Modified Alcohol Cleaning Solution
Case study: A precision mechanics company achieved cost savings, increased operating efficiency, and reduced energy consumption by transitioning from aqueous cleaning to solvent cleaning
A precision mechanics company specialising in the hydraulics sector has a success story worth noting. Founded by three engineers in 2002, this Italian company quickly gained a reputation as a reliable industry sub-contractor for precision mechanical parts manufacturing. The company has grown from a small enterprise with less than 10 employees to a vibrant organisation with over 30 staff and an annual turnover of almost €4 million. They work with various materials, including aluminium, steel, and cast iron, and believe in constantly introducing performance-oriented technologies to maintain their competitive edge. Their production plant has 11 horizontal and 2 vertical machining centres, 3 turning machines, and can perform various operations, including surface treatments, heat treatments, and pre-assembly of parts in plastic and/or other components, depending on customer specifications and sectoral specificities. The company's manufactured products are critical for providing functionality to integrated systems, which is why attention to detail, cleanliness, and precision are essential. During the production process, two main types of lubricants are used, including one suitable for processing aluminium. Finally, at the end of the production cycle, the workpieces undergo a delicate and critical cleaning process to remove any impurities and oil remnants so they can be further processed or assembled downstream in the supply chain.
The company had been relying on a water-based cleaning system, but it was inflexible and inefficient, with disposal costs every three months. To enhance operational performance, the company recognised the need to improve its parts cleaning process. While evaluating alternative cleaning technology, the company came across IFP, a leading manufacturer of modified alcohol cleaning machines, at a trade show. IFP invited the company to perform cleaning trials and comparative tests on its machines, and recommended the modified alcohol solvent DOWCLENE™* 1601 provided by SAFECHEM for optimised cleaning results. The company invested in an industrial solvent cleaning machine from IFP, which would be running on DOWCLENE™* 1601. This decision was based on multiple trials and evaluations, and solid validation from other companies adopting modified alcohol cleaning machines for their parts cleaning requirements.
IFP recommended the use of DOWCLENE™* 1601, a high-performance and virgin-grade solvent with non-polar and partially polar properties, for optimal cleaning outcomes. The solvent can effectively eliminate oils, greases, as well as certain polar contaminants.
Kemet is proud to serve as the exclusive UK distributor for IFP cleaning machines. With a long-standing reputation for excellence in the precision cleaning industry, Kemet is uniquely equipped to provide our customers with access to the latest advancements in cleaning technology. As an authorised distributor, we are committed to delivering unparallelled customer service and technical support to help our clients achieve optimal cleaning results with IFP's innovative machines. Our team of experts is dedicated to providing comprehensive solutions tailored to each customer's unique needs, whether they are looking to optimise their cleaning process for efficiency, reduce costs, or improve overall cleaning performance. At Kemet, we believe that our partnership with IFP enables us to provide our customers with the highest quality precision cleaning solutions available in the market.
Benefits of Using Modified Alcohol Cleaning Solution: High Flexibility, Time Savings, and Reduced Energy Costs
The effectiveness of cleaning largely depends on both the cleaning machinery and the cleaning solution used. DOWCLENE™* 1601 is a solvent with proven outstanding solvency power, process stability, and reliability, making it an excellent choice for achieving cleaning excellence. The solvent is distributed by Univar Solutions, SAFECHEM's partner, in the SAFE-TAINER™ System, which is an active risk management measure developed by SAFECHEM to ensure safe and sustainable transport, storage, and handling of the solvent. SAFECHEM's solvent control kit, MAXICHECK™ DCL 1-N, was utilised by the company to conduct routine monitoring of the quality of DOWCLENE™* 1601 cleaning solvent and to detect any potential negative changes. These observations are meticulously documented in an operating diary and provided to SAFECHEM for evaluation and consultation purposes.
The modified alcohol cleaning solution offers numerous benefits, including increased flexibility, time savings, and reduced energy costs. The combination of IFP's innovative cleaning equipment and the unique properties of DOWCLENE™* 1601 has not only improved cleaning performance but has also led to efficiency gains and cost savings. With the new cleaning equipment, 4 trays of different metal types can be cleaned in one cycle, and the machine can automatically spray protection oil on cleaned components. The machine's optimised drying function has also eliminated the need to blow dry small components, resulting in reduced energy consumption and cost savings. The General Manager of the company stated that the results achieved with the IFP machine and DOWCLENE™* 1601 have been impressive and highly effective. The company recommends this solution to other companies that need to engage in metal parts cleaning.
