CASE STUDY SEVEN
Micro Bubble Coolant Cleaning and Purification Unit | JCC-HM Tripling Cleaning Solution Life While Cutting Waste Disposal Costs by Two-Thirds DETAILS CUSTOMER OVERVIEW A pressed components manufacturer cleaned each part after pressing to remove residual press oil. Over repeated cleaning cycles, oil concentration in the cleaning solution built up, leading to a range of downstream problems. To address this, the customer treated the cleaning machine's tank solution with JCC-HM, continuously removing press oil and keeping the solution clean.
WASHER (TANK 300 L) TARGET WORKPIECES Parts with Press Oil Remaining
KEY CHALLENGES
Residual Oil Caused Parts to Stick Together After Cleaning As press oil accumulated in the cleaning solution, cleaned parts became sticky, making transportation, counting, and handling more difficult. Sticky parts also increased the risk of customer complaints and rework.
Part Rewashing Increased Labor and Processing Costs When oil contamination compromised cleaning performance, parts had to be rewashed to meet quality requirements, resulting in additional labor and processing costs.
High Cleaning Solution Disposal Costs To prevent contamination-related issues, approximately 3,000 liters of cleaning solution were discarded each month across ten press machines, resulting in monthly industrial waste disposal costs exceeding $3,200.
RESULTS: After Introducing the JCC-HM By continuously removing press oil from the cleaning solution, Sugino’s JCC-HM restored cleaning performance, reduced waste generation, and significantly lowered disposal costs. Tripled Cleaning Solution Service Life The JCC-HM Weir and Baffle filterless system enabled the customer to extend the usable life of the cleaning solution by three times, reducing the frequency of fluid replacement. Eliminated Oil Build-Up That Caused Sticky Parts By removing accumulated press oil from the cleaning solution, JCC-HM prevented parts from sticking together after cleaning, improving downstream handling and reducing the likelihood of rework Reduced Waste Cleaning Solution Volume by 67% Monthly waste cleaning solution volume decreased from approximately 3,000 liters to 1,000 liters, reducing waste generation to one-third of previous levels.
Industrial waste costs: $3,255 USD/month $1,070 USD/month
Savings of: $2,185 USD/month × 12 months = $26,220 USD reduction • Data and values shown are representative values obtained by our company based on prescribed test methods and are not guaranteed. • The information provided is current as of June 2020 • Unauthorized copying and reproduction is prohibited.
Cut Industrial Waste Disposal Costs by Two-Thirds Industrial waste disposal costs decreased from approximately $3,255 per month to $1,070 per month. Delivered More Than $26,000 in Annual Savings The reduction in waste disposal costs generated annual savings of approximately $26,220.
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