Foundry Magazin EN

DRY ICE

IN FOUNDRY & METALFORMING

WHAT IS DRY ICE? CLEAN IN-PLACE

THE MOST SUSTAINABLE CLEANING SOLUTION ON THE MARKET

EXTEND PRODUCTION RUNS, IMPROVE PART QUALITY & REDUCE OPERATING COSTS

IoT-ENABLED MACHINES

FOR INDUSTRY 4.0

Innovative foundries are constantly looking for ways to increase the productivity of their equipment and the quality of their parts, while also being more reactive to customer needs.

Die cleaning remains a critical component for the production of quality products in foundries. Deposits on core box vents or openings and cleaning of die cast tooling can cause a number of problems. To ensure the quality of products, foundries must have a process to regularly and reliably remove residues of the cold-box binder from the core boxes and permanent molds.

Traditional cleaning methods that are well known on the market like sand/soda/ water blasting, chemical cleaning and hand tools generate delays in mold cleaning and cause longer downtimes. Cleaning with Cold Jet dry ice blasting is a more effective technology compared to the traditional methods. As an example, cleaning core boxes is often done with our unique dry ice MicroParticle technology, due to the very complex geometries that require a precise and consistent clean that only Cold Jet dry ice cleaning can provide. We offer a significant improvement in cleaning times (up to 60%), as well as an increase in high-quality parts, less scrap and without damage to your equipment. It allows for a nonconductive, in-place method to clean parts.

Today, technology goes even further by providing robotic automation for a wide range of applications, including cleaning equipment, parts and surface preparation. With the integration of an automated dry ice MicroParticle blasting system within the existing production line, manufacturing operations are seeing further reductions in downtime, improvements in part quality, as well as a quicker ROI. Integrated cleaning systems are cost effective solutions with a superior cleaning performance and minimal space requirements. They provide continuous, uninterrupted and completely automated operation. Cold Jet provides systems which combine dry ice production and dry ice blasting into one system (Combi System), which is able to integrate with a robot.

The custom-built, integrated Combi System helps to improve quality and lower operating costs. It enables customers to focus on their production needs on a 24/7 basis and saves them a lot of time, trouble and money. Intelligent dry ice cleaning and production systems communicate with the customer via Cold Jet Connect, which enables the monitoring, diagnosing, and implementation of corrective actions, maintenance programs, remote troubleshooting and enables them to track all information and settings that are required for a modern foundry production facility.

Steve Wilson Applications Development Director

WHAT IS DRY ICE?

SUPPORT ESG INITIATIVES WITH DRY ICE

Due to the fact that dry ice is recycled CO2, it will not contribute to your greenhouse gas score. In the calculation of a carbon footprint, CO2 is accounted for at the producer level. It is not counted a second time at the point of use.

California Air Resources Board CO2 path

GIVING CO 2 A SECOND LIFE

THE MOST SUSTAINABLE CLEANING SOLUTION ON THE MARKET

Dry ice is based on the conversion of captured carbon dioxide (CO2) into a value added, commercially useful product. It's the product of the carbon capture and utilization (CCU) process in which CO2 is captured at industrial, biogas, or ambient air capture facilities, converted to liquid CO2, and transformed into dry ice - giving it a second life as a cooling and cleaning medium.

THE UNIQUE CHARACTERISTICS OF DRY ICE

Dry ice is non-abrasive, non-conductive and will not damage surfaces or equipment. By sublimating on impact, no secondary waste is left behind. It is also non-toxic and safer for employees than traditional cleaning methods. These attributes make dry ice cleaning an efficient, cost effective, environmentally sustainable, and occupationally safe cleaning solution.

40%

Estimated amount of water used at industrial facilities for sanitation

60%

Average cost of water increases from 2010 - 2019 in 30 largest US cities

Dry ice eliminates single use brushes, pads, and rags that end up in landfills

TRADITIONAL CLEANING

Eliminate downstream contamination, reduce GhG scores, and improve worker safety by removing solvents

DRY ICE CLEANING

Water

Chemicals

Contaminant

Stop Production, Cool, Pull Tool, Transport, Clean, Transport, Reinstall Tool, Reheat, Restart Production

We strive for a balance between economic, environmental and social goals. We categorically reject the ruthless pursuit of a profit at the expense of the environment. This process supports the environmental program of Geberit Productions AG.

Engineer | Geberit Productions AG

FOUNDRY BOOK #0816_05242023

Impact of pellets creates a kinetic energy effect. The soft dry ice is accelerated by compressed air through specially designed nozzles at supersonic speeds.

Cold temperature of dry ice pellets creates a thermal effect. The temperature of dry ice (-109F/78.5C) causes the contaminant to embrittle. This helps break the bond between the substrate and the contaminant.

Expansion of the dry ice pellets. Dry ice pellets sublimate upon impact, volumetrically expanding in size by 800%, removing the contaminant.

Dry ice cleaning is similar to sand, bead and soda blasting in that it prepares and cleans surfaces using a media accelerated in a pressurized air stream. It differs in that dry ice cleaning uses solid CO2 pellets or MicroParticles, which are blasted at supersonic speeds and sublimate on impact, lifting dirt and contaminants off the underlying substrate.

250+ BY THE NUMBERS

WORLDWIDE PATENTS More patents than any competitor

7,2%

ANNUAL REVENUE USED FOR R&D

3%+ Higher R&D spend than other industry leaders

KINETIC ENERGY THERMODYNAMIC SHOCK CO 2 EXPLOSION

Because dry ice is non-abrasive and turns to gas, you are left only with a clean surface that extends the asset life of your mold.

Today, it takes one worker 10 minutes to clean a mold while it remains hot and online, whereas it took two to three workers, 3-4 hrs to clean one or two molds previously.

INCREASE EQUIPMENT PRODUCTIVITY AND THE QUALITY OF FINISHED PARTS

Dry ice blasting effectively and safely cleans permanent molding and die casting equipment without the need for disassembly

THE NUMBERS

Tooling Supervisor | Progress Casting

A major issue for the foundry and forging industries is the downtime caused when cleaning permanent aluminum molds, core box vents, semi-solid castings and die casting machines. Typical manual cleaning methods require cool down, disassembly, unproductive hours of messy hand cleaning or bead blast cleaning and then reassembly. In addition, most traditional cleaning methods are not fully effective and often result in damage to the part or equipment.

Dry ice cleaning offers significant improvement in cleaning times (up to 60%) as well as reduction of damage to equipment and resulting scrap product. Dry ice blast cleaning is a non-conductive, in-place method to clean parts and even touch-up cleaning is safe and easy.

PROVEN APPLICATIONS

PERMANENT ALUMINUM MOLD

SEMI-SOLID CASTING / FORGING

CORE BOX AND VENT

DIE CAST TOOLING

SHELL CORE MOLD

REFRACTORY COATING

REMOVE RESINS AND RELEASE AGENTS

CONVEYOR

GENERAL PART CLEANING

GENERAL EQUIPMENT EQUIPMENT

FACILITY CLEANING

COUNTRIES WITH COMMERCIAL ACTIVITY

DRY

Over 300 Cold Jet employees and over 30 Cold Jet distributors support our global install base

PERMANENT ALUMINUM MOLD CLEANING

One of the obstacles for permanent aluminum molders are coating irregularities and resin buildup, which may lead to product quality defects and ultimately scrap. Uneven refractory coating can affect end product quality and production time.

With Cold Jet’s dry ice cleaning, you can completely remove refractory coating and residual material without damaging mold vents and rounding mold edges. You can clean molds in the machine at processing temperature without causing mold wear – thus increasing production capacity and improving product quality.

Learn more at coldjet.com

FOUNDRY BOOK #0816_05242023

CORE BOX AND VENT CLEANING

Core boxes have delicate screen and slot vents for catalytic gas or heat to enter and bind the resin to the sand (from which the core is usually made). Buildup of resin and sand on vents prevents core material from solidifying, and often cause vent clogging. Traditional cleaning methods are very slow, ineffective, can damage tooling and destroy vents on the core boxes.

With Cold Jet’s environmentally responsible cleaning systems, you can reduce cleaning time up to 60% while also increasing productivity and product quality. As a non-abrasive method, it reduces screen and slot vent damage. Dry ice blasting offers an in-place, online, quick and effective way to clean without damaging expensive tooling.

FOUNDRY BOOK #0816_05242023

Vorher

Nach der Reinigung mit Trockeneis

AUTOMATED DIE CLEANING

Cold Jet’s environmentally responsible systems were developed to improve quality and reduce operating costs for foundries. Cold Jet provides systems which combine dry ice production and dry ice blasting into one machine (Combi System), which is able to integrate with a robot.

Our automated systems eliminate the need for manual cleaning and surface preparation, thus improving part quality, increasing productivity and lowering cost. With the integration of an automated dry ice blasting system within the existing production line, you can reduce downtime and improve part quality. Integrated cleaning systems are cost effective solutions with superior cleaning performance and minimal space requirements. They provide continuous, uninterrupted and completely automated operations.

The cleaning time of one employee could be reduced from one hour to 20 to 25 minutes. Due to the setting options it was also possible to clean with less dry ice and lower compressed air consumption. The aero 40 FP had already paid for itself after 6 months.

–Foundry Manager | SHW Automotive GmbH

BY THE NUMBERS

YEARS OF DRY ICE INDUSTRY EXPERIENCE

FORGING

When using a closed or open die forging method of shaping a hot metal, it is crucial to clean the top and bottom dies. In forging technology, the process of removing scale, oxides or lubricant from the surface of the forging is very difficult. Effectively removing lubricant residue from the workpiece is an important factor for product quality and process efficiency. Preventing buildup of lubricant residue in the die cavity prevents problems, such as forging underfill.

Dry ice cleaning allows you to clean in-place, without disassembly. Hot dies can be directly cleaned using dry ice without cooling, which provide significant improvement in cleaning time while also minimizing damage to the equipment.

Learn more at coldjet.com

FOUNDRY BOOK #0816_05242023

GENERAL MAINTENANCE

Dirt, soot, grease and oil buildup in production facilities causes machinery to function improperly and can create an unsafe working environment. Effective cleaning extends the life of electric motors, reducing or eliminating costly repair, lower energy costs, replacement or rental programs.

Cold Jet dry ice blasting equipment provides a quick, safe, non-toxic and economical cleaning solution for facilities, industrial equipment, machinery, machine tools and assembly line equipment. Any item that is part of a production process can be cleaned online and without requiring cool down. Cold Jet dry ice blasting is non-abrasive, non-conductive, non-corrosive and does not use water. Cold Jet’s systems can clean on and around hydraulic power units and electrical power and distribution components. Additionally, adhesives and oil and grease buildup are easily removed with dry ice blasting.

Through the adjustment options of dry ice flow rate and air flow volume, we were able to significantly reduce our dry ice and compressed air consumption from 6 to 4 bar and tune the system exactly to our requirements. It has also made the cleaning more efficient for us.

ENHANCE PRODUCTIVITY THROUGH AN UNRIVALED INTELLIGENCE CUSTOMER SERVICE AND SUPPORT PLATFORM

Cold Jet CONNECT introduces Industry 4.0 capabilities to our portfolio of dry ice technologies, providing you with a clear view of the data you need to make decisions that will accelerate your return on investment and profitability through increased machine efficiency and uptime.

Cold Jet CONNECT enables tracking and support of your installed fleet of Cold Jet equipment and helps you understand, control, delegate and orchestrate your daily business without us needing to be physically present.

Advancing dry ice technologies is what we do best. Cold Jet CONNECT offers actionable insights so you can focus on what you do best.

FEATURES & BENEFITS

MACHINE DOCUMENTATION AT YOUR FINGERTIPS

MACHINE & APPLICATION TRAINING

IOT DATA & REMOTE SUPPORT

FLEET MANAGEMENT

ONSITE PREVENTATIVE MAINTENANCE

REMOTE ASSISTANCE PLATFORM

REMOTE MACHINE MONITORING

DRY ICE BLASTING MACHINES

IoT-ENABLED MACHINES FOR INDUSTRY 4.0

DRY ICE BLASTING REINVENTED

PCS 60

MACHINE DIMENSIONS

Length x Width x Height:

39 in (99 cm) x 19 in (48 cm) x 45 in (114 cm)

Weight: 269 lb (122 kg)

POWER REQUIREMENTS

110/220V AC (50/60 Hz)

Compliant with the EU Machinery Directive (CE) and UL Design Standards

60 lb (27 kg)

HMI DISPLAY

7” LCD Color Screen

FEED RATE

Variable - up to 4 lb/min (1.8 kg/min)

PARTICLE CONTROL SYSTEM

Variable Dry Ice Size: 3mm - 0.3mm

Utilizes 28 distinct dry ice particle sizes

BLAST PRESSURE RANGE

20 - 145 psi (1.4 - 10 bar)

THE NEW STANDARD IN DRY ICE BLASTING

COMPRESSED AIR SUPPLY

40 - 145 psi (2.8 - 10 bar)

NOZZLE AIR CONSUMPTION

12 - 100 cfm (0.3 - 2.8 m3/min) at 80 psi (5.5 bar)

BLAST FLOW PATH

3/4” Straight Through Tubing

SUREFLOW

Thumper, Ramrods, Electric Vibrator

“Always-On” Hopper Agitation

Our most versatile machine. Easily adjust particle size, blast pressure, and other parameters according to the location and stubbornness of the contaminant you are blasting.

The Cold Jet PCS 60 utilizes finely controlled particles of dry ice as a blasting medium via our proprietary and patented Particle Control SystemTM (PCS). The machine accepts 3mm pellets and, via the PCS, precisely cuts the dry ice into diamond shaped particles in the exact dimensions chosen by the operator.

Program, save, and quickly access tried and true blast recipes for every time of tooling.

CHOOSE BETWEEN 28 DRY ICE PARTICLE SIZES

FROM 3MM TO 0.3MM AND EVERY SIZE IN BETWEEN

Users can adjust dry ice particle sizes from 0.3mm to 3mm and every size in between, giving complete control to effectively fine-tune the machine for each unique application

7” LCD color screen with digital controls makes it easy to view and control blasting parameters

MICROCLEAN 2 SPEC SHEET

DIMENSIONS

Length x Width x Height

FULL SYSTEM *

31 in (78 cm) x 25 in (62 cm) x 47 in (120 cm)

Weight: 190 lb (86 kg)

MACHINE ONLY

31 in (78 cm) x 19 in (48 cm) x 21 in (51.5 cm)

Weight: 133.38 lb (60.5 kg)

CART ONLY

25 in (64 cm) x 22 in (56 cm) x 27 in (68 cm)

Weight: 56.2 lb (25.5 kg)

*Including i 3 MicroClean 2 and standard cart

DRY ICE BLASTING REINVENTED

DESIGNED FOR PRECISION

SHAVED DRY ICE MICROPARTICLE BLASTER

POWER REQUIREMENTS

110-240V AC (50/60 Hz)

DRY ICE CAPACITY

Up to 25 lb (11 kg)

FEEDER SYSTEM

Shaved dry ice use blocks or pellets

HMI DISPLAY

7 in (17.8 cm) LCD Color Screen

FEED RATE

0-1.5 lb/min (0-0.7 kg/min)

SMART, IoT-ENABLED PRECISION BLASTER

BLAST PRESSURE RANGE

20-145 psi (1.4-10 bar)

COMPRESSED AIR SUPPLY 50-145 psi (3.4-10 bar)

NOZZLE AIR CONSUMPTION

12-50 cfm (0.3-1.4 m 3/min) at 80 psi (5.5 bar)

BLAST FLOW PATH

0.5 in (1.3 cm)

#0615.07022021 MICROCLEAN

Compliant with the EU Machinery Directive (CE) and UL Design Standards

PLT 60

SPEC SHEET

#0523.07022021

DRY ICE BLASTING REINVENTED PLT

MACHINE DIMENSIONS

Length x Width x Height:

39 in (99 cm) x 19 in (48 cm) x 45 in (114 cm)

Weight: 251 lb (114 kg)

POWER REQUIREMENTS

Input Voltage: 110/230V AC (50/60 Hz)

AMPS: 4.3

Compliant with the EU Machinery Directive (CE) and UL Design Standards

HOPPER CAPACITY

60 lb (27 kg)

HMI DISPLAY

7” LCD Color Screen

FEED RATE

Variable - up to 6 lb/min (2.7 kg/min)

DRY ICE PARTICLE SIZE

Input: 3mm ; Output: 3mm

THE NEW STANDARD IN DRY ICE BLASTING

BLAST PRESSURE RANGE

35 - 250 psi (2.4 - 17.2 bar)

COMPRESSED AIR SUPPLY 40 - 250 psi (2.8 - 17.2 bar)

NOZZLE AIR CONSUMPTION

50 - 165 cfm (1.4 - 4.7 m 3/min) at 80 psi (5.5 bar)

BLAST FLOW PATH

1” Straight Through Tubing

SUREFLOW

Thumper, Ramrods, Electric Vibrator

“Always-On” Hopper Agitation

Isolated Hopper

DESIGNED FOR POWER BLAST UP TO 250 PSI

PLT = PELLET BLASTER

DRY ICE MANUFACTURING SYSTEMS

PE 50 PE 80

DRY ICE OUTPUT

DRY ICE PELLET SIZES

DIMENSIONS (LxWxH)

23.6in x 39.3in x 61.4in (600mm x 1000mm x 1560mm)

WEIGHT

447.5lb (203kg)

CO 2 TANK PRESSURE 217.5 - 261 psi (15 - 18 bar)

OPTIMAL AMBIENT TEMPERATURE Up to 104°F (40°C)

TAKE CONTROL OF YOUR DRY ICE SUPPLY

LOW-VOLUME, LOW-MAINTENANCE DRY ICE PRODUCTION SYSTEMS

Cold Jet’s PE Series Pelletizers provide an affordable solution for businesses in need of a dry ice supply without investing in an oversized machine. Their compact design and casters make them easy to move around, making them a perfect fit for businesses with limited space.

They’re also compatible with various liquid CO2 storage and supply options, ensuring users can choose the option that best suits their needs. Whether you’re a small business or a large enterprise, the PE Series Pelletizers are easy to use and can help you take control of your dry ice supply.

MANUFACTURER WITH MULTIPLE BLASTERS

EASY TO OPERATE & EASY TO MAINTAIN

User-friendly interface & simple controls will have you producing dry ice pellets in minutes.

EASY MOBILITY

Utilize their lightweight design & caster wheels or choose to have it fixed to a wall.

MINIMAL INFRASTRUCTURE REQUIREMENTS

Compatible with regular fixed liquid CO2 tanks, transportable dewer tanks, and micro bulk tanks.

AUTOMATED DRY ICE BLASTING SOLUTIONS

AUTOMATED SOLUTIONS FOR CONTINUOUS CLEANING PROCESS

3 X 380-480 V AC + PE, 50-60Hz

TN-S Earthing system

Imax: 16A

Ipk: 10 kA

Compliant with the EU Machinery Directive (CE) and UL Design Standards

AIR QUALITY

ISO 8573-1, Minimum Class 2

BACK PRESSURE ON REVERT GAS 0-14.5 psi (0-1 bar)

EXHAUST GAS PIPE

Internal diameter: 2 in (50mm)

*Robot and blasting cabinet not included

AUTOMATED DRY ICE BLASTING SOLUTIONS CONTINUOUSLY

CLEAN

The COMBI PCS series of integrated dry ice blasting systems offers manufacturers the most advanced automated cleaning solution on the market.

With our patented dry ice production and particle control systems (PCS) built in, the COMBI PCS makes cleaning in an automated facility easier and more effective.

Our PCS system allows machine programmers to finetune the dry ice particle according to the surface or contaminant being blasted.

AUTOMATED SURFACE PREPARATION AND PART FINISHING SOLUTIONS

AUTOMOTIVE MANUFACTURING

RUBBER MANUFACTURING

ELECTRONIC MANUFACTURING

BATTERY MANUFACTURING

SUREFLOW DOSING

Thumpers and vibrators provide reliable dosing and clog-free operations

GREATER CONTROL

16” Beckhoff Industrial HMI allows programmers to control particle size, blast pressure, feed rate, production rate, blast path, and more

GREATER VERSATILITY

Three machine options provide two to four simultaneous blasting operations at various outputs

PARTICLE CONTROL SYSTEM

Easily adjust dry ice pellet sizes from 0.3 mm - 3 mm and every size in between

FULLY AUTONOMOUS

Produce dry ice pellets and blast without the need for an operator

Cold Jet GmbH

Weinsheim, Deutschland

+49 6551 96060

Global Headquarters

Loveland, Ohio, USA

+1 513-831-3211

Europe Headquarters

Zellik, Belgien

+32 13 53 95 47

Asia Headquarters

Tokyo, Japan

+81 3 6869 2665