set
Once the machine specification has been
capacity of the machine. If you require a period. This normally includes several
developed, usually with essential advice and
machine to offer continuous service, steps or stages. Each step is designed
support from vendors then a choice can be
then there may be a need to have twin to contribute to the cleaning process by
made about the vendor itself. Things to note
systems that allow some off-line removing various contaminants or by
are;
maintenance whilst still offering some rinsing or treating and finally drying. In
throughput. Where machines are only aqueous cleaning these stages can be 1. Capability and experience
used in irregular or infrequent service performed in a set of tanks arranged in Check that the vendor has the
then this should be reflected in the a linear configuration. Other aqueous necessary expertise in process
machine specification. options and most solvent systems offer knowledge and engineering capability to
a single chamber where the process design and manufacture the equipment.
9. Maintenance chamber completes various stages Essentially the ability to understand how
No machine can operate without through a regime of emptying and filling to put the process into operation in a
maintenance. But the frequency and with various chemistries. safe and environmental compliant
level of maintenance is important to The process will be dictated by the system. A visit to view vendor facilities
understand. Operational maintenance standards required and the trials which is essential.
should be relatively simple and be have proven that a given set of actions
capable of being carried out by the will achieve the standard. 2. Cap
Capacity
acity
operator with minimal training. It will Has the vendor enough capacity to
inevitably be necessary to have more in- 11. Cleaning standard if required. manufacture your machine. Check the
depth servicing which can be provided In many critical applications a clearly resources available and the expected
by the vendors’ engineers. defined cleaning result will be required. delivery schedule.
Most machine suppliers will offer a It is essential that some proof is
service and support facility in addition to obtained that the chemistry and 3. Business security
offering a warranty. It’s important to machine specification will deliver this It is important to reassure yourself that
understand what this means and in the standard and as importantly will offer the vendor has a stable business with a
case of on-site support, where that recording methods to support and suitable proven track record and is
support comes from (i.e. UK based). documentation necessary. financially viable
4. Training and support The Implementation phase Review and improve
Your vendor should be able to provide
you with essential training for the
operators and offer appropriate manuals 7. Check that stakeholder needs have
Once you have selected your vendor and
to allow you to operate and maintain the been satisfied
placed an order for the machine it is necessary
equipment.
to work closely with the vendors’ design and Ensure that early problems regarding the
production team. function of the process have been reported and
5. Partnership
It is easy to talk about partnership addressed
1. Ensure that the details of the machine
working, but if you can do the vendor meet your needs Check that operators are familiar with the
appraisal and selection early in the 2. Keep to deadlines, especially where key controls and maintenance, refresh training if
project, there are significant benefits in milestones need your approval and necessary
using their expertise to support you and decision
ensure that simple pitfalls are avoided. 3. Make certain that any changes are Consider on-going maintenance, including a
agreed and documented with any planned maintenance programme and regular
associated cost approved service.
4. Allow time for possible delays, don’t ‘cut
it fine’ if you are planning to replace an
existing and essential cleaning process.
5. Plan the necessary preparation for For more information
services and other ancillary engineering
to allow a smooth installation www.laytontechnologies.com
6. Hold regular review meetings with
stakeholders and equipment vendors. Tel +44 (0) 1782 370400