ICT n. 1 - Supplement to ipcm® 2011 n. 10

Supplemento a IPCM n° 10 - Luglio 2011

INDUSTRIAL CLEANING TECHNOLOGIES P R O T E C T I V E C O AT I N G S

POSTE ITALIANE SPA – SPED. IN A.P. 70% LO/MILANO

Image courtesy: Reinhausen Plasma GmbH

“Coming together is a beginning, keeping together is a progress, working together is a success” Henry Ford

“Mettersi insieme è un inizio, rimanere insieme è un progresso, lavorare insieme un successo” Henry Ford

eos eos

MKTG & COMMUNICATION MKTG & COMMUNICATION

www.eosmarketing.eu www.eosmarketing.it

Ultrasonic cleaning

The ideal component in every situation, from 25 kHz to 1 MHz )) parts2clean, Stuttgart 25. - 27. October 2011 Hall 1, G 714 / H 813

Weber Ultrasonics brand sets new standards in the development and manufacture of high quality ultrasonic equipments. The wide range of products combines innovation, quality and efficiency, always offering the ideal solution for every cleaning requirement.

See for yourself! www.weber-ultrasonics.com 路Tel. +49 7248 9207- 0

Alziamo lo sguardo e guardiamo lontano.

Insieme è piÚ facile.

Dal 1973 Ucif è un punto di riferimento per le aziende del settore dei trattamenti di superficie.

Segreteria Ucif via A. Scarsellini 13 | 20161 Milano tel. +39 0245418.519 | fax +39 0245418.545 info@ucif.net | www.ucif.net

Federata

AUGUST2011 EDITORIAL INDUSTRY NEWS HIGHLIGHT

06 Ultrasonic cleaning: Flexible, Efficient, Delicate System with “Non-Ozone Destructive” 08 Cleaning solvents.

10

Safechem Establishes an Innovative Chemical Leasing Concept COMPLEASE™ – Complete and Future-Oriented Solution to Optimise the Cleaning Process

CASE STUDY

12

Volkswagen Plastics Technology Relies on CO2 Snow Jet Technology. Basis for the Application of a Single-Layer High-Gloss Finish to Injection-Molded Parts

TECHNOLOGY OVERVIEW Solutions in the Automotive Industry 16 Cleaning Achieving Cleanliness Reliably and Efficiently Technologies for Medical Engineering.

20 Cleaning Value Added through High Levels of Cleanliness

24

Monitoring Surface Cleanliness and Bath Contamination.

Controlled Cleaning Quality Reduces Cost Risks

28

Ultrasonic Cleaning Efficient Cleaning with Ultrasound From Coarse to Fine

PRODUCTS SHOWCASE EXHIBITIONS CALENDAR

CONTENTS

ZOOM ON EVENTS

WE INVENT MACHINES, WE INVENT SOLUTIONS IMPIANTI AUTOMATICI & ISOLE ROBOTIZZATE PERSONALIZZATI CUSTOMIZED AUTOMATIC MACHINES & ROBOTIC CELLS

Smerigliatura, Lucidatura, Satinatura, Sbavatura Grinding, Polishing, Mat Finishing, Deburring

Pulimetal Cittadini s.r.l.

Via Sebina, 8 25050 Provaglio d’Iseo Brescia - Italy

MACCHINE PULITURA METALLI METAL POLISHING MACHINES

Tel: + 39 030 9823718 Fax: + 39 030 9823856 Web: www.pulimetal.it

ICT ICT HIGHLIGHT EDITORIAL

by Paola Giraldo

I

n a production process, the inter-operational cleaning or the cleaning used as a finishing step play a key role. In the production of any metal object – a pair of scissors, a hydraulic component, a connecting rod or any other part of an engine – the components need to be cleaned between one production step and the other, in order to remove the residues from the processing, be they organic or inorganic: emulsions, processing oils, swarf and whatever may affect the subsequent stages of production.

Normally, the production flow of an object involves the following steps: a semi finished product is obtained by moulding or casting, it is sandpapered or deburred and then it undergoes various other mechanical processes such as drilling, welding, polishing and so on, until the finished product is finally obtained. Sometimes, between one stage and the other, a so-called “inter-operational” cleaning is necessary. In the production of assembled objects, the components must be cleaned several times to ensure the perfect assembly. In many cases, the tolerances are so small that the components must be perfectly clean: if we consider the production of an internal combustion engine, it is easy to imagine the degree of cleanliness required for each component. In the past, a new car needed a long running in period because the various components of the engine had to “settle” and therefore it could be dangerous, from the mechanical point of view, to force the engine, since the processing residues could damage the components. Modern cars do not need any (or little) running in, because all components of the engine are perfectly clean when assembled, thanks to the modern cleaning and mechanical polishing technologies.

The industrial cleaning field is complex and multifaceted, but sometimes undervalued.

There exist several industrial cleaning technologies, each suited to a different type of product: from cochlear implants, spray tunnels and ultrasonic tanks to plasma systems for the microfine cleaning of surfaces, no matter how complex. The cleaning process often involves more than one step; in these cases (normally, with small objects such as the glasses frames and lenses or the components for the watchmaking, electronics, goldsmith, etc. industries), multi-tank ultrasonic plants are used. Also the spray cleaning process involves different stages; that is why new multi-stage cleaning machines – where all cleaning steps, from degreasing to rinsing and drying up, are carried out in a single chamber – have been developed.

Also the cleaning products have experienced a great development in the last few years: nowadays, we increasingly use low or very low environmental impact products, ensuring the same results of the old chlorinated solvents thanks to their technical characteristics. In certain fields, the solvents are still irreplaceable, but some last generation products have been developed in order to limit their environmental impact and dangerousness.

All of the most innovative technologies and products will be on display on October, 25th to 27th at the parts2clean trade fair in Stuttgart – an event which, for nine years now, has been the largest and most profitable European meeting point for the producers and users of industrial cleaning and mechanical polishing technologies. The fact that in Europe there exists such a specialised and such a successful event means that the surface washing and cleaning industry is dynamic, active, innovative and ready to face the future challenges posed by an increasingly demanding market. This sector therefore needs – besides an exhibition bringing together all the players in the industry once a year – a magazine which gives it a voice.

The new Ipcm_Industrial Cleaning Technologies comes out for the first time as a special issue in conjunction with parts2clean. It aims to become a technical and cross-sectional source of information for this sector at European level, with a range of contents in line with the editorial policy of ipcm: technical, verifiable and high-level.

Happy reading!

Francesco Stucchi Stuccchi Editor

1 AUGUST 2011

ICT

HIGHLIGHT ICT

INDUSTRY NEWS

by Paola Giraldo

DAN TECHNOLOGY PRESENTS GRINDING AND POLISHING SYSTEM FOR CHAIR FRAME DAN TECHNOLOGY DE ANTONI has more than one century experience in the mechanical and automation field and more than 35 years (since 1973) in the grinding, polishing, satin finishing, and mirror finishing of metals and other materials.

The “heart” of our exclusive robotic systems is the working pressure control (patented), that makes the programming system of the robot easier and assures perfection during the process and an high quality standard.

In the innovative systems for grinding and polishing chair frames, two robots works on completely automatic way. The first robot picks up the part from the station where are located the raw parts and goes in front to the grinding units for the weld removing (weld profiling operation).

AUTOMATIC GRINDING AND POLISHING MACHINES Via Gazzolo, 2/4 - IT 25030 Coccaglio (BS) T. +39 0307721850 - F. +39 0307240612 d a n t e c h @ d e a n t o n i . i t

2 AUGUST 2011

Then removes the spatters that have been left by the weld (remove spatters operation).

If needed, this machine is also able to make working process on the whole piece for uniforming the part.

When the first robot has finished these grinding operations it leaves the part on an exchange bench located on the middles of the two robots so that the second robot can pick up the ground part for starting the finishing operation.

This second robot makes the polishing and mirror finishing operations of all the part in order to obtain the needed result.

When the mirror finishing operation is finished the second robot unloads the finished part on the unloading station.

For more information: www.deantoni.it

ICT ICT INDUSTRY HIGHLIGHT NEWS

by Paola Giraldo

AUTOMATIC CLEANING AND SOLVENT RECYCLING SYSTEM

I

RAC S.r.l. started its activity of solvent use and recovery 25 years ago, when the “distiller” was still designed as a response to the small business management problems.

During the following two decades, it has transformed and increased the response capabilities of its equipment by preferring some constructive choices to others and by enhancing the capability and versatility of its products. IRAC aims at all those market segments where the solvents, be they flammable or not, including water, are the only or the best way to wash, degrease, clean.

One of the company’s flagship systems is the specific tank for cleaning 30 l commercial cans, combined with an automatic distiller type PAIL-WASH DISTI COMBO 1100.

The washing tank is made entirely of stainless steel AISI 304 and allows the use of both flammable and non flammable products.

The control panel is pneumatic.

The average cycle length is between 8 and 12 minutes: its duration is influenced by the amount and the fluidity of the ink, as well as by the type of solvent used.

The inside of the can undergoes a washing process whose quality is ensured by special high liquid flow rotary heads, while the process liquid is recycled. The tank is equipped with a device for the discharge of the dirty solvent by means of a pneumatic pump and with a suction hood to remove any vapour through a Venturi system.

The T working dimensions are: a max 3x 30 l commercial cans, 1100 x c 500 5 x 500mm.

A solvent distiller is automatically connected with the tank, so as to create a “washing/recycle” closed circuit.

This automatic system draws the exhausted solvent from the tank, regenerates it through distillation and reintroduces it into the tank, a without stopping the washing w process. The number of washing p ccycles after which the solvent must be recycled can be regulated. The b plant is designed to work both with p and without vacuum, thus making it possible to treat every solvent on the market.

For further information: www.irac.it

3 AUGUST 2011

ICT

HIGHLIGHTNEWS INDUSTRY

by Paola Giraldo

METAL POLISHING MACHINES

Specification of a Grinding Robotic Cell Grinding Unit • 4kw power • 2,000 to 4,500 belt length • Air compensation with electronic proportional valve • Automatic belt centring • Belt-broke Sensor • Automatic speed regulation according to the belt “life” • Plug-in connection for power and signals • Easy diagnostic with plug-in connector for signals • Double dust aspiration holes

W

ith an experience of over forty years, Pulimetal Cittadini designs and manufactures automatic systems for polishing and grinding metals. This company took its first steps with the application of advanced, revolutionary technologies on the transfer machines – an experience which helped it find, after many years, the ideal combination of advanced technology, automation and ease of use.

In the last few years, the company has specialised in the design and production of automated robotic systems through the use of anthropomorphic robots.

Over time, it has constantly refined its techniques in order to offer functional and technologically advanced systems, always being attentive to the customers’ needs and giving priority to the quality of the services and the human relations. Nowadays, Pulimetal has more than 1,200 facilities around the world. Dynamism, flexibility, experience and innovation are the key elements that have allowed it to achieve great goals.

Pallet • N° 2 Drawers • Fast changing production system Electrical Cabin • Multilanguage Touch-screen • User-friendly commands • Fast connection with units and robot • Teleservice with internet connection.

For more information: www.pulimetal.it

4 AUGUST 2011

by Paola Giraldo

ICT

INDUSTRY NEWS ICT

FROM THE WATER TREATMENT TO THE CUSTOM-MADE CLEANING SYSTEMS

Industrial Wastewater Purification and Treatment Plants

✓ Chemical-Physical Plants

T

hanks to the decennial experience of its engineers and workers, WATER ENERGY operates in the field of water treatment capably and professionally.

The main activities of thecompany are: • design and production of equipment for the treatment of water intended to be discharged or recycled; • development of custom-made systems; • customer care and plants maintenance.

The presence of CEIF SOCIETA’ COOPERATIVA – which has been working in the ecological field (purification plants, water purifiers, incinerators, etc.) for over twenty years, with an average turnover of more than 31,000,000 € in the past five years – in the company structure provides WATER ENERGY with a highly specialised technical support as regards design, management and logistics at a national and international level.

HIGHLIGHT

✓ Rain Water Treatment Plants ✓ Quarzite and Carbon Filters ✓ Mechanical Filters of various kind

✓ Osmosis Plants ✓ Demineralization Systems ✓ Oil Separators ✓ Sedimentation Systems ✓ Vacuum Concentrators Dynamic and young, WATER ENERGY is also able to find specific solutions to the customers’ problems, developing with them the most appropriate and suitable application.

With this working method, it has developed a completely automatic multi-stage cleaning system for cleaning the cooling coils of moulds for various plastics. It can use up to two products as reagents, has a double water rinsing cycle and can wash the coils of twelve moulds simultaneously. It may be placed in the moulds storage area or wheeled and moved where necessary.

Made entirely of AISI 304 stainless steel, with all fittings in AISI 316, this system is fully automatic; all process steps are manageable by the operator. It is already successfully used in several plastics moulding facilities, e.g. from the eyewear, lighting, etc. industries.

We are a company with a good experience in the industrial water treatment, particularly the treatment of water coming from spray painting booths using coatings which are water-based, solvent-based or a mixture of both. Our systems ensure a reduction of the ordinary costs up to 90% and the recycling of the water used up to one year.

For further information: www.waterenergy.it

5 AUGUST 2011

✓ Automatic Cleaning Plants for Moulds Cooling Coils

✓ Flotation Units ✓ Product Dosing Unit ✓ Treatment Control Units ✓ Sludge Treatment Systems Maintenance of Wastewater Treatment Plants Design and Manufacturing of Plants for Industrial Wastewater Treatment Study and development of custom-made systems Technical Services and support Air Conditioning Plants Photovoltaic Plants

www.waterenergy.it

Water Energy Srl Via R. Morandi 25 40018 S. Pietro in Casale BO - Italy Tel. +39 051 6630725 Fax +39 051 6632704 info@waterenergy.it

ICT

HIGHLIGHT

ULTRASONIC CLEANING: FLEXIBLE, EFFICIENT, DELICATE

Advantages of Ultrasonic Cleaning Ultrasonic cleaning is a wet chemical process based on physical principles. This combination enables the removal of both film contaminants (such as oils, greases, emulsions) and particulate contaminants such as chips and dust. Ultrasound offers the advantage that high levels of purity can be achieved within a short time, even with workpieces, parts and components with complex geometry (e.g., blind holes, undercuts). Moreover, the cleaning process is very delicate and the use of cleaning medium and chemicals is minimised.

drying. If flammable solvents are used, the ultrasound equipment must be protected against explosion. High-boiling solvents, finally, require suitable, temperature-resistant ultrasonic transducers.

Materials which can be Cleaned With ultrasound, virtually all materials can be treated.

However, this process is not particularly suitable for elastic materials, soft plastics, textiles and so forth.

Cleaning Effect Components Required For the ultrasonic cleaning, a generator of ultrasonic waves, a transducer or a resonator for the transmission of waves in the liquid and a cleaning container are required. The stainless steel containers that have an inlet and outlet and can be heated are particularly suitable. Finally, in order to prevent the ultrasonic components from dry running, the cleaning container should be equipped with a level control.

Cleaning Medium

The cleaning effect is based on cavitation: the ultrasonic generator produces sound waves in a specific frequency range and the immersed transducer or resonator transfers them in the liquid.

The waves create an interplay between positive and negative pressure. The vacuum steps produce tiny bubbles which implode during the overpressure steps.

This releases the energy resulting from the strong currents and turbulence, almost “blowing” the dirt up.

The ultrasonic cleaning can be performed with aqueous cleaning agents or solvents.

The cleaning medium is chosen depending on the material and the contamination level.

The aqueous cleaning agents require a rinse to remove the washing-active substances from the surface and a subsequent

The Ultrasonic Cleaning Process In order to achieve the best cleaning results, the ultrasonic power and frequency as well as the treatment time and the cleaning medium should be adjusted according to the parts to be treated.

The rule of thumb for the ultrasonic power – Watts / litres – is that its value should lie between 5 watts per litre of liquid and 20 w/l, where 5 w/l is the lower limit.

The lower the frequency,

6 AU AUGUST AUGU GUST ST 201 2 2011 011 1

Sabine Fragosa, Weber Ultrasonics GmbH, Baden, Ittersbach, Germany

the greater the cavitation bubble and therefore the greater the energy released. This means that too low a frequency may damage the delicate workpieces, while too high a frequency can mean unsatisfactory cleaning results.

In this case, the reference values are: • 20 to 30 kHz: metal degreasing • 40 kHz: electronic components + polished aluminium parts • 80 to 120 kHz: semiconductor devices and high-gloss polished parts.

In order to accurately define the various parameters, the manufacturers of ultrasonic cleaning systems perform their cleaning tests with original dirty parts. This ensures optimal and reproducible results, shorter cleaning times and an easier handling.

About Weber Ultrasonics Based in Baden, Ittersbach (Germany), Weber Ultrasonics GmbH was founded in 1998 by Dieter Weber. With its high quality innovative products for ultrasonic cleaning, ultrasonic welding and special applications, within a few years Weber Ultrasonics has grown into a global technology leader.

Besides its standard products, Weber Ultrasonics can design and manufacture customised solutions. Among the customers of this ultrasound components manufacturer, certified according to DIN EN ISO 9001:2000, there are small,

medium and large companies from the automotive, plumbing and watchmaking, electrical engineering and electronics, precision engineering and optics, surface treatment and cleaning equipment, metal processing and PCB manufacturing industries.

Two new subsidiaries were founded in 2009: Weber Ultrasonics America and Weber Ultrasonics weld & cut GmbH. Nowadays, Weber Ultrasonics gathers the extensive expertise of all its business partners and combines it in these new businesses in the field of ultrasonic welding and cleaning at an international level.

7 AUGUST 2011

ICT

HIGHLIGHT

CLEANING SYSTEM WITH “NON-OZONE DESTRUCTIVE” SOLVENTS

M

EG is a well-established company in the field of surface treatment, specialised in machines, plants, products and technologies for industrial cleaning. It is a valuable partner for those who are looking for a practical solution to their cleaning problems, whether new or related to the need to meet the current standards of environmental protection.

In this regard, MEG presents the degreasing plant type 3S 24/12-P-F/T AC, exploiting the new generation low boiling solvents, which are “non-ozone destructive”.

This plant is equipped with the state-of-the-art technology in terms of cleaning (ultrasound, filtration, particle control), environmental (reduction of vapour and condensation, atmospheric emissions control) and energy saving performance (heating with heat pump).

Key features and equipment • Distillation and boiling tank with the possibility of automatic solvent filling directly from the can; • Immersion cleaning tank with ultrasound and power control from the operator panel; • Solvent recirculation and filtration system; • Drain pump with tank; • Total dual compressor cooling unit with temperatures down to -25°C; • Solvent heating with heat pump; • Automatic motorised lid for closing the tank; • TA 20/2 ROBOT; • Baskets loading/unloading station; • Full fairing with sliding doors and lighting; • Suction system; • Control cabinet with touch screen for monitoring and programming; • Particle counter; • PPM detector.

8 AUGUST 2011

Giampaolo Rossi, MEG Srl, San Martino di Lupari (PD), Italy

Heat pump

Ultrasonic Generator Mod. STEEL

The use of this technology results in significant energy savings, since the heat generated by the cooling unit is exploited to warm up the solvent and therefore the system does not require any electrical resistance heating in the boiling tank.

A second advantage is the significant reduction of heat dispersed by the cooling unit.

On the average, a plant with a heat pump has a 50% lower installed electric power than the ones with a traditional electric heating.

• Generator MEG STEEL, with simultaneous and pulsed multifrequency supply • Manufactured with Stainless Steel and designed for use in adverse environment with high pollution (dust, vapour, moisture etc.)

• Fast connection IP 65 • Power regulation by means of touch screen with cycle memorization • Multifunction, Frequency Sweep, Multi-frequency StepMode e Software Frequency Tracking.

PPM detector The PPM detector is calibrated depending on the solvent used.

The values detected by the sensor inside the fairing of the machine are sent to the PLC, which allows to manage the opening of the door of the baskets loading and unloading station.

Particle counter MEG PS50 The particle counter is a modern electronic microcontroller, intended to be used as an on-line system and consisting of a high performance laser sensor. It sends real-time data reports to the PLC of the machine. MEG PS50 is a high performance laser-based device, easy to integrate into the industrial data management systems.

An automatic system of digital detection of the flow rate provides accurate measurement results. In the three counter channels for particles > 4 micron (c), > 6 micron (c) and > 14 micron (c), the particle counts are high resolution and showed on the device display or sent to the PLC via a communication interface. The measurement data reports comply with the cleaning standards SAE AS 4059 and ISO 4406. The particle counter measures the ISO 0-22 classes.

9 AUGUST 2011

ICT

HIGHLIGHT

Safechem Establishes an Innovative Chemical Leasing Concept COMPLEASE™ – COMPLETE AND FUTURE-ORIENTED SOLUTION TO OPTIMISE THE CLEANING PROCESS

C

hlorinated solvents are essential to numerous precision cleaning applications, especially in the aerospace, automotive and medical industry as well as in the production of safety devices. However, to protect man and the environment, the use of these cleaning agents is strictly regulated by law such as the SED Directive and REACH. Additionally, Trichloroethylene is subject to the Voluntary Industry Commitment.

The innovative COMPLEASE™ concept from SAFECHEM enables users to lease the entire solvent cleaning process. Thus, highest requirements to both component cleanliness and environmental and occupational safety can be met. At the same time, this serviceoriented leasing model provides continuous process optimisation.

Ever-changing and increasing requirements to component cleanliness challenge hallenge ha the customers´ decision-making aking ng for the right cleaning process. ss.

Due to their specific physical al and chemical properties, organic rganic solvents – in particular chlorinated orinated hydrocarbons hydrocarbon oca ns – supply a lot of advantages in cleaning heavily lubricated and difficult to dry metal components or work pieces. Their benefits include excellent degreasing attributes, low surface tension, high chemical stability and good drying characteristics.

Nevertheless, comprehensive regulatory requirements for environmental and occupational safety dictate that the product specific risks are properly managed.

State-of-the-art solvent cleaning To meet the high requirements of environmental and occupational safety, today chlorinated solvents should only be used in completely closed cleaning equipment. For the supply and disposal of solvents, the SAFE-TAINER™ system, developed by SAFECHEM Europe GmbH – a wholly owned subsidiary of The Dow Chemical Company – represents the Best Available Technology (BAT). Since last year SAFECHEM offers this advanced system also to the North American market under the brand name SAFECARE™. It consists of two different, specially designed double-walled containers for fresh and used solvents. In combination with closed cleaning equipment, the system ensures not only practically emission-free operation, but also an ecology-minded and legally compliant closed-loop process. The range closedof solvents, which includes solve both chlorinated hydrocarbons ch (perchloroethylene, (perchl trichloroethylene and methylene trichlor chloride) and solvents based on chloride modified alcohols, is being expanded with a comprehensive consulting and service offer and the CHEMAWARE™ information platform. The latter supports customers in their decision-making with expert knowledge and information on best practices for a high quality cleaning process. The goal of this service is the sustainable, safe and ecology-minded use of solvents.

10 AUGUST 2011

Doris Schulz, Schulz.Presse.Text, Korntal, Germany

COMPLEASE™ – leasing the entire cleaning process SAFECHEM takes an additional step with their innovative COMPLEASE™ model, enabling customers to lease the entire cleaning process. This chemical leasing service, which is a genuine innovation in industrial component cleaning, includes high quality solvents from Dow, comprehensive services from SAFECHEM, CHEMAWARE™ know-how as well as closed cleaning equipment from leading manufacturers upon request. The leasing package is customised to meet individual requirements. Cost calculations are not based on the quantity of solvents used, but for example on the number of components cleaned. Customers pay the fixed all inclusive leasing fees on a monthly basis. In contrast to the conventional sale of solvents, with chemical leasing solvent consumption is no longer a cost factor for the customer, but rather for the solvent supplier. The latter will of course do everything possible to increase the efficiency of the cleaning process by solvent maintenance and to lower the consumption rate.

Benefits for customers and the environment In addition to the supply and take-back of solvents using the SAFE-TAINER™ system, including all corresponding analyses and documentation responsibilities, SAFECHEM also coaches and consults on solvent maintenance. This includes test kits for testing the solvent on site, extensive laboratory analyses, solvent additives, stabiliser systems as well as a comprehensive chemical-technical consultancy.

This service offer is designed to facilitate continuous optimisation of the cleaning process for high quality, efficiency, and environmental compliance. Initial projects have shown that the leasing model can reduce solvent consumption by up to 96 percent compared to a non-optimised closed cleaning process.

Comprehensive solvent trainings for the customer´s relevant employees for safe and efficient handling of solvents are provided via the CHEMAWARE™ Service Business and support the Risk Management goals. In addition, customers benefit from expert CHEMAWARE™ knowledge e.g. about the regulatory framework for solvent cleaning and Responsible Care®. The latter is targeted at the continuous improvement of employee health and safety, the preservation and improvement of air, water and soil quality, process safety, product responsibility and emergency measures. If the cleaning system is a part of the leasing agreement, accessories, machine maintenance and services are included.

Best practice solutions for solvent cleaning On the one hand, COMPLEASE™ enables high-quality precision cleaning based on continuous process improvement in compliance with relevant legal requirements. On the other hand, chemical leasing provides users with cost transparency and planning security – and thus optimal risk management. This could be of particular benefit to small and mid-sized businesses, as they often need support to optimise their cleaning processes.

11 AUGUST 2011

ICT

CASE STUDY

VOLKSWAGEN PLASTICS TECHNOLOGY RELIES ON CO2 SNOW JET TECHNOLOGY. Basis for the Application of a Single-Layer High-Gloss Finish to Injection-Molded Parts

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Foto: Volkswagen, Plastics Technology, Braunschweig

1

The CO2 snow jet system has been integrated into a paint booth measuring 5.5 x 4 x 3 meters together with a turning station, and needs much less space than a powerwasher with a dryer.

C

onform to the motto “less is more”, Volkswagen Plastics Technology in Braunschweig in Germany has started using a single-layer painting system for a new interior component.

The process not only reduces the consumption of resources and pollutant emissions, but the semi-transparent metallic painting also lends the already-shiny injection molded part a sophisticated look. However, the painting system demands an absolutely clean, residue-free surface. This has been achieved with the aid of a dry CO2 snow jet cleaning technique which is gentle on materials.

In order to economize on resources and costs as well as reduce environmental damage, Volkswagen’s production plants implement the latest technologies such as cogeneration units, biogas plants, filler-free body paints and thermal afterburners to recover energy from solvent-polluted exhaust air. In the development and manufacture of interior components such as panels, trims, ventilation grilles and air diffusers, Volkswagen finds ways of further increasing sustainability at its Plastics Technology in Braunschweig.

12 AUGUST 2011

Doris Schulz, Schulz.Presse.Text, Korntal, Germany

Cleaning – decisive to product quality

The solution: CO2 snow

Every day, Plastics Technology processes approximately 45 tons of granulate material to manufacture injection-molded parts. A range of about 450 interior components of different colors are produced and installed into various passenger vehicle models and the Multivan T5 around the world. Some of these are injection-molded parts with a high-gloss finish and which can be installed without needing to be coated. One of the latest vehicle models produced by Europe’s largest car manufacturer is fitted with a high-gloss panel made from ABS-PC blend (ABS - Acrylonitrile-Butadiene-Styrene, PC - Polycarbonate) which is subsequently painted with a semitransparent high-gloss metallic paint. “This paint is applied to the component as a single layer without an undercoat, so the surface has to be flawless. The tiniest dust particle or water mark would cause rejects. Therefore, we needed a cleaning solution which is efficient, gentle on materials and guarantees consistent results”, explained Uwe Strauß, Painting Systems / Plastics Technology Planning at Volkswagen in Braunschweig.

The classic alternative – wet-chemical cleaning with a powerwash system – was mainly rejected for reasons of costeffectiveness and sustainability. However, due to its high space requirements, it would have been impossible to install such a cleaning system upstream of the paint shop. In tests with conventional dry-ice cleaning systems, it was observed that the coarse ice pellets damaged the sensitive surface of components when used as a cleaning medium. “The CO2 snow jet process from acp gave us an alternative, so we told one of the company’s employees about what we needed. It wasn’t long before we were sent a proposal for a solution, and tests confirmed that we could achieve optimum cleaning results with the process”, Uwe Strauß remembered. With the CO2 snow jet technique, liquid carbon dioxide is used instead of dry ice pellets. Carbon dioxide gas is produced as a by-product in a variety of manufacturing processes in the chemical industry; it is environmentally neutral and gentle on resources.

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Foto: Volkswagen, Plastics Technology, Braunschweig

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Component-specific cleaning programs are stored in the robot controls for approximately 20 different workpieces.

To prevent recontamination, all dirt which has been removed is extracted.

13 AUGUST 2011

ICT

CASE STUDY

Dry, gentle on materials and free of residues

Cleaning integrated into the painting process

The modularly-constructed CO2 snow jet system made by acp – advanced clean production GmbH achieves its effective cleaning power via the supersonic two-component ring nozzle integrated into the compact cleaning head. Liquid carbon dioxide is guided through the nozzle and expands on exit to form a mixture of snow and gas. Oil-free compressed air is fed to the core jet as a jacketed jet, accelerating the non-toxic, non-combustible CO2 snow crystals to supersonic speed. When the easily-focused jet impacts on the surface to be cleaned, the snow crystals liquefy and then sublimate. The sublimation impulse causes any particulate contamination present to detach and be carried away. In the liquid phase, carbon dioxide also acts as a solvent which removes organic contamination.

At the same time, the low degree of hardness of the snow crystals ensures gentle and reproducible cleaning results on the highgloss surface of the component.

“During the test phase we also carried out test series with other components made of different materials. This proved that the CO2 cleaning process can be implemented for 3 our entire range of workpieces”, 3 reported Uwe Strauß.

The various parts are cleaned in batches

In line with Volkswagen Plastics Technology requirements, acp designed a robotic cleaning system with a nozzle array containing seven cleaning heads. The component-specific programs stored in the robot controls ensure that each of the approx. 20 different workpieces is cleaned fully-automatically according to its geometry. Oil-free compressed air and liquid carbon dioxide stored in tanks are fed to the array via a hose system.

The robot installation is integrated into a booth measuring approx. 5.5 x 4 x 3 meters (LxWxH). The cleaning cell located at the rear wall has a continuous extraction unit.

This prevents cleaned parts from becoming recontaminated by dirt as it is removed. A turning station, which can be switched on separately, is located in the booth downstream of the cleaning process, allowing suspension gear to be rotated by 180 degrees. “acp provided us with ideal support both during the test phase and afterwards when we started implementing the cleaning system, enabling us to integrate it into the painting process within Foto: Volkswagen, Plastics Technology, Braunschweig the space of just three months”, said Uwe Strauß.

14 AUGUST 2011

Doris Schulz, Schulz.Presse.Text, Korntal, Germany

Foto: Volkswagen, Plastics Technology, Braunschweig

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A single layer of semi-transparent paint is applied to the injection-molded panel which already has a high-gloss finish.

This demands an absolutely particle and film-free surface.

Series operation with high cost-efficiency The CO2 snow jet system has been running in three-shift series operation at the Volkswagen works in Braunschweig since August 2010. Several thousand plastic parts are cleaned by it every day.

“The workpieces are suspended on special painting racks directly at the injection-molding plant. If high-gloss parts are handled, workers wear gloves“, Uwe Strauß explained. The racks are mounted on trolleys, transported to the painting line and fed into the painting chain. The first station in the line is the cleaning unit. To prevent any dust from sedimenting on

the workpieces after cleaning, they are fed through a station fitted with two ionizing rods. After being transported along a short stretch designed as a cleanroom, paint is then applied to the components by two robots in the painting booth. On leaving the evaporation zone, the parts are then dried at around 80°C. “With the CO2 snow jet system from acp, we’ve not only found a cost-effective and reliable cleaning solution, we’ve succeeded in reducing the workload on our staff, decreasing environmental pollution and also lowering our reject rate by another 3%”, summarized Uwe Strauß.

15 AUGUST 2011

ICT

TECHNOLOGY OVERVIEW

Cleaning Solutions in the Automotive Industry ACHIEVING CLEANLINESS RELIABLY AND EFFICIENTLY

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omponent cleanliness is a quality criterion in the motor vehicle industry. Requirements are becoming stricter and stricter with each vehicle generation – with simultaneously increasing cost pressure. And thus for the automotive industry and its suppliers it’s becoming more and more important to exploit optimisation potential in the area of parts cleaning.

required in some cases. For example, based on calculations, the outlays required for cleaning technology which fulfils a specified requirement of “no particles larger than 1,000 μm” are two to three times higher than for systems in which cleaned parts are contaminated with larger particles.

Minimising Contamination

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Image source: LPW Reinigungssysteme

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Modular cleaning systems, which allow for adaptation in accordance with actual needs and integration into the production line, offer flexibility. Parts from diesel injection systems advance from the cleaning chamber to vacuum drying.

Global emphasis is being placed upon reducing CO2 emissions and fuel consumption, as well as increasing safety and comfort within the vehicle manufacturing industry.

Downsized engines are in demand which run more efficiently with high power output, as are components that are capable of withstanding extreme loads and are distinguished by tight tolerances. However, this is only possible with high precision components – and this is associated with increased sensitivity to contamination. If they end up in the wrong place, even particles with sizes down to 500, 200 or even just 100 μm can cause damage and failure in the field.

This is why, in the meantime, the automotive industry has started defining particle size distributions for certain parts in functional modules such as the power train, steering and brakes, for example no more than 1,000 particles between 100 and 200 μm, 500 particles between 200 and 400 μm etc. In order to fulfil and document these requirements, large investments in industrial parts cleaning technology are

The issue of potential for economic optimisation in the parts cleaning process is pursued despite, or perhaps precisely due to the large investment sums involved in some cases. One approach is component design, because the geometry of the workpiece and the individual steps of the manufacturing process, for example turning, milling and assembly, as well as cleanability, are determined during the design stage. The latter usually plays no role at all, for which revenge is taken during the subsequent production process: The parts have corners, edges or drill holes from which particles and processing residues can only be removed with considerable effort, or not at all.

Due to the fact that material is removed during the course of chip-forming machining processes, contamination can never be entirely avoided. The quality of cooling lubricants and machining fluids influences the quantity of chips, burrs and particles on the workpieces. Suitable purification/filtration prevents previously washed away contamination from being

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Image source: PERO

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This system has been adapted such that cleaned parts are transported directly into a cleanroom by means of a sealed roller conveyor.

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Doris Schulz, Schulz.Presse.Text, Korntal, Germany

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Image source: Metallform Wächter

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When cleaning safety relevant components or workpieces which are joined by means of soldering or welding such as cooler system parts, economically optimised results can be obtained with perchlorethylene.

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Image source: SAFECHEM

returned to the component once again. A special rinsing step with the tool in the machining centre – perhaps even with more finely purified fluid from a separate tank – can also make a contribution to reducing the number of chips. At first glance, this represents an additional expense. But it pays for itself later on in the manufacturing process thanks to shorter cleaning times and/or a longer bath service life, as well as better component quality. And residues which are removed after machining by means of mechanical pre-cleaning based on vibration, shaking, spinning or vacuum blasting the surfaces of the part do not place any unnecessary load on the cleaning agent.

In the case of multi-stage machining processes in metal forming and machining applications, intermediate cleaning steps prevent the accumulation of contamination, as well as any mixing or drying out of media on the workpieces.

Ideally Laid Out Cleaning Processes Modern cleaning systems are capable of fulfilling even very high demands for component cleanliness – assuming the cleaning process has been ideally matched to the contamination to be removed, part geometry, the utilised material and the cleanliness specification to be complied with.

Assuring that the parts in the container are readily accessible on all sides for the medium and the washing mechanism, and that targeted treatment of critical areas is possible, are essential factors for an optimised batch process.

The limit value of “smaller than 1,000 μm” for components in engines and gearboxes can only be adhered to with a cleaning process which has been laid out specifically for the respective part. The current state-of-the-art makes use of a multistage procedure to this end. The workpieces are thus usually subjected to mechanical cleaning during the first step, which removes some of the adhering machining fluid. The second step involves immersion flooding: Water is injected into the cleaning chamber below the surface of the bath at a pressure of 10 to 15 bar. The resulting whirlpool effect rinses chips and contamination out of hollow spaces such as threaded blind holes. Water jet systems which are aimed at openings in the component, and lances which advance into holes, allow for optimised results within short periods of time. This applies as well to subsequent high-pressure cleaning or deburring. Rinsing is followed by a drying process.

Numerous engine and gearbox variants, as well as ever shorter product life cycles, necessitate a great deal of flexibility – even for individual part cleaning. This is accomplished by automated cleaning solutions with robots, which are integrated into the production line. Thanks to options provided for easy reprogramming, these assure levels of flexibility which are comparable to those offered by machining centres.

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ICT

TECHNOLOGY OVERVIEW

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In the face of increasing cost pressure within the manufacturing processes used by suppliers to the automotive industry, functional surface cleaning, for example by means of the CO2 snow jet process, provides a viable approach to saving both time and money.

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Image source: acp

Large numbers of vehicle parts are cleaned in batch processes as individually positioned items or bulk goods. Single and multichamber systems which can be integrated into the production line are available for these cleaning tasks as well. A modular design with various interlinking options assures adaptability to specific requirements, as well as expandability in accordance with actual needs.

In addition to the utilised process technology and the medium, the container also has a great deal of influence on the results and the economic efficiency of the cleaning process. There are two primary questions in this respect: Are the parts in the container readily accessible from all sides for the medium and the washing mechanism? Is it possible to position the part within the container such that critical areas can be treated in a targeted fashion? An additional requirement for efficient cleaning processes is the removal of loosened contamination from the cleaning bath so that it isn’t redeposited on the parts. In order to assure continuous particle removal, gentle but constant bath motion is necessary on the one hand, and effective filtration which is matched to the actual particle size is required on the other hand.

Aqueous Medium or Solvent Wet chemical cleaning processes with aqueous media or solvents are generally used in the automotive industry.

Aqueous media, available as alkaline, neutral and acidic cleaners, are used with preference where very large volumes of parts have to be cleaned and/or where fine cleaning and micro-cleaning are required. Their cleaning effectiveness is based on an organic or an inorganic builder and tensides.

The latter are able to “push” themselves in between the contamination and the material to be cleaned, and dislodge non-polar contamination such as oil and grease, as well as polar contamination (e.g. emulsions, salts and particles).

Continuous monitoring of the bath and bath replacement at regular intervals are necessary for consistently good results.

Aqueous media are also used for rinsing processing oils from auto body parts prior to zinc phosphating. The industry offers specially developed products in order to reduce bath maintenance expenses, which is frequently accomplished by means of ultrafiltration. Through the use of demulsifying tensides, they allow for the precipitation of oils introduced to the process, making it easier to remove them from the

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Doris Schulz, Schulz.Presse.Text, Korntal, Germany

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Image source: Gläser

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Image source: Hermann Bantleon

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Cleaning in the automotive industry frequently involves more than just achieving the specified cleanliness requirements – inspection and documentation are required as well.

VCI materials, which consist of powders, granules, liquids, impregnated foils, foams or paper, create a gas phase inside the closed package which protects against corrosion.

cleaning baths. Matched cleaning media are also available for the new, more environmentally compatible alternatives to zinc phosphating. They assure that not only oils on the components are removed: they reliably remove oxides as well.

Chlorinated hydrocarbons (CHCs), the traditional degreasers, assure especially effective degreasing and drying of metals – even for components with complex geometries. Particles which cannot be dissolved by the solvent, for example chips, are removed along with the oil because they are no longer able to adhere to the surface. Perchlorethylene (per) has proven its worth for cleaning safety relevant workpieces, for example parts used in air bags, brake systems and power steering systems. Due to its chemical-physical characteristics, it’s also frequently the solvent of choice when parts need to be cleaned which have been joined by means of soldering or welding, such as components in cooling and air-conditioning systems, as well as electrical plug contacts.

Non-halogenated hydrocarbons (HCs) provide good dissolving performance for animal, vegetable and mineral oils and grease, and demonstrate outstanding materials compatibility.

Polar contaminations like salts from emulsions cannot be removed with non-polar hydrocarbons.

which the entire component demonstrates the same high degree of cleanliness as specified for the functional surface, is often associated with very high costs. In the face of increasing cost pressure within the manufacturing processes used by suppliers to the automotive industry, functional surface cleaning, for example by means of CO2 snow jet, laser or plasma processes, provides a viable approach to saving both time and money. A further advantage offered by functional surface cleaning integrated into the production process is the fact that the cleaned surface is made available just-in-time, thus eliminating any need to implement measures targeted at maintaining cleanliness after cleaning and during transport.

Functional Surface Cleaning Saves Time and Money Due to cleanliness requirements which vary greatly for a single workpiece in some cases, targeted cleaning of specific component surfaces such as sealing, joining, bonding and laser welding surfaces may be advantageous. In these cases, conventional cleaning with aqueous media or solvents, after

Caution: Recontamination As soon as the parts leave the cleaning system, there’s a danger of recontamination. In order to prevent contamination with particles from the environment in the case of functionally critical components, it may be necessary to inspect, package and store them in a so-called clean zone, and to provide personnel who work there with appropriate clothing and gloves.

In the automotive industry, functionally critical cleaned components are transported and stored in appropriate packaging. These frequently consist of so-called VCI foils, which at the same time offer corrosion protection. Partspecific, deep-drawn sheet materials are also used which, like the small load carriers usually used for small parts (these are additionally lined with foil), have to be cleaned at regular intervals.

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ICT

TECHNOLOGY OVERVIEW

Cleaning Technologies for Medical Engineering VALUE ADDED THROUGH HIGH LEVELS OF CLEANLINESS

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cycle breaks up the liquid – the cohesive forces are overcome.

This causes the formation of millions of microscopically small bubbles. During the subsequent pushing phase, these cavitation bubbles are rendered unstable and collapse (implode), and they generate hydraulic impacts with very high energy densities, thus causing micro-currents in the liquid.

When these strike a surface, they blast off contamination which has been partially dissolved by a suitable cleaning agent and rinse the “dirt” away.

In addition to the cleaning agent, the frequency of the electrical signals generated by the ultrasonic generator which is transferred to the liquid bath by the vibration system in the form of sound waves is also decisive with regard to the cleaning effect. In general we can say that the llower the frequency of the electrical ssignals is, the more energy is released by the sound waves. b Ultrasonic cleaning is used in the U field of medical engineering for pre, intermediate and final cleaning of, in for fo example, implants and instrument components, cannulae and other co metallic parts. In particular machined m parts are frequently subjected to pa pre and intermediate cleaning pr with solvents such as chlorinated wi hydrocarbons, non-halogenated hy hydrocarbons and modified alcohols. hy The reason for this is the fact that Ultrasonic Cleaning – Th 1 machining media which have been Standard Procedure in ma Image source: Amsonic carried over into the solvent, for example Medical Engineering car 1 cutting oils, can be continuously distilled Wet chemical ultrasonic cut out, so that the cleaning agent delivers cleaning allows for economic, Various cleaning technologies are available in order to efficiently uniformly high cleaning performance gentle and ecological removal achieve high levels of cleanliness for medical products such as implants. over a long period of time. The current of particulate and film-like state-of-the-art for solvent cleaning contamination. Even parts involves closed systems. These minimise the emission of volatile with difficult to access hollow spaces, for example blind holes, organic compounds (VOCs), and thus comply with current can be quickly and effectively cleaned with this process. environmental protection and work safety standards.

The cleaning effect is based on cavitation: When a liquid is In order to assure the required levels of biocompatibility subjected to ultrasonic sound, the high intensity of alternating for technical medical components, ultrasonic systems with sound pressure during the pulling phase of the oscillation

election of the ideal cleaning technology makes an important contribution to quality and efficiency in the production of technical medical products. Not only can both be enhanced with modern cleaning technologies, they frequently make it possible to realise new product ideas as well.

Regardless of the fact that to date no legal requirements exist with regard to particulate and film-like residual contamination on technical medical products such as implants, instruments, cannulae and catheters, component cleanliness is becoming a more and more important quality and competitive criterion in the field of medical engineering.

Various cleaning technologies are available in order to efficiently achieve high levels of cleanliness. Essential factors involved in selecting a suitable process include the material or material combination, type of contamination, component geometry and production throughput. The technically and economically most effective cleaning solution frequently consists of a combination of various processes.

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Doris Schulz, Schulz.Presse.Text, Korntal, Germany

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Image source: Hoeckh

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Image source: Roll

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Image source: acp

aqueous cleaning agents are used for final cleaning. Rinsing, which is usually a multi-stage process, involves the use of fully deionised water – at least in the final stage. This prevents the adhesion of residues left by the cleaning agent, or surface spots on the parts which impair quality and biocompatibility.

Integrated Passivation for Additional Protection In order to destroy germs, more and more aggressive, in some cases highly alkaline cleaning agents are utilised in hospitals to clean surgical instruments after use. Due to the fact that these media attack the surfaces of the instruments, passivation is becoming increasingly important during the instrument manufacturing process, because the additionally applied passive layer provides improved protection against these chemicals. The passivation process can be easily integrated into the final cleaning system.

CO2 – Usable in Various Phases Cleaning with carbon dioxide is an environmentally sound process. Odourless, colourless, non-flammable and non-toxic CO2 occurs as a by-product of chemical and industrial processes and is reconditioned for use in cleaning applications.

Compressed CO2 – Good Gap Penetration and Solvent Characteristics

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In particular machined parts are frequently subjected to pre and intermediate cleaning with solvents. The state-of-the-art in this area is represented by closed systems with integrated distillation units for continuous reconditioning of the solvent.

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Cleaning with compressed carbon dioxide represents a supplement to wet chemical processes, and at the same time meets demands for environmentally sound, dry, residuefree technologies. Compressed carbon dioxide is CO2 which has been liquefied by means of pressure, i.e. carbon dioxide

The ultrasonic cleaning system with automated workpiece transport is laid out for multi-stage aqueous cleaning processes and subsequent passivation.

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Cannulae can be simultaneously cleaned and deburred with CO2- snow-jet technology.

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ICT

TECHNOLOGY OVERVIEW 5

In the case of low-pressure plasma, parts are processed in a closed chamber under partial vacuum. Various process gases can be used.

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Image source: Plasma Technology

in its supercritical phase, in which it demonstrates very good solvent characteristics for numerous non-polar contaminants such as greases and oils. Supercritical CO2 is distinguished by low viscosity and minimal interfacial surface tension, which results in improved gap penetration.

This makes it possible to clean parts with highly complex shapes such as extremely small drill holes and gaps.

In the field of medical engineering, this technology offers strong potential for the cleaning of cavities with large aspect ratios such as cannulae, endoscope cavities and small diameter 6 tubing used as supply lines for oxygen and other gases.

This technology is also opening up new possibilities for components with highly porous surfaces which previously could not be cleaned, or only with disproportionately high costs. A further advantage which makes CO2 extremely interesting for medical engineering is the bacteriostatic effect of this cleaning agent.

CO2 reaches its supercritical state at a temperature of 31° C. For liquid parts cleaning, it’s used within a temperature range

Plasma sources which are operated at atmospheric pressure allow for inline compatible processes. Components are cleaned and their surfaces are activated simultaneously during plasma treatment.

Image source: Reinhausen Plasma

of 15 to 25° C. And thus the cleaning process is well suited for temperature sensitive materials as well. Due to the fact that CO2 is immediately sublimated at atmospheric pressure, the goods to be cleaned are fully dry as soon as cleaning has been completed. This is particularly advantageous for cleaning materials which are highly sensitive to moisture. Thanks to a direct transition to the gaseous phase, absolutely no solvent residues or secondary waste are left on the components.

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Doris Schulz, Schulz.Presse.Text, Korntal, Germany

Snow for Clean Surfaces

plasma, treatment takes place in closed chambers in a partial vacuum. This makes it possible to treat workpieces with Liquid carbon dioxide is also used for CO2 snow-jet cleaning complicated shapes as bulk goods or single parts. Various – in the form of extremely fine snow crystals. Thanks to a process gases can be used as well. The second alternative combination of mechanical, thermal and chemical effects, involves inline compatible plasma sources which are operated the non-toxic, non-flammable CO2 snow gently removes filmat atmospheric pressure. These include traditional barrier like and particulate contamination in a residue-free fashion dischargers, as well as plasma nozzle systems. In these from nearly all materials such as metals, plastics, glass end systems, discharge takes ceramic substrates, even if place in the plasma nozzle they have finely structured and is directed towards the surfaces. Thanks to the surface to be treated by readily focusable jet stream, means of compressed air. defined functional areas The surface is simultaneously can be treated in a targeted cleaned and activated fashion, for example bonding during plasma treatment. surfaces. Due to the fact that This double function is it’s a dry cleaning process, based on a physical and there’s no need for energychemical reaction within intensive drying with CO2 the process: Ions in the snow-jet cleaning. plasma are capable of In the field of medical absorbing large amounts of engineering, the process energy, and are thus able is used for, amongst other to remove contamination things, simultaneous from surfaces like a blasting cleaning and deburring of process in the nanometre cannulae, dental implant range. Reactive species sockets and surgical saws. such as oxygen radicals are Burrs with sizes down into capable of removing organic the micron range can be contamination like oils and reliably removed in this greases by means of “cold way. On the one hand, burning”, and entering deburring action is based on into a chemical bond with a mechanical effect which the surface. This results in is caused when the snow increased surface tension crystals strike the surface of which improves results for the respective material. On subsequent bonding, coating the other hand, turbulent and printing processes. flow occurs at the surface 7 Image source: Fraunhofer IPA Biocompatible plasma is to be deburred, and the used in the field of medical burrs are thus subjected to 7 engineering, for example alternating bending stress Supercritical CO2 makes it possible to clean parts with extremely complex shapes for final cleaning of stents, causing them to break off. such as very small gaps. A cleaning system equipped with a lance is shown here, surgical and dental implants, which is being retracted from a small drill hole. as well as guide wires prior Cleaning and Activation to coating with hydrogel or in a Single Step PTFE, and for increasing the surface energy of microtiter plates Plasmas, i.e. gaseous mixtures of atoms, molecules, ions and free electrons, allow for efficient surface treatment of technical and other diagnostic instruments, silicone breast implants, catheters and syringes. The surface stickiness and permeation medical products made of various materials such as steel, noncharacteristics of contact lenses made of silicon rubber can also ferrous metals, plastics, glass and ceramics. Two technologies be improved by means of plasma treatment. are available in this respect: In the case of low-pressure

23 AUGUST 2011

ICT

TECHNOLOGY OVERVIEW

Monitoring Surface Cleanliness and Bath Contamination CONTROLLED CLEANING QUALITY REDUCES COST RISKS

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The consequence is often costly and resource-intensive process control: – In order to be on the safe side, cleaning agent concentrations are significantly higher than required for adequate cleaning in many cases. As a result, cleaning agent is carried over into the rinsing zones, where it’s removed by means of bath maintenance measures.

– Due to the fact that the concentration levels of the cleaning agent’s ingredients and contamination in the baths are often unknown, baths are changed earlier than necessary, either partially or entirely, in order to be on the safe side.

In addition to increased consumption of water, chemicals and energy, this results in considerable wastewater reconditioning and disposal costs, as well as reduced availability of the cleaning system.

Overdosing of the cleaning agent and premature bath replacement can be avoided by continuously monitoring cleaning agent and contamination concentrations in the baths and by inspecting part cleanliness.

Not infrequently, optimising runs reveal Process and Cost that specified residual Optimisation through contamination limit Continuous Bath values can also be Monitoring 1 reliably adhered In aqueous cleaning Image source: SITA to with lower processes, results are Messtechnik 1 concentrations influenced decisively Control unit for a system for fully automated monitoring of bath quality and cleaning agent of cleaning agent by temperature, concentration, as well as consumption-dependent, additional dosing of builders and tensides. ingredients and/or concentrations of reduced temperatures. builders and tensides in Measuring systems based on sensors which have been the cleaning agent and contamination in the baths. On the one specially developed for cleaning processes are available for hand, cleaning agent performance is decreased by carried-over determining the contamination load in the cleaning baths. particulate and oily contamination. On the other hand, builders They detect and document the extent to which the bath is and tensides are depleted to different extents during the cleaning contaminated with particulates and oils, and reliably indicate process, which also changes the quality of the cleaning results.

dmittedly, cleaning components represents a cost factor, but inadequate or no cleaning at all engenders a cost risk. For this reason, residual contamination limit values which have to be monitored and documented are being specified for more and more workpieces. Process optimisation by means of continuous monitoring of cleaning and rinsing baths is consequently becoming increasingly significant.

Regardless of whether residual particulate contamination on components impairs their function or even causes complete failure, or if film-like residues diminish the quality of downstream processes such as coating, hardening, bonding or welding – the consequences are costly rework, complaints and, in the most unfavourable cases, expensive recalls which damage the company’s corporate image. In order to eliminate this cost risk, more and more companies are specifying component-specific residual contamination limit values, compliance with which has to be monitored and frequently documented. This is associated with stricter cleaning requirements, especially with regard to the quality of the cleaning and rinsing baths.

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Doris Schulz, Schulz.Presse.Text, Korntal, Germany

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Image source: SensoTech

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Cleaning agent concentration can be continuously ascertained and monitored on the basis of highly precise measurements of absolute sound propagation velocity and process temperature with this system.

when the bath needs to be changed. Other parameters which are relevant for the process, for example pressure, temperature, pH value and specific conductance, can also be integrated in order to generate a complete process image.

As an alternative, manufacturers also offer monitoring systems which not only measure bath contamination, but rather individual concentration levels of builders and tensides as well, document the results and automatically add ingredients based on consumption.

Detecting Film-Like Residual Contamination Various test procedures are used in order to determine surface energy (mN/m = milli-Newtons per metre) for the inspection of cleaned parts and surfaces for residual contamination such as residual oil and grease, as well as finger prints and preservatives, which might impair the quality of downstream processes such as coating, painting, bonding, hardening and welding. These procedures begin with simple test inks. Test inks are liquids with a specified surface tension which are applied to the surface under test with a brush. If the brushed on stripe remains for at least two seconds without shrinking together, the surface energy of the substrate is equal to or greater than the surface

tension of the test ink. Beyond this, portable and inline test methods are available as well which also make it possible to document the ascertained values. These are based on various principles: In the case of contact angle measurement, the angle is measured which is formed by a drop of liquid on a solid surface. Various characteristics of the surface of the substrate can be determined in this way, for example surface energy. Fluorescence measurement is based on the tendency of organic substances such as oils, greases and waxes to fluoresce when excited by UV light. The thicker the film-like layer, the greater the fluorescence. Calibration is conducted individually with the help of an ideally cleaned surface.

In the case of laser induced, time integrated fluorescence spectroscopy, excitation is accomplished by means of laser radiation. Even small traces of contamination can be detected using ultra-short light pulses in the nano-second range at a high pulse frequency. Another concept is based on the relative change in luminance which results from thin layers on surfaces. A target value is ascertained using a reference surface and is saved to the measuring instrument. Comparative measurements then make it immediately possible to draw conclusions regarding film-like contamination on the surface.

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TECHNOLOGY OVERVIEW 3

Measurement of contact angle and surface energy on specimens of nearly any desired size is made possible by this portable, semiautomatic, fully integrated device.

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Image source: Krüss

Thanks to interchangeable measuring probes, this system can be used for flat surfaces, as well as for inspecting the cleanliness of shafts. Furthermore, a flexible measuring probe tip which is connected to the controller allows for inspecting the inside surfaces of drill holes.

Tracking Down Particles In particular in the automotive industry, VDA volume 19, “Technical cleanliness testing – Particulate contamination of function-relevant automobile components”, and its international counterpart, namely ISO 16232, volumes 1 through 10, “Road vehicles – Cleanliness of components of fluid circuits”, are now referred to in supply contracts with regard to particulate cleanliness for the respective components.

In the meantime, more and more companies from other sectors such as precision engineering and microtechnology, hydraulics, medical engineering, optics and the clock making industry are aligning themselves to this directive, which

specifies unambiguously described methods and procedures for extracting and analysing particulate contamination from production and the environment.

As a result, the technical cleanliness of a part is rendered objectively assessable and comparable.

One of the essential criteria set forth in VDA 19 stipulates that the required cleanliness value, and its entry to the drawing of the respective part, is always associated with a test specification. This specification includes unequivocal instructions regarding cleaning test parameters and the technique used to measure particulates. It is further stipulated that cleaning test parameters for the respective type of component must be debugged and optimised by means 4 Image source: Kienzle Prozessanalytik of so-called decay curves, in order to achieve completest possible removal 4 of particles without attacking the This measuring system based on laser induced substance of the part. fluorescence spectroscopy is equipped with a fibreSince particles cannot be optic bundle consisting of two mono-fibres – one for the transmission of the excitation light from the laser to substantiated directly on the surface a measuring probe, and one from the measuring probe of the majority of the components to the detector. The measuring probe can be laid out to under test due to their geometry, a match the component under test.

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Doris Schulz, Schulz.Presse.Text, Korntal, Germany

cleaning step is required which washes particles into a liquid medium. This type of extraction, i.e. removal of particles from the part, is made possible by means of various fluid methods, for example spraying, ultrasound, rinsing or shaking. The liquid resulting from the extraction process is fed through filtration media which are subsequently evaluated.

Various procedures with differing degrees of validity are used to evaluate the specimens: Gravimetry is a method involving an unused analysis filter which is weighed after filtering the liquid specimen. Differential weight indicates the degree of contamination of the tested components on the basis of the overall weight of the particles rinsed from the parts. Microscopy makes it possible to issue statements regarding particle size and distribution, as well as the largest particle rinsed from the component. It can thus be determined whether or not certain specifications are being adhered to, for example “no particles larger than 400 microns”. Automated microscopy with image processing examines the analysis filter’s entire surface, defines the particles according to quantity and size, and documents them. This allows the user to draw conclusions regarding potential damage which might be caused by individual particles. Scanning electron microscopes provide information about the size and distribution of detected particles, as well as the chemical elements they contain.

This method allows us to draw conclusions regarding the origin of the particles and their potential for causing damage, and makes it possible to examine extremely small particulates. Even more accurate information is furnished by micro-tomographs, by means of which particles can be measured three dimensionally.

The use of fluid particle counters, for example extinction particle counters, eliminates the need for analysis filters which are required for gravimetry and microscopy. As a prerequisite for reliable results, the test fluid may not contain any gas bubbles or droplets of extraneous liquids during measurement.

Inspection systems are available for dry, manual and inline cleanliness inspection which illuminate the surface under test by means of direct sidelighting. Thanks to integrated optical filters, the measuring probe generates very high contrast levels which assure reliable inspection even under difficult conditions, for example in the case of structured surfaces. Representations of orientation, position and the contours of existing particles are displayed live at an integrated monitor screen, and particle quantity and size are ascertained automatically and displayed as well.

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Image source: Leica Cleanliness Expert

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This system for qualitative cleanliness analysis consists of a fully automated reflected-light microscope, a digital camera and an image analysis system. Particles can be measured in all relevant directions in space (height, length and width).

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Image source: acp

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Integration of optical filters into this inspection system, which is based on illumination of the surface under test by means of direct sidelighting, results in such high contrast that reliable particulate cleanliness inspection is even assured under difficult conditions, for example in the case of structured surfaces.

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TECHNOLOGY OVERVIEW

Ultrasonic Cleaning EFFICIENT CLEANING WITH ULTRASOUND FROM COARSE TO FINE

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cohesive forces are overcome. This causes the formation here’s hardly a company today that can do without parts of millions of microscopically small bubbles. During the and surface cleaning. This work step can be executed subsequent pushing phase, these cavitation bubbles are in an extremely effective, economic and ecological fashion rendered unstable and collapse (implode), and they generate with ultrasound in numerous manufacturing applications, hydraulic impacts with considerably high energy densities, as well as in the field of MRO. Regardless of whether coarse contamination needs to be removed, or highly sensitive, finely thus causing micro-currents in the liquid. When these strike a surface, they blast off contamination which has been structured parts have to be cleaned. partially dissolved with a suitable cleaning agent and rinse Ultrasound technology has only been in commercial use the “dirt” away. for about 100 years. It was sparked off by the sinking of Ultrasound is rendered effective due to the fact that the Titanic after it collided with an iceberg. This led to the cavitation occurs at boundary surfaces – precisely development of an ultrasonically supported where contamination tends to positioning system for maritime adhere to the surface. This traffic. A great variety of cleaning effect is also other applications for known as “microthe use of sound scrubbing” or waves evolved “electronic thereafter, brushing”. amongst others And ultrasonic ultrasonic cleaning is just cleaning. as thorough Its mode of as it is gentle, operation because the allows for effects of efficient, cavitation – environmentally when applied for sound removal a short time only – of particulates and leave even sensitive film-like contamination, surfaces unscathed. which is also gentle Image source: Bandelin on the material to be 1 cleaned, for tasks in Ideal Oscillation Due to the great intensity of the alternating sound pressure during the pulling phase of the oscillation cycle, the liquid is broken up during exposure of the cleaning bath to ultrasonic waves. manufacturing, as well The sound waves are Cavitation bubbles are formed as a result. as in MRO – even for produced by means parts with difficult to of a generator which access hollow spaces, for example blind holes, knurling and converts the normal electrical mains frequency of 50 to 60 grooves. Complete sub-assemblies, for example gear units, no Hz into high-frequency oscillation. This electromagnetic longer need to be dismantled for cleaning. oscillation is then transformed into mechanical oscillation of the same frequency by so-called sonic transducers.

The dimensions of the oscillator are decisive with regard to Micro Scrubbing based on Liquid Currents the working frequency.

Ultrasonic waves develop their full cleaning effectiveness The sound waves spread longitudinally through the cleaning in a liquid bath. The cleaning effect is based on cavitation: bath. This results in aphonic and phonic zones. Ultrasonic When a liquid is subjected to ultrasonic sound, the high intensity of the alternating sound pressure during the pulling oscillation can be more evenly distributed in the cleaning liquid with the help of frequency modulation (sweep function). phase of the oscillation cycle breaks up the liquid – the

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Doris Schulz, Schulz.Presse.Text, Korntal, Germany

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Image source: Weber Ultrasonics

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Not only can coarse contamination be removed by means of ultrasonic cleaning, highly sensitive, finely structured parts can be cleaned as well.

Decisive Criterion: Frequency The ultrasonic frequency has a significant influence on cleaning results. Generally speaking, the lower the frequency, the larger the cavitation bubbles and thus the more energy they release.

Low frequencies exert powerful cleaning forces on the surface of the part, which nevertheless have only minimal depth penetration for cleaning pores and structures in boundary surfaces – and vice versa. Reference values for the selection of ultrasonic frequencies: 25 to 35 kHz Removal of particles, grease, oil and other contamination from hard, unpolished surfaces, for example engine cleaning 40 to 80 kHz Final cleaning tasks and cleaning of porous and polished surfaces 120 kHz and above Micro-cleaning tasks and cleaning of finely porous and high-gloss, polished surfaces As of 500 kHz Cleaning of finely structured and sensitive surfaces, for example wafers and components from the fields of micro and nano-technology, LCD technology and photovoltaic

In particular in the case of components with highly complex shapes, multi-frequency or mixed frequency ultrasonic systems are used to an ever greater extent which generate several frequencies, for example 25 and 40 kHz. As a result of the mixed numbers of larger and smaller cavitation bubbles, ideal cleaning forces are achieved at outside surfaces and boundary surfaces.

Megasound for Sensitive Surfaces Particles with sizes of down to roughly 4 μm can be removed with frequencies of up to 400 kHz. High frequency sound waves (600 kHz to 4 MHz) are used in order to remove smaller particles down into the nano range. Frequencies as of one megahertz are designated megasound. These frequencies generate directional micro-currents which remove contamination from extremely sensitive substrates and valleys in microstructures in a residue-free, nondestructive manner.

29 AUGUST 2011

ICT

TECHNOLOGY OVERVIEW

Matching the Ultrasonic System to the Goods to be Cleaned.

The number of oscillators is decisive with regard to the performance of an ultrasonic cleaning system. As a rule, good cleaning results can be achieved with a power rating of 8 to 10 W per litre. This means that for a cleaning bath with 100 litres, 800 to 1000 W of output power is required, which can be controlled via the generator within a range of 10 to 100% either in steps or in an infinitely adjustable fashion.

Due to the fact that the sound waves are propagated longitudinally from the sound emitting surface,

the arrangement of the oscillating elements has a considerable influence on cleaning results. For example, if the oscillators are only attached to the floor of the working chamber or cleaning basin, the sound waves are emitted vertically up to the surface of the bath, from where they are reflected back down to the floor.

This has consequences for the cleaning of parts with hollow spaces and blind holes: If bubbles form in these areas, the air creates an obstacle for the sound waves and no cleaning takes place. For this reason it must be assured that all hollow spaces are filled with cleaning fluid, which means that the parts should be oscillated

3

Image source: Amsonic

3

Ultrasonic cleaning systems operated with aqueous media are frequently used for micro-cleaning of sensitive components. Thanks to their modular design, they can be precisely matched to the actual cleaning task.

30 AUGUST 2011

Doris Schulz, Schulz.Presse.Text, Korntal, Germany

4

The working frequency of the sonic transducers is dictated by their dimensions.

5 4

As a rule, an ultrasonic power rating of 8 to 10 W per litre of bath liquid assures good cleaning results.

Image source: Bandelin

or rotated within the bath. As a result of the fact that component shapes are becoming more and more complex, ultrasonic cleaning systems are now being equipped with oscillators at multiple locations, i.e. on the floor and the side walls.

Overly dense loading of the bath, for example parts stacked closely on top of each other, or large volumes of bulk goods, prevent the ultrasonic waves from reaching all of the workpiece surfaces to be cleaned.

As a rule of thumb we can say that the surfaces to be exposed to ultrasonic waves should not be bigger than the sound emitting surface. At the same time, the mass of the part(s) should not exceed 50% of the volume of the bath, because the ultrasound cannot otherwise be propagated as required for good cleaning results.

Compatible with All Cleaning Agents Ultrasonic cleaning is possible with aqueous cleaning agents or solvents. The cleaning agent is matched to the material and the respective type of contamination.

If aqueous cleaning agents are used, rinsing cycles are necessary in order to remove the active cleaning substances from the surface, and subsequent drying is required as well. In the case of flammable solvents, the ultrasonic cleaning system must either be explosionproof or be operated under full vacuum. Solvents which boil at high temperatures necessitate correspondingly temperature resistant ultrasonic oscillators.

Efficient and Ecological Cleaning time can be reduced by as much as 90% by using ultrasound in combination with a cleaning agent which is matched to the respective type of contamination. At the same time, cleaning agent consumption can also be reduced.

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31 AUGUST 2011

Image source: Fisa-Schall

ICT

PRODUCT SHOWCASE

BATH MONITORING

SensAction AG

Precise Monitoring of Liquids The LiquidSens sensors from SensAction AG measure concentrations in liquids e.g. cleaning agents (bath monitoring) - highly accurate.

The measurement system LiquidSens evaluates the data during the on-going process

BATH MONITORING

SensoTech GmbH

Quality Optimising of Cleaning Baths In cleaning baths it is essential to monitor the concentration of the cleaning agent for a continuously optimal bath quality. The measurement has to be performed during mixing as well as during the process, as deviations from

CLEANING AGENTS

Bio-Circle Surface Technology GmbH

Bio-Rust – pH-neutral Deruster Bio-Rust is an innovative product for the fast and reliable removal of rust from metals in the pH-neutral range. The bio-deruster produces exceptional results in the fields of slight rust films and fingerprint

and reads out the values immediately. A key advantage of the innovative sensors is that they have no moving parts and therefore are completely free from wear and need just low-maintenance. Their robust construction allows a longterm operation directly in the process while maintaining precision and speed. This is of great importance in many areas of liquids-analysis.

SensAction AG, Rosenauer Strasse 27, 96450 Coburg, Germany, Telefon +49 9561 976230, info@sensaction.de, www.sensaction.de Hall 1, Stand B 230

the target concentration can result caused by losses and disappearances of water due to evaporation. A suitable measuring system is LiquiSonic manufactured

by SensoTech. With the sonic velocity measurement, the system determines the concentration of the cleaning agent directly in the process and contributes in that manner to control the optimal bath reconditioning. The system consists of maximum

corrosion, and also in the removal of thick rust layers.

Tarnish is effectively removed from brass and copper, and the metal will be brightened.

The deruster is water-based and dispenses with aggressive acids in high concentrations.

It contains selected ingredients that are easily biodegradable in accordance with OECD standards. Parts can be derusted even at ambient temperature and with process times of approx.

four maintenance free sensors, made of stainless steel and one controller.

The controller manages the collected measuring data. The connection to the PCS allows to sharpen the bath liquid automatically or to discharge the circulating bath liquid.

SensoTech GmbH, Steinfeldstrasse 1, 39179 Magdeburg, Germany, Phone +49 39203 514100, info@sensotech.com, www.sensotech.com Hall 1, Stand F 615

Bio-Circle Rostvergleich

30 minutes. Rust removal times can be accelerated by increasing the temperature and by using ultrasound.

32 AUGUST 2011

Bio-Circle Rust

Bio-Circle Surface Technology GmbH, Berensweg 200, 33334 Gütersloh, Germany, Phone +49 5241 94430, service@bio-circle.de www.bio-circle.de, Hall 1, Stand A 115

CLEANING AGENTS

NGL Cleaning Technology SA

New cleaning agent for applications after polishing

required in high demanding applications: fast cleaning, preservation of a bright finish surface, easy to rinse and no spots after hot air drying. Parts of high cost have been cleaned with Galvex 18.01.

NGL Cleaning Technology SA,

With Galvex 18.01 NGL will introduce a new cleaning agent without NTA (nitrilotriacetic acid) for the removal of polishing compounds and oil residues on all kind of metals. The new product offers all characteristics

CLEANING AGENTS

Petroferm Inc.

New CleanSafe Aqueous Cleaner for Aerospace Petroferm Inc. introduces CleanSafe 686 Aqueous Cleaner, an innovative cleaning solution recommended for cleaning today’s aerospace components and assemblies. It has been demonstrated to outperform

CLEANING AGENTS

ph-cleantec GmbH

Machine Cleaning with Cutting Oil The well-proven, low pressure hot cleaning technology of ph-cleantec can also be used for the maintenance of tool machines operating with cutting oil or grinding oil.

The gentle cleaning method is based in principle on a

7, Ch. de la Vuarpillière, 1260 Nyon, Switzerland, Phone +41 22 3654666, ngl@ngl-cleaning-technology.com, www.ngl-cleaning-technology.com Hall 1, Stand B 214

the competition in removing the following materials: Aeroshell 500 Turbine Oil, Aeroshell 33 Grease, Ardrox 985 P14, Boelube 70106, Castrol X-52, Houghton Draw V-2000, Ionoplus 3000, Iloform PN 270, Microcut 26D, MIL-C-16173e, Quaker AVR and Rustillo 4135NF. Test results are available upon request. The objective throughout the product development process was to create a high-performance, environmentally-accepted material that would be

straightforward to operate and control. Unlike other products in the marketplace, CleanSafe 686 does not require additives, boosters or pH adjusters to help monitor concentration or maintain cleaning effectiveness.

CleanSafe 686 has a strong possibility to be a market leader due in part to its unique combination of proven cleaning ability, low bath maintenance, versatility, low environmental impact and materials compatibility.

combination of low pressure (up to 8 bar) and 95°C hot water/cleaning agent mixture.

However, for machine cleaning it is important not to drag in any „foreign“ media. ph-cleantec has enlarged their device series to the effect that the cutting oils can also be used for cleaning. The low pressure and the media consumption of only 1,8 l/min guarantee in comparison with a high-pressure cleaner, that sensitive components such

as seals, sensor technology etc. will not be damaged, no chips will get under the guide tracks, the surrounding area or the operator will not be affected, and no high media drag-in gets into the machine.

33 AUGUST 2011

Petroferm Inc., 3938 Porett Drive, Gurnee, IL 60031, USA, Phone +1 859 312-4602, techservice@petroferm.com, www.petroferm.com Hall 1, Stand F 621

ph-cleantec GmbH, Gutenbergstrasse 14, 70736 Fellbach, Germany, Phone +49 711 5180600, info@ph-cleantec.de, www.ph-cleantec.de Halle 1, Stand G 726

ICT

PRODUCT SHOWCASE

CLEANING AGENTS

SAFECHEM Europe GmbH

COMPLEASE – Leasing Concept for Cleaning Processes with Solvents Solvents, especially chlorinated hydrocarbons, offer advantages to numerous applications in precision cleaning or due to certified processes they are required as cleaning agent. With its

CLEANING AGENTS

solvadis gmbh

Cleaning Agents for Different Tasks Solvadis is a major trading and distribution company primarily operating with organic chemicals and additional high quality solutions for surface cleaning. Its surface technology business offers high quality cleaning solutions

CLEANING SYSTEMS

acp - advanced clean production GmbH

CO2 snow jet cleaning for microcomponents and products – dry and inline If one needs to comply with residue standards for parts and products in microtechnology and micromechanics, the CO2 snow jet technology from acp – advanced clean production GmbH can open up

chemical leasing concept COMPLEASE SAFECHEM offers an innovative solution for the process-optimised, ecological, and futureoriented precision cleaning with solvents. The leasing package is customised to meet individual requirements.

Beside the supply and disposal of high quality chlorinated hydrocarbons (Perchlorethylene, Trichlorethylene, Methylene Chloride) or modified alcohol

for the surface technology segment. The product range comprises both pure solvents and mixtures for a wide range of applications, such as nonchlorinated hydrocarbons, modified alcohols, and aqueous cleaning agents. The portfolio also includes associated test procedures, stabiliser systems and cleaning enhancers, aimed to boost application times of the cleaning agents and reduce the corrosion risk of cleaning machines resulting in cost

whole new horizons. The dry and environmentally-friendly technique is process-reliable and gentle on materials.

Integrated into assembly or production lines, it can be used to clean complete products such as relays, sensors, electro-hydraulic switches and pacemakers as well as components such as MIDs, printed circuits and sophisticated contact surfaces.

The sole installation requirement for the cleaning module is an

solvents from Dow in the closed SAFE-TAINER system it includes comprehensive services from SAFECHEM, and CHEMAWARE know how.

Closed cleaning equipment from leading manufactures can be included upon request.

SAFECHEM Europe GmbH, Georg-Glock-Strasse 3, 40474 Düsseldorf, Germany, Phone +49 211 4389-300, service@safechem-europe.com, www.safechem-europe.com Halle 1, Stand G 713

benefits for their customers.

The products offer solutions for a variety of cleaning challenges in industries such as automobile industry, electronics, precision engineering, optics and materials (for example metals, plastics, and glass).

solvadis GmbH, Scharnhölzstrasse 346, 46240 Bottrop, Germany, Phone +49 2041 79620, info-ot@solvadis.com www.solvadis.com, Hall 1, Stand A 104

acp_Reinigen_Mikroteile – The cleaning module is placed in the middle of the picture

acp – advanced clean production GmbH, area approx. the size of a DIN A4 sheet of paper. The module does away with additional handling steps and also logistics processes associated with the input and output of components necessary in conventional wetchemical cleaning techniques.

34 AUGUST 2011

73730 Esslingen, Germany, Operating Site Dürrn, CarI-Zeiss-Strasse 6, 75248 Ölbronn-Dürrn, Germany, Phone +49 7237 44294160, mail@acp-micron.com, www.acp-micron.com Hall 1, Stand C 316

CLEANING SYSTEMS

Amsonic AG

A3 solvent based cleaning state of the art With its broad program of water based cleaning machines and closed circuit units for non chlorinated solvents, spray cleaning and ultrasonic units Amsonic meets the demands of various industries. At parts2clean

CLEANING SYSTEMS

BvL Oberflächentechnik GmbH

Integrated Process Control becomes standard equipment in BvL industrial cleaning systems In foresight of the parts2clean BvL Oberflächentechnik GmbH announces a product innovation.

The light version of Libelle

CLEANING SYSTEMS

Cemastir Lavametalli S.r.l.

Environment-friendly solvent cleaning Cemastir Lavametalli has been one of the leading companies in the production of water metal degreasing machines for more than 35 years and took over the historic brand of solvent industrial cleaning AMA

the Swiss based company will present the latest development of the Amsonic 4000 line, a compact, closed circuit single chamber cleaning unit for A3 solvents.

It complies with the latest VOC regulations as well as with ATEX directive 94/9/EC. The machine is used for small to medium capacities - cleaning of precision tools and turned parts, precision cleaning prior to PVD or CVD coating, cleaning prior to plating or

laser welding - these are only a few applications. Due to its compact construction the Amsonic 4000 requires only little floor space. The cleaning unit is loaded and unloaded manually.

“Fluid Control” will become standard equipment in BvL’s industrial cleaning systems.

From autumn 2011 this process control system will continuously control bath contamination in BvL industrial cleaning systems. This will help plant managers to extend intervals for expensive, time-consuming residual dirt analysis. Even with different impacts of parts the change of baths can be carried out to the optimal point of time and therefore minimizes

defectives and product recalls.

Also filter bursts get detected immediately. This process control permanently helps to ensure even highest delivery specifications.

Universal. The association of these experiences has given shape to a model of great technological innovation, offering incomparable results as it uses a class AIII hydrocarbon solvent or a modified alcohol: CSK series. Characterized by a reduced environmental impact, it completes the wide range of plants functioning with chlorinated solvents by improving the environmental protection. Functioning under

complete vacuum, it offers spray washing option, dipping and solvent steam, together with the ultrasonic system, with cutting edge filtration and distillation systems, answering to the most demanding cleaning needs such as oil, emulsions, chips and contaminant substances removal.

Amsonic AG, Zürichstrasse 3, 2504 Biel, Switzerland, Phone +41 32 3443500, amsonic.ch@amsonic.com www.amsonic.com, Hall 1, Stand C 322 / D 419

BvL Oberflächentechnik GmbH, Grenzstrasse 16, 48488 Emsbüren, Germany, Phone +49 5903 95160, info@bvl-group.de www.bvl-group.de Hall 1, Stand B 202 / C 301

35 AUGUST 2011

Cemastir Lavametalli S.r.l., Via C. Bonazzi 2, 40013 Castel Maggiore (BO), Italy, Phone +39 051 6256111, sales@cemastir.it www.cemastir.it, Hall 1, Stand B 210

ICT

PRODUCT SHOWCASE

CLEANING SYSTEMS

Cold Jet Deutschland GmbH

Complete Automated Dry Ice Blast Cleaning System Cold Jet, LLC, the global leader in environmentally responsible dry ice blast cleaning and production solutions will exhibit at parts2clean a complete automated system. A robot is going to clean live with

CLEANING SYSTEMS

GLA-WEL GmbH

German-Italian cooperation in the mechanical engineering industry GLA-WEL, a machine building company in Lower Saxony, and FIRBIMATIC SPA, a manufacturer of cleaning machines for the cleaning of

CLEANING SYSTEMS

HOBART GmbH

As clean as necessary Requirements on parts cleaning focus on one main point – technical cleanliness. One question always comes up – how clean does it have to be? As clean as necessary would be the answer from Hobart, and the key to keeping the complete process cost-effective. The company

pellets molds and other small parts. Furthermore Cold Jet will showcase its full product range of dry ice pellets and block shaving systems with excellent cleaning performance and the lowest power consumption available among competitive technology. In addition to being clean and safe, it is also important to remember that dry ice is obtained as a byproduct of other industrial processes - i.e. it is made

from reclaimed CO2. It does not produce CO2 or add CO2 to the atmosphere and therefore does not contribute to the greenhouse effect.

industrial parts in Bologna, re-enforce their collaboration.

Both engineering companies take this year’s trade fair parts2clean as an occasion to re-confirm their collaboration which they already have started in 2010. The companies share a joint exhibition stand at the trade show. In their partnership the companies work together in manufacturing and selling machines and services for the parts manufacturing industry in selected countries. Both parties

have agreed on a clear division of work in the building of cleaning machines to make best possible use of their own core competencies in order to drive forward their mutual growth.

COLD JET Deutschland GmbH, Zum Niesenberg 2, 54595 Weinsheim, Germany, Phone +49 6551 96060, info.de@coldjet.com, www.coldjet.com Hall 1, Stand D 409

has focussed on tailoring the cleaning concept to customer specification using reliable single-chamber, multi-chamber and conveyorised lines from the standard range.

Specialised techniques for water treatment, filtration and wastewater treatment keep operating costs for water and waste water as well as chemicals at an optimised level.

GLA-WEL GmbH, Friesenweg 8a, 49324 Melle, Germany, Phone +49 5422 943901, info@gla-wel.de www.gla-wel.de, Hall 1, F 614

HOBART GmbH, Robert-Bosch-Strasse 17, 77656 Offenburg, Germany, Phone +49 781 6000, info@hobart.de www.hobart.de, Hall 1, Stand A 109

36 AUGUST 2011

CLEANING SYSTEMS

KKS Ultraschall AG

Ultrasonic for a Broad Range of Applications At parts2clean KKS Ultraschall AG will present its existing core-competencies in the specific segments of ultrasonic-technologies, industrial cleaning and surface technologies. In addition to multi-frequency-

CLEANING SYSTEMS

PERO AG

Economic parts cleaning solutions Pero AG will present at parts2clean cleaning plants for aqueous solutions as well as for solvents. The German manufacturer presents machines developed and manufactured for world markets at the plant in Gotha (Thuringia)

CLEANING SYSTEMS

plasma technology GmbH

Pre-processing of any sort of small batches PlasmaFlecto10, developed

by Plasma Technology GmbH, allows for surface preparation using low-pressure plasma in laboratories and for small batches. The machine has been developed for clients who want to test

ultrasonic equipment, small ultrasonic tanks, single-chamber cleaning units and customer specific cleaning units the company offers solutions in the field of surface-technologies.

While in ultrasonic cleaning technologies the company covers a wide range of industrial applications it focuses its surface technology competences primarily to the medical industry.

KKS Linearanlage rechts

KKS Schrauben

KKS Ultraschall AG, Frauholzring 29, 6422 Steinen, Switzerland, Phone +41 41 8338787, www.kks-ultraschall.ch, info@kks-ultraschall.ch Hall 1, Stand I 915

and at the headquarters plant in Koenigsbrunn (Bavaria). The leading process engineering of the cleaning plant R1 - working e.g. with 530 x 320 x 200 mm baskets - will be explained. The focus will be on the factors parts cleanliness and batch speed, both relevant to an economic cleaning process. Representing the broad programme of cleaning plants working with aqueous solutions the tunnel plant KDA 35 WST will be on show. Especially for small

cleaning batches in the format of a “shoe box” the performance of a compact cleaning plant will be presented by means of the solvent plant V0.

the whole spectrum of plasma technology for their company’s value chain and to engineer processes. The design of the machine is such that all known variants of plasma processes for surface treatments of a wide range of material can be performed.

Currently, PlasmaFlecto10 is used to purify metal parts as well as to activate plastic parts and silicon hoses prior to adhesion.

PlasmaFlecto 10 is a high-

capacity, multifunctional plasma equipment for R&D as well as serial production of low piece numbers or small components.

PERO AG, Hunnenstrasse 18, 86343 Königsbrunn, Germany, Phone +49 8231 60110, pero.info@pero.ag, www.pero.ag Hall 1, Stand A 102 / B 201

37 AUGUST 2011

plasma technology GmbH, Marie-Curie-Strasse 8, 71083 Herrenberg- Gültstein, Germany, Phone +49 7031 9132146, info@plasmatechnology.de, www.plasmatechnology.de Hall 1, Stand E 521

ICT

PRODUCT SHOWCASE

CLEANING SYSTEMS

Dürr Ecoclean GmbH

Fast. Straightforward.

Effective.

At the parts2clean 2011, Dürr Ecoclean will present the EcoCBase W3, a costeffective, high-performance part cleaning system relying on aqueous cleaning technology. Innovative efficiency-boosting features

are the hallmarks of this new, modular equipment generation. The EcoCBase W3 can particularly be used to remove chips and emulsion.

Easy-to-retrofit options make it possible to cover a broad range of cleaning requirements, from the single-stage basic version for simple washing tasks via a two-stage “wash-and-rinse” intermediate cleaning configuration, on to a demanding

“wash-rinse-preserve” final cleaning system.

Dürr Ecoclean GmbH, Mühlenstrasse 12, 70794 Filderstadt, Germany, Phone +49 0711 7006-0, info.filderstadt@ecoclean.durr.com www.durr-ecoclean.com, Hall 1, Stand D 416 / E 515 plasmabrush® is a trade mark of Reinhausen Plasma GmbH.

CLEANING SYSTEMS

Reinhausen Plasma GmbH

Cold.active plasma equipment for industrial use Whether an application is based in the automotive, electronics, medical engineering, household appliance or solar industry – surface cleaning and activation by atmospheric pressure plasma is one of the established

CLEANING SYSTEMS

Karl Roll GmbH & Co. KG

Laid Out for Exceptional Economy Karl Roll GmbH presents its “Advantage” for cleaning with halogen-free hydrocarbon or modified alcohol, a new system which has been specially developed for users with medium throughput volumes and exacting demands for

procedures in many industry sectors today. With Plasmabrush PB2, Reinhausen Plasma will present a high-performance device for industrial use at the parts2clean. The PB2 enables organic contaminants such as soot, lubricant deposits, tenside, solvent and parting agent residue, as well as dust and oxide coating to be cleaned.

Thanks to pulsed gas discharge, the generated plasma is more efficient in the conversion of power, in comparison with

parts cleanliness. The process chamber of this extremely compact cleaning system accommodates baskets measuring 530 x 320 x 200 mm or 480 x 320 x 200 mm (L x W x H). Both the cleaning and the drying process take place in a partial vacuum. Energy required in order to condition the medium in the integrated distillation unit is recovered by means of heat exchangers and made use of within the process.

This, as well as easy access

RP_Anwendung-Reinigen

conventional atmospheric plasmas and cold.active, so that even temperature-sensitive materials can be treated. The space-saving system can be incorporated easily in existing production processes as an integration package.

RP_PB2_Integrationsmodul

Reinhausen Plasma GmbH, Weidener Strasse 16, 93057 Regensburg, Germany, Phone +49 941 40909100, info@reinhausen-plasma.com, www.reinhausen-plasma.com Hall 1, Stand B 211

for maintenance, contributes to economic operation. Thanks to numerous options such as ultrasound, pressure flushing and tube filters, the Advantage can be ideally adapted to individual requirements.

38 AUGUST 2011

Karl Roll GmbH & Co. KG, Kanalstrasse 30, 75417 Mühlacker-Enzberg, Germany, Phone +49 7041 8020, verkauf@karl-roll.de, www.karl-roll.de Hall 1, Stand E 506 / F 605

CLEANING SYSTEMS

Rosink GmbH + Co. Maschinenfabrik

Rosink presents world innovation at parts2clean The Rosink Crossbeam Cleaner is focused on the rapid and economical cleaning and rinsing of long components and was developed due to specific customer requirements. An effective height and width of 1,200 mm x 1,000 mm and

CLEANLINESS CONTROL

HYDAC INTERNATIONAL GmbH

Partner for Technical Cleanliness In addition to the CTU series, which are used to monitor residual contamination values, Hydac will introduce a further generation of new modules of CTM series with the supply and extraction module for special components. The

CLEANLINESS CONTROL

KIENZLE-Prozessanalytik GmbH

Mobile instrument for quick cleanliness checks At parts2clean, KIENZLEProzessanalytik GmbH will show its latest instrument development from the Mini instrument range, the KONTAmini, a compact and mobile hand-held instrument for quick cleanliness checks.

a 2,500 mm loading length allowing it to clean particularly bulky components easily.

In a two-stage process, the components are first cleaned and then rinsed. The speed and travel distance of the rectangular nozzle system, and the duration of the cleaning can be varied by a PLC. At the end of the cleaning process the nozzle system sets back into the starting position and the component can be unloaded.

Rosink GmbH + Co., Maschinenfabrik, Bentheimer Strasse 207, 48529 Nordhorn, Germany, Phone +49 5921 78090, suenneker@rosink.de www.rosink.com, Hall 1, Stand B 218 / C 317

company therefore provides a wide spectrum of extraction devices for verifying the technical cleanliness of components. Furthermore sensors for monitoring, control and visualisation of production will be presented.

Hydac has the hardware and software for recording sensor data for process monitoring. As a worldrenowned filter manufacturer, Hydac produces a filter range with filtration ratings from 1

Registered data will be displayed as KONTAindex, a contamination index value.

Start- and endpoint settings of index scale (0-100% contamination) can be fixed individually by the operator and stored in up to 20 parameter sets. Intuitive operation steps and built-in safety functions enable easy and reliable setting and prevent i.e. from mismatching clean and contaminated calibration test samples. By using light-fibre

HYDAC Bild 2010 CTM1 HYDAC Bild 2010 CTM with Software

mm to 3,000 mm. Automatic backflush filters, strainer filters and candle filters for high standards of cleanliness are part of the comprehensive range.

HYDAC Bild 2010 CTM-EF

HYDAC INTERNATIONAL GmbH, Industriegebiet, 66280 Sulzbach, Germany, Phone +49 6897 50901, info@hydac.com, www.hydac.com Hall 1, Stand G 717

technology and a very slim measure head, a flexible, easy and safe evaluation of existing or absence contamination even on complex or geometrically structured samples becomes possible.

39 AUGUST 2011

KIENZLE-Prozessanalytik GmbH, Lise-Meitner-Strasse 14, 24941 Flensburg, Germany, Phone +49 461 570290, www.kienzle-prozessanalytik.de, info@kienzle-pa.de Hall 1, Stand I 910

ICT

PRODUCT SHOWCASE

CLEANLINESS CONTROL

Leica Microsystems

Leica Cleanliness Expert for Quantitative Particle Analysis Leica Cleanliness Expert is a complete package from Leica Microsystems for quantitative cleanliness analysis of high precision components. It consists of an automated incident light microscope,

CLEANLINESS CONTROL

Quality Analysis GmbH

Clean parts live longer On three pillars-based detection method components testing, environment monitoring and logistics processes are the issues, which necessarily connected in a control loop recorded and influenced so that the products through a

CLEANLINESS CONTROL

SITA Messtechnik GmbH

Maximum Quality during Coating Processes by Controlling the Cleanliness of Parts Surfaces After the manufacturing process, components are mostly contaminated by oils, greases or cooling lubricants which have to be completely removed before coating.

a digital camera and image analysis system. As particle length and width as well as height may be functioncritical parameter, Leica Cleanliness Expert offers this additional measuring dimension. The advantage: more reliable determination of the product’s cleanliness.

Fibers and particles are detected in the live image and can be distinguished as reflective or non-reflective within one scanning process.

Measurement parameters and system settings are fully reproducible and automatically documented in the report. A scanning algorithm enables particles of any size to be detected and then reclassified and documented in the list of results.

systematic process can be carried out and evaluated.

These themes and priorities are all provided by the Quality Analysis GmbH with its own engineering and clean room laboratory, including the wellestablished lab equipment. A high degree of individual and component-specific processes is at the top priority to ensure the required conditions.

.

Leica Microsystems, Ernst-Leitz-Strasse 17-37, 35578 Wetzlar, Germany, Phone +49 6441 294100, www.leica-microsystems.com, sales.germany@leica-microsystems.com Hall 1, Stand F 613

Quality Analysis GmbH, Kirchheimer Strasse 188, 73265 Dettingen, Germany, Phone +49 7021 737810, info@quality-analysis.de www.quality-analysis.de Hall 1, Stand D 408

Residual contamination disturbs the adhesion between parts surface and coating and reduces the adhesive strength significantly.

SITA Messtechnik GmbH developed new fluorescence measuring devices for the cleanliness control and thus detecting slight contamination on surfaces.

A continuous monitoring of parts by the device user ensures an immediate detection of unacceptable contamination as well as a control of the cleaning process.

The robust process measuring technology SITA clean line CI allows a contact-free detection of residual contamination on parts surfaces by measuring the fluorescence. The higher the contamination the higher is the measured fluorescence respectively. The measuring system is a customized solution adapted to various production processes.

For random and single quality controls in the laboratory or at the process, the mobile and hand-held measuring device SITA CleanoSpector is used.

40 AUGUST 2011

SITA clean line CI – Sensor of Measuring System

SITA Messtechnik GmbH, Gostritzer Str. 63, 01217 Dresden, Germany, Phone +49 (0)351-871-8041, info@sita-messtechnik.de, www.sita-process.com Hall 1, stand F 601

MEDIA CONDITIONING

EnviroFALK GmbH

DI water for ultra-pure surfaces in medical technology Highest possible surface cleanliness requires innovative rinse water conditioning defined to the specific application. This is especially true for the manufacturing of medical technology products.

MEDIA CONDITIONING

GÜTLING Wassertechnologie GmbH

Modern process and wastewater treatment Increasing demands on the water used in cleaning processes and the requirement to carry water as much as possible in a circle or comply with legal limits, require modern methods in the field of

WORKPIECE CARRIERS

Butek Makine San. ve Tic. A.S.

Workpiece Carriers for Optimized Cleaning Processes BuTech Engineering develops technologies for industrial parts cleaning, handling and automation for individual needs. The company offers numerous structures in workpiece carriers, washing

Reverse osmosis installations and mixed bed ion exchangers remove salts from water that otherwise, after the rinsing process, would leave stains on the dried surface.

Unlike mixed bed cartridges that have to be regenerated externally, the EnviroFALK EDI cell (electrodeionisation) can be regenerated on site by means of electric current, thus saving the costly shipment of cartridges. And what’s more: EDI provides

consistently high water quality. The use of suitable materials, high-grade welding processes, ultrafiltration and UV radiation can permanently minimise contamination by microorganisms and endotoxins.

water treatment. Guetling will present at parts2clean reverse osmosis technology with a type maxiRO and a permeate capacity of 450-5000 l/h in cabinet design with a modern microprocessor control.

For wastewater treatment and recycling of purified water Guetling will show the latest version of its vacuum evaporator EVALED series.

The plants with a capacity of 30-2000 liter/h distillate

combine excellent quality with cost-efficient operation in a compact and inexpensive construction.

boxes, and wire baskets.

They are uncomplicated, stackable, resistant, robot adjustable, safe and full adapted to the cleaning methods and processes.

BuTech offers intelligent systems e.g. combinations of sheet metal and wire with teflon / delrin or plastic in which workpieces are cleaned safely and gently. Another innovation is the development and construction of workpiece carriers with clip systems

EnviroFALK GmbH, Gutenbergstrasse 7, 56457 Westerburg, Germany, Phone +49 2663 99080, info@envirofalk.com www.envirofalk.com, Hall 1, Stand C 320

Gütling Evaled

Gütling Zoom Entsalzung maxiRO

GÜTLING Wassertechnologie GmbH, Merowingerstrasse 7, 70736 Fellbach, Germany, hone +49 711 5185500, guetling@veoliawater.com www.guetling.com, Hall 1, Stand D 424

for different work pieces which allow a cost saving and flexible use.

41 AUGUST 2011

Butek Makine San. ve Tic. A.S., Nosab Nilüfer Org. San. Bölgesi Köknar Cad. No. 7, 16140 Bursa / Nilüfer, Türkey, Phone +90 224 4111675, info@butek.com www.butek.com Hall 1, Stand D 407

ICT

PRODUCT SHOWCASE

WORKPIECE CARRIERS

Metallform Wächter GmbH

Part handling before the hardening minimised Due to the high temperatures prevailing in hardening processes, special containers are required for this process.

The parts to be hardened must therefore be moved from a cleaning or shipping basket into the hardening container. This is

WORKPIECE CARRIERS

Schnee Gruppe, Fischer-Draht

Wire-Folding Basket in Premium Quality Lean Production’ – a thought which will be even more important for companies.

With the cleaning baskets of Fischer-Draht companies can fulfill present requirements to the optimum. The baskets can be used not only for cleaning

usually done manually, causing high labor costs. Besides, there are the risks of re-contamination and that the parts get damaged.

In order to minimise these risks, Metallform has developed a solution, which allows that the parts can be relocated after the cleaning in one „turn“: An adapter plate as well as the hardening container, both precisely geared to the cleaning basket with its load of 300 parts, will be put onto this cleaning basket and turned by 180° in one direction. This

but also for transport, for storage and for provision of the workpieces, so that time-consuming measures for parts handling will no longer be necessary. At parts2clean, Fischer-Draht presents the innovative wire-folding basket.

It supports once more the thought of ‚Lean Production‘, because this basket takes only 1/4 of its original volume in the folded state. Thus, it is possible to transport and to storage the baskets efficiently

operation moves all 300 parts in one go into the hardening container, virtually with a flick of the wrist. This „semi-automatic“ operation before and after the hardening saves a significant amount of cost every year.

Metallform Wächter GmbH, Gewerbestrasse 35, 75015 Bretten, Germany, Phone +49 7252 94260, kontakt@metallform.de www.metallform.de, Hall 1, Stand F 612 / G 709

and cheap after use. High transportation and storage costs become a thing of the past.

Schnee Gruppe, Heinrich Fischer GmbH & Co. KG, Flandernstrasse 78, 72474 Winterlingen, Germany, Phone +49 7434 9320, info@fischer-draht.de, www.schnee-gruppe.com Hall 1, Stand G 703

WORKPIECE CARRIERS

Zell Metalltechnik GmbH

Carrier Systems for Sensitive Parts Zell 66

Zell Metalltechnik GmbH will present cost-saving carrier system for sensitive components as bulk material or single positioning. This system ensures surface gentle storage, transportation and cleaning processes.

The materials used are temperature-, acid- and oil resistant. The system is compatible with existing transport- or cleaning systems, space-saving, automatable and suitable for

Zell 14

conveyor belt. Competent support from development to realization is ensured, for standard applications as well as for special solutions.

Zell 8

Zell Metalltechnik GmbH, Zum Tannenesch 24, 89584 Ehingen- Volkersheim, Germany, Phone +49 7391 770040, info@zell-gmbh.de, www.zell-group.de Hall 1, Stand A 112

42 AUGUST 2011

DRYING SYSTEMS

Knoth Automation GmbH

Drying module with vacuum chamber Increasing cleanliness requirements necessitate in a sophisticated cleaning solution – not only at the end of the production line, but also in between. With its patented compressed air cleaning units, Surface-

CLEANING MEDIA

OTEC Präzisionsfinish GmbH

Innovative mass finishing compound The new SC 36 compound from OTEC represents the birth of a completely new generation of highperformance compounds.

For the first time ever, it has been possible to integrate a precipitant into a compound

Aircleaner Knoth automation offers a solution which achieves excellent results due to customized cleaning bars for every individual part. At parts2clean the company will showcase a drying chamber with vacuum chamber. The part gets predried with compressed air before it is delivered into the vacuum chamber. By doing so residues can be removed from the work piece in the vacuum chamber at relatively

low temperatures and the cleaning system gains more time for the actual cleaning process.

Knoth Automation GmbH, Schillingstraße 17, 1220 Vienna, Austria, Phone +43 1 33037380, office@knoth-automation.at www.knoth-automation.at, Hall 1, Stand D 412

without detriment to the mass finishing process. The new compound has been tested and well received by numerous customers. That depends among others on the following advantages: Flakes automatically form in the waste water as it leaves the process container whenever ceramic and/or plastic grinding media are used. It can easily be recycled via filter bag or cascade tanks.

A considerable improvement

in the cleaning effect of centrifuges is achieved. The fine waste particles from plastic grinding media can normally cause problems when recycling, since they are difficult to separate out. The flocculation effect achieved by the SC 36 compound makes it much easier to separate out fine debris.

gives a long-lasting performance.

VCI NOXY can be activated by unscrewing the red cover before closing the pack. This also allows the activation and deactivation several times. The diffuser quickly and constantly spreads the VCI molecules until

the environment is saturated.

Thanks to the vibrations during the transport, VCI NOXY spreads the VCI molecules inside the packaging. VCI NOXY is suitable to be applied inside the voluminous packaging and automotive CKD.

OTEC Präzisionsfinish GmbH, Dieselstrasse 8-12, 75334 StraubenhardtFeldrennach, Germany, Phone + 49 7082 491120, info@otec.de, www.otec.de Hall 1, Stand C 311

CORROSION PROTECTION / PACKAGING

PROPAGROUP GmbH

VCI NOXY – The VCI diffuser patented VCI NOXY diffuser consists of a plastic container assembled on a special spring from which the VCI molecules are spread. It can be easily applied inside the packaging and it provides a better protection against corrosion.

Furthermore, it is reliable and it

43 AUGUST 2011

PROPAGROUP GmbH, Am Reinertshaus 12, 96328 Küps, Germany, Phone +49 9264 801664, info@propagroup.de, www.propagroup.de Hall 1, Stand G 715

ICT

PRODUCT SHOWCASE

DEGAUSSING

Vallon GmbH

Customised Degaussing Solutions Vallon GmbH develops and produces degaussing tools and degaussing systems since 1965. The experience of more than 40 years allows offering reliable standard solutions as well as customised installations,

ready for connection. In an own application laboratory, the company develops in close cooperation with customers the best degaussing solution, considering not only technical but also economical aspects.

Whether bulk goods, palletised items or individual parts are involved the work piece weight can vary from only one gram to several tons. Powerful low frequency generators guarantee thorough and durable

degaussing. The degaussing solutions enable twentyfour-seven operation, both manually and fully automatic with customised feeding systems.

Vallon GmbH, Im Grund 3, 72800 Eningen, Germany, Phone +49 7121 98550, info@vallon.de, www.vallon-degaussing.com Hall 1, Stand H 804

CLEANING AND TRANSPORTATION TANKS

Norddeutsche Seekabelwerke, POLY-NET

For surface protection and maximised cleanliness POLY-NET washing meshes are used as intermediate layers in washing baskets, and prevent the parts stocked on top of each other from actually touching. Costly damage is thus dependably avoided. At the same time, the special mesh construction reduces the area of contact with the workpieces. The

NSW Zwischenlage fĂźr Waschprozesse

NSW Waschgitter

minimised number of supporting points ensures unimpeded contact of air and washing liquid with the surface of the components involved. This means that the cleaning agent can be deployed to optimum effect, and the drying process is assisted as well. Besides a choice of mesh sizes, there are also different

materials available: polypropylene (PP) for aqueous cleaners, and polyamide (PA) for chemical cleaning processes. POLY-NET washing meshes can also be used for handling hot solvents.

They can be supplied either by the metre or as cut-to-size blanks, matched to the particular size of the washing baskets involved.

Norddeutsche Seekabelwerke GmbH, Kabelstrasse 9-11, 26954 Nordenham, Germany, Phone +49 4731 820, www.nsw.com

Vertrieb POLY-NET‚, 26954 Nordenham, Germany, Phone +49 4731 821249, nsw@corning.com www.polynet.de, Hall 1, Stand B 216

ICT

EXHIBITIONS CALENDAR

DECEMBER 2011 PARTS2CLEAN Pavilion Bangalore, India December 6-9, 2011 www.parts2clean.de

JANUARY 2012 EUROGUSS Nuremberg, Germany January 17-19, 2012 www.euroguss.de

FEBRUARY 2012 WIN - part 1 Istanbul, Turkey February 2-5, 2012 www.win-fair.com PARTS2CLEAN Pavilion Istanbul, Turkey February, 2-5, 2012 www.parts2clean.de SAMUMETAL Pordenone, Italy February 1-4, 2012 www.samumetal.it MACHINEX ARABIA Jeddah, Saudi Arabia February 19-22, 2012 www.machinex-arabia.com

MARCH 2012 MIDO Milan, Italy March 11-13, 2012 www.mido.it INDUSTRIE Paris, France March 26-30, 2012 www.industrie-expo.com

APRIL 2012 METEF Verona, Italy April 18-21, 2012 www.metef.com HANNOVERMESSE Hannover, Germany April 23-27, 2012 www.hannovermesse.de

45 AUGUST 2011

ICT

ZOOM ON EVENTS

9TH PARTS2CLEAN FROM 25 THROUGH 27 OCTOBER 2011

N

euffen – Roughly 240 exhibitors will be represented when the 9th parts2clean opens its doors at the Stuttgart Exhibition Centre on the 25th of October, 2011.

And they’ll present the world’s most comprehensive range of products and services for requirements oriented, economical industrial parts and surface cleaning. Representative, multi-industry information and procurement offerings covering the entire process sequence will thus await the visitors – regardless of whether simple degreasing or complex micro-cleaning is involved.

Beyond this, valuable know will be imparted by the integrated expert forum held in German at the leading international trade fair for industrial parts and surface cleaning.

Whether degreasing, deburring, cleaning, residual

contamination monitoring or temporary corrosion protection is concerned – cleanliness requirements for components, products, machines and equipment have become much more strict in recent years. At the same time, cost pressure is also on the rise. And thus manufacturing firms, as well as maintenance service providers and remanufacturers, are faced with the question of how the required levels of cleanliness can be achieved and maintained efficiently and ecologically. Roughly 240 exhibitors from 16 countries in Europe, America and Asia will provide the answers at parts2clean. Just under 15% of the exhibitors at this year’s leading international trade fair for industrial parts and surface cleaning come from outside of Germany.

46 AUGUST 2011

New Developments in All Exhibition Segments “Numerous companies will present new and further developed products targeted at optimising the cleaning process in various applications and in different industry sectors.

Primary emphasis is being placed on increased energy efficiency, process reliability and economy”, reports Hartmut Herdin, managing director of event promoters fairXperts GmbH. And thus participating equipment manufacturers will showcase new systems for wet chemical cleaning which make use of aqueous media as well as solvents, and special processes such as cleaning with carbon dioxide and plasma. The range of innovations goes right on up to options for leasing the entire cleaning process. There are lots of new cleaning media waiting to be discovered as well. These include, for example, a pH neutral water-based rust-removing agent which functions at room temperature, a cleaning agent developed especially for use prior to hardening processes, aqueous media for use in photovoltaic applications and high performance barrel finishing compounds. New developments in the areas of cleaning containers and workpiece carriers contribute to reduced processing times and minimised manual parts handling. The exhibitors also have a number of innovations up their sleeves with regard to bath monitoring and maintenance systems, as well as systems for monitoring film-like and particulate contamination, amongst others reverse osmosis

systems for the efficient reconditioning of process water and wastewater, devices for measuring concentrations in liquids and particulate monitoring in manufacturing environments. parts2clean exhibitors will also offer innovative solutions for effective and economic corrosion protection, preservation and packaging of cleaned parts and surfaces.

47 AUGUST 2011

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TECHNICAL ADVISORY BOARD

Redazione - Sede Legale: Via Enrico Tazzoli, 15 20031 - Cesano Maderno (MB) - Italy

Adolfo Acquati: Enamelling lines

Dr. Ezio Pedroni: Coil coating

Attilio Bernasconi: Paint stripping technologies and cryogenic processes

Loris Rossi: Surface treatment on aluminium

Ernesto Caldana: Coil coating pretreatment Michele Cattarin: Electrostatic application of powder coatings EDITOR IN CHIEF/ DIRETTORE RESPONSABILE

Enzo Colapinto: UV systems and technologies

The first international magazine for surface treatments

ALESSIA VENTURI venturi@ipcm.it

2011 2nd YEAR Bimonthly N°10-July www.ipcm.it

Ivano Pastorelli: Measurement and quality control

EDITORIAL DIRECTOR / DIRETTORE EDITORIALE FRANCESCO STUCCHI stucchi@ipcm.it

Dr. Felice Ambrosino: Marketing

MEDIA SALES

NICOLE KRAUS kraus@ipcm.it MARCELLO MOLINARI molinari@ipcm.it

Giuseppe Tarquini: Liquid coatings Gianfranco Verona: Water treatment Dario Zucchetti: Coating lines Lauro Gatti: Air treatment

EDITORIAL BOARD

EDITORIAL OFFICE / REDAZIONE PAOLA GIRALDO giraldo@ipcm.it FRANCESCO STUCCHI stucchi@ipcm.it

Dr. Thomas Schmidt: Powder coatings and inks

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Prof. Massimiliano Bestetti: Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Section of Applied Chemistry and Physics Dr. Franco Busato: European environmental legislation and new technologies Prof. Paolo Gronchi: Department of Chemistry, Material and Chemical Engineering, Politecnico of Milan – Chemical Engineering Section

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