| Customer | Engineering company |
| Sector | Drive technology |
| Industry | Automotive industry |
Issue
Machining technology utilises a variety of cutting tools and procedures. Accordingly, a wide range of lubricants is also used. What do they all have in common? At the end of the process, the cutting material must be separated from the lubricant. This is because liquid residues on the finished workpiece sometimes negatively impact further processing and storage.
Challenge
To optimise the efficiency of the entire production process, all production steps are regularly put to the test. As the residue-free removal of lubricants and additives at the end of the machining process also constitutes a relevant cost factor, it is necessary to identify and implement the potential for optimisation.
The solution is regarded from a 360° perspective: Sinner’s circle.
It is possible to solve a task in a variety of ways. We take an integrated approach. This is why we look at all contributing factors that are relevant for the wash result and analyse how they influence each other. Sinner’s circle names temperature, time, chemistry and mechanics as decisive factors for the wash result. If the influence of one component decreases – for example, the temperature is lowered – the influence of the other factors must compensate this to achieve an identical cleaning result. In light of these interrelationships, we analyse the situation and develop solution strategies that yield a significantly improved result.
Analysis
The company produces large quantities of components specifically for the automotive industry. The process in question involves the inner spaces of a variety of components on a cutting tool. Depending on the process, lubricants and additives are used, which then have to be removed from the workpiece again.
The broaching oil is cleaned from the component immediately after the inner space has been cleaned. To do so, workpieces are cleaned at 65-70°C. A strongly alkaline cleaning agent is used for this.
The cleaning result is described as satisfactory.
Best advice
Caramba assessed the general conditions and carried out various test washes on the system.
In the test series, a variety of surfactant solutions were run at different bath temperatures on the system. The aim was to carry out the washes at lower temperatures in a less alkaline environment and to achieve at least equivalent results. The best result was achieved with I-Line AD-10, a slightly alkaline cleaning agent that does not require special labelling.
Due to the good cleaning results already achieved at lower temperatures, Caramba recommended adjusting the wash solvent in future with I-Line AD-10 at a concentration of 3.5% at 50°C.
Caramba effect
The I-Line AD-10 is a cleaning agent that is exempt from the labelling requirements of the Hazardous Substances Regulation. Simplified handling eliminates labour-intensive storage and disposal procedures.
Thanks to the high efficiency of the cleaning agent, system temperatures can also be reduced, which leads to noticeably lower energy costs during use. Due to the shortened warm-up phase of the system, the lead time is reduced when starting up the system.
» Lower energy costs due to lower temperatures
» Time savings due to a shortened warm-up phase
» Reduced workload and costs through simplified occupational safety regulations
Ein rundes Ergebnis im Sinnerschen Kreis.
The Caramba effect moved the balance of power in Sinner’s circle. The improved wash result with the same wash mechanism and time, despite a lower temperature, demonstrates the high efficiency of the cleaning chemistry.
Optimal selection of the chemistry components resulted in successful integration into the wash process and a cost-effective solution for the customer.
before
after
Product used
I-Line AD-10
For efficient removal of drawing and punching oils, grease and stubborn particulate contamination.
- Does not require special labelling
- Especially low foaming
- Demulsifying action
- Contains temporary corrosion inhibitors
- pH value at 1% concentration (±0.5): 9
Area of application
The slightly alkaline cleaning agent I-Line AD-10 is for efficient removal of drawing and punching oils, grease and stubborn particulate contamination. Its particularly low-foaming combination of surfactants ensures problem-free use in spray procedures. The industrial cleaning agent includes special demulsifiers to prolong the service life of the cleaning bath. The temporary corrosion protection included protects parts that are particularly sensitive to corrosion.
Responsible person at Caramba
„With my customer, we were able to replace a highly alkaline cleaning agent with a cleaning agent exempt from labelling requirements. This is a positive step towards employee and environmental protection. Changing the product meant the temperature was also lowered, which is a tremendous achievement in economic terms. Overall, a great outcome for both sides.“
Do you have any questions?
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+49 (0)203 – 7786 333
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