1. Cost efficiency. In an open-top degreaser, most of the solvent is not used for the cleaning process itself. Instead, it is evaporating into the atmosphere, which is both a cost and environmental problem. Figure 1 shows the amount of solvent required to remove 100 Ibs of oil and the corresponding losses because of air emissions and solvent that ends up in waste streams when different machine technology is applied.

In airtight/airless machines, used solvent can be constantly re-purified and almost completely recycled in the distillation unit. This routine recycling means there are very low solvent replacement volumes necessary. Thanks to efficient recycling with vacuum distillation, solvent in the waste stream is minimized. Less than 10% solvent in waste is typical compared to 50% or more in average open-top systems.

For example, one Safechem customer that has implemented an airtight degreaser now requires 99.5% less solvent consumption than it did with its previous open-top cleaning equipment.

Vacuum degreasers can further expand solvent life by the addition of stabilizers, which results in less solvent consumption and fewer bath exchanges. In an open-top system, frequent disposal of solvent as waste as well as replacement is much more costly than the use of stabilizers.

Also, in a vacuum degreaser, the working chamber only opens following vacuum drying, so there are no solvent residues left on parts and no drag-out losses.

2. Process security. You can easily monitor the condition of your solvent on site using simple test kits. Usually, testing takes no more than 20 minutes a week, and the results will tell you whether re-stabilization is necessary. The addition of stabilizer concentrates not only helps counteract the evolving acidity but also prevents discoloration or metal catalytic effects while enabling safe pH value and reliable processes.

Because of distillation, vacuum degreasers use clean solvent to achieve consistent and repeatable results. While the high solvent quality in the rinsing step already enables a required level of cleanliness, this is followed by

Fig. 1.The chart shows the amount of solvent required to remove 100 Ibs of oil and the corresponding losses that are due to air emissions and solvent that ends up in waste streams when different machine technology is applied. Photo Credits: Safechem 

vapor degreasing as the last cleaning step. This process is highly effective given the temperature difference between parts and vapor.  

Furthermore, vacuum drying minimizes the risk of solvent being trapped in blind holes and small crevices even when rotation is not used.

3. Environmental protection. There are virtually no air emissions in an airtight/airless machine which is a cost, environmental and worker safety benefit. Hermetically sealed construction means there is minimal risk of contaminating ground water compared to open-top systems.

Vacuum degreasers can be fully automated with handling systems and robotics removing operator handling so operators have virtually no contact with the chemical. The safety aspect can be further enhanced by closed loop safety containers to enable emission-free and spill-free transfer of solvent to/from the cleaning machine.

Both halogenated solvents and non-halogenated solvents, such as modified alcohols, can run in airtight/airless degreasers.

Given that new stringent regulations are coming for many traditional solvents such as perchloroethylene and trichloroethylene following the EPA’s risk assessment, modified alcohols — which are chlorine-free, bromine-free and fluorine-free — have no environmental legislation concerns and represent a viable cleaning solution. Also, they are much more cost-effective than fluorinated products, which run on open systems and are similarly subject to increasing global regulatory pressure.

The capability of modified alcohols to process both polar and non-polar contaminations may also reduce the need for additional cleaning processes and help save costs.

The advanced technology of vacuum degreasers requires very low maintenance. Equipment manufacturers are also able to customize machines capable of processing large parts such as aerospace structures, nacelles, meter-long tubes, and so on. Particularly for companies who need to meet a high-volume throughput of cleaned and dry parts, airtight/airless degreasers can deliver exceptional results.   

About the Author

Chris Tivnan

Chris Tivnan is sales manager North America at Safechem North America Inc. Contact:
c.tivnan@safechem.com  

Pumped eductor agitation has many advantages that include lower heating costs, reduced emissions, even temperature, reduced brightener consumption and chemical evaporation, elimination of distorted air spargers, better filtration and plating on complex parts that may have bends or folds. The manifolds design by Serfilco (Northbrook, Illinois), for instance, can also help to eliminate the buildup sometimes experienced around heating elements or anode bags.

Eductor nozzles use the Venturi principle that amplifies and directs solution from the pump to the required area in the process tank. For each gallon of pressured liquid that enters the nozzle, five gallons recirculate at the output of the nozzle. The nozzle is converting a high pressure, high velocity, low volume flow into a low pressure, low velocity, high volume flow, creating a closed loop agitation, all while using a small pump and strategically positioned nozzles.

Other common methods of agitation, such as air or mechanical, have more disadvantages than advantages. For instance, air agitation’s explosion of air

An alternative to pumped eductor agitation, air agitation, has more disadvantages than advantages. Air agitation’s explosion of air bubbles on the surface of process tanks produces foam and chemical fumes which create a potentially dangerous environment as well as an increase in rejects. As these air bubbles rise to the top of the process tank, latent heat is lost to the atmosphere, increasing the energy input required to sustain operating temperature. Photo Credits: Serfilco

bubbles on the surface of process tanks produces foam and chemical fumes which create a potentially dangerous environment as well as an increase in rejects. As these air bubbles rise to the top of the process tank, latent heat is lost to the atmosphere, increasing the energy input required to sustain operating temperature. The holes in the air sparger are small, making them prone to blockage, commonly producing a turbulent surface in only parts of the process tank, which is an indication that the agitation is not uniform throughout. Air oxidation also accelerates the breakdown of brighteners, causing consumption to increase drastically. Finally, compressors are inefficient and expensive to run, while air blowers are noisy and difficult to control.

Mechanical agitation, another common type of agitation, consists of lateral movements of a cathode bar throughout the length of a tank. Cathode rod movement is limited to a slow backward and forward movement through the length of the process tank, making the distance the bar moves become lost cathode space. The rod cannot have too much movement because a wave within the tank can form, which then can cause solution to splash out of the tank.

Designing the right system

Taking the time to understand an application’s needs in order to design a pumped eductor agitation system unique to the process tank is essential to maximize the system’s effectiveness to provide a homogenous tank. Most process tanks use vigorous turbulence to ensure constant movement within and throughout the tank. Electroless nickel, electroless copper and alkaline zinc should avoid direct impingement on the parts where general agitation is effective.

Solutions such as phosphating and cleaners benefit from agitation focused on the tank floor to prevent any sludge from settling and keeping those solids in suspension for removal by a separate filtration system. Filtering these types of solutions alone with no agitation would not produce the desired cleansing of the process tank.

Considering the tank configuration, including the dimensions, anode/cathode placement, heater locations and rack placement, along with the type of process, is the most effective way to calculate the size, number and position of the eductor nozzles. This then determines the size pump required to achieve the calculated flow required to successfully agitate the process tank. It is always recommended that a flow valve be installed between the pump and the eductor manifold so the agitation can be controlled easily. To avoid excessive

Taking into account the tank configuration, including the dimensions, anode/cathode placement, heater locations and rack placement, along with the type of process, is the most effective way to calculate the size, number and position of the eductor nozzles.  

pressure drop, it is important to ensure pipework is at least the same size as the pump discharge.

Filtration and agitation

It is recommended that a separate pump from a filtration system be used. When sizing a pump for a calculated number of eductor nozzles, the tank turnovers should not be considered for filtration. Instead, consider the appropriate pump for the calculated number of eductors and separately calculate tank turnovers, depending on the process tank, to recommend a separate filtration system complete with its own housing, pump and media. When there is cartridge media that retains contaminant, there will be a drop in flow. When this occurs, the effectiveness of both the filtration and the agitation is severely compromised.

Best processes

Eductor-pumped agitation has been successfully introduced in several processes where it has exhibited performance improvements compared to other methods by reducing heating costs, saving brighteners and reducing rejects (especially with complex parts), reducing hydrogen pitting and, most importantly, providing a homogeneous solution.

Nickel and chrome, acid copper, electroless nickel and copper, phosphating, cleaning and rinses, anodizing, alkaline and acid zinc, cadmium, tin, cyanide copper; electroforming, gold, rhodium and silver are the processes that are most successful using eductor-pumped agitation.

A relatively small capital investment is required to install an eductor-pumped agitation system, and a payback can be seen in a short amount of time.

About the Author

Melissa Escobar

Melissa Escobar is the Business Development Manager for Latin America and a
technical applications specialist at Serfilco. Melissa has had the honor to work with global electroplaters and anodizers in North and South America, providing outstanding customer service and technical advice.

These electron microscope photos show that true neutral cleaners clean better than alkaline cleaners. Source: Environmentally Sensitive Solutions Inc.

Q. How can I lower operating costs on my parts cleaning process without sacrificing cleanliness or quality?

A. While there are a number of ways to tighten up a parts cleaning process to reduce operating costs (for example, upgrading wash/drying equipment and utilities), one of the easiest ways might be to switch from the current alkaline cleaner to a true neutral pH cleaner. True neutral cleaners are not watered-down alkaline cleaners with sodium bicarbonate (baking soda) replacing sodium hydroxide (caustic), although the industry sometimes refers to them that way. A true neutral cleaner has a neutral pH of 6.5 – 7.5, both concentrated and diluted.

Alkaline cleaners have been around since the 1960s to replace solvent cleaners and are by far the most commonly used parts cleaning product for cleaning a variety of parts in a variety of washer styles. Acidic cleaners are used to clean/brighten and deoxidize parts in more niche parts applications. Solvents are still used on occasion, although on a limited basis for specific applications.

True neutral cleaners evolved about 35 years ago as a viable and cost-effective replacement for alkaline cleaners. True neutral cleaners are used in a variety of cleaning equipment styles including spray, immersion, rotary drum, vibratory, ultrasonics and pressure washers. True neutral cleaners have successfully cleaned the gamut of industrial parts processing soils, including synthetic coolants, semi-synthetic coolants, chlorinated paraffin oils, machining oils, buffing compounds, drawing compounds, among others.

There are many ways properly formulated true neutral cleaners can eliminate costs generated using traditional alkaline cleaners:

1. Wastewater simplification and reduction: True neutral cleaners automatically split oils for recovery, eliminate heavy metal solubilization and do not require pH neutralization prior to discharge. Oftentimes, wastewater generated by true neutral cleaners is categorized as non-regulated.
2. Better part quality for less rework and scrap: True neutral cleaners rinse better with less residue and less rinse water needed. Neutral pH eliminates potential etching of soft metals without the need for silicates, so white rust on metals like aluminum is eliminated. The quality of post-cleaning part bonding processes can be dramatically improved (with less scrap) because the surface to be bonded is cleaner and contains less residue when washed with a true neutral cleaner.
3. Multi-metal safe: True neutral cleaners can be safely and interchangeably used on any type of metal part, including aluminum, brass, copper, stainless steel, steel (among others) without the need for silicates of alkaline cleaners. Neutral cleaners can reduce the number of different alkaline parts cleaning products for various metal types.
4. Wash bath-life extended: True neutral cleaners automatically split oils (once bath agitation stops) for easy skimming and recovery, thus extending bath-life for reduced cleaning costs.
5. Reduces wash equipment wear and tear: True neutral cleaners significantly reduce the residue build-up in wash equipment and the labor needed to routinely clean nozzles and regularly maintain washers. The ongoing expense of acid boil-outs is eliminated.
6. Worker safety and protection: True neutral cleaners almost eliminate the chance for worker injury because of chemical exposure from high pH alkaline cleaners. The neutral pH cleaner is non-corrosive and non-hazardous, vastly simplifying worker chemical training, personal protection equipment and expense.
7. Product simplification: Alkaline cleaners often require additives like wetters and defoamers to be purchased and added separately tank side for the alkaline cleaner to function properly. True neutral cleaners eliminate those additives in that wetting and foam control is built into the formulation itself.
8. Lower freight costs: Because they are not limited by ingredient solubility issues like alkaline cleaners, true neutral cleaners can be super concentrated to 2x and beyond to cut freight costs. At a 2x concentrate, it is like getting two drums in one, which cuts freight costs almost in half.
9. Greener alternative: As parts manufacturing companies are “greening” up their products and processes, true neutral cleaners can play a hugely positive role in that narrative by being more environmentally friendly than alkaline cleaners without sacrificing performance.

True neutral cleaners are a drop-in replacement for alkaline cleaners in most parts cleaning applications. Other than some initial cleaning of an alkaline washer switching over to a neutral cleaner, true neutral cleaners simplify wash processes and reduce costs.

About the Author

Matt Pliszka

Matt Pliszka is a true neutral cleaner formulating pioneer and parts cleaning expert, with a 37-year track record of success at Environmentally Sensitive Solutions Inc. (ESS). Visit neutralcleaner.com for more information.

For energy-efficient and fast cleaning processes, Ecoclean’s plants have effective heat recovery and can be equipped with different process technologies. Photo credit: All images courtesy of Ecoclean

Component cleaning is an essential manufacturing step in all industrial sectors to ensure requirement-compliant downstream processes and high, stable product quality. Regardless of the industry, new and modified products, increasingly compact and complex geometries, an ever-greater variety of materials, and workpiece dimensions ranging from one millimeter or less to several meters all contribute to the fact that the spectrum of required cleaning applications is more diverse today than ever before. The demands on the process and the cleanliness to be achieved vary depending on the production stage as well as on the product and industry.

For example, in the final cleaning of high-tech components, including those for the semiconductor industry, medical, sensor and analysis technology, and precision optics, particulate contamination in the nanometer range and nanolayers of residual film contamination must be removed.

In contrast, in general industry, for example, with its very different areas and components, the first task is often to clean off large quantities of chips and machining media. Frequently, factors such as high throughput requirements, heavy workpieces, a widely varying range of components and short delivery times also play a role. In addition, cleaning must, in any case, be economical, energy- and resource-efficient. 

Adapt cleaning solution to the task 

To optimally adapt a cleaning solution to the task at hand, other product and company-specific criteria must be considered in addition to the cleanliness specifications to be met. 

As a full-range supplier of solutions for industrial component cleaning, Ecoclean (Filderstadt, Germany) and UCM (the Group's division specializing in precision and ultra-fine cleaning), cover the entire spectrum of wet-chemical processes using water-based media, solvents and modified alcohols. This means that cleaning processes and systems, including the most suitable process and drying technologies for both batch and individual part cleaning, can be efficiently tailored to product- and company-specific requirements. Process design is carried out in the company’s own test centers, with cleanroom test centers with adapted plant and measuring technology available for tasks in medical technology and for high-purity applications. 

Special plants for water-based cleaning are covered by the modular EcoCvela with working chamber diameters up to 1,500 mm as well as several flood tanks and, if required, several working chambers. 

Modular system makes special chamber systems available more quickly 

With a broad range of standardized chamber systems for cleaning with water-based media, solvents and modified alcohols, as well as a wide variety of process technologies such as spray and high-pressure cleaning, ultrasonics, injection flood washing (IFW), vapor degreasing, Ultrasonic Plus, Pulsated Pressure Cleaning (PPC) and plasma cleaning, Ecoclean covers most cleaning tasks in general industry as well as the automotive and supplier sectors.

The modular EcoCstretch concept was developed for solvent cleaning applications that previously required special equipment with complex design and long production times. Among other things, it includes four working chamber sizes and several flood tanks. 

However, applications that required individually designed special equipment, for example, due to component dimensions, throughput requirements, cleanliness specifications or other company-specific factors, have increased significantly in recent years. To reduce the design effort required for this and shorten delivery times, the plant manufacturer has developed the innovative modular systems EcoCvela for water-based cleaning and EcoCstretch for cleaning with solvents or modified alcohol.

For the solvent systems, the modular concept includes four working chamber sizes with diameters from 750 to 1,200 mm and equipment with several flood tanks. For individual cleaning processes, the systems can be equipped with all process technologies available for solvent cleaning. With the EcoCvela, the diameters of the modular working chambers vary from 650 to 1,500 mm. In addition, the plants can be equipped with several working chambers and flood tanks. In these highly flexible plants, various process technologies and systems for efficient heat recovery also ensure short process times and energy-saving operation. For very high cleanliness requirements, both plant types can also be supplied with the corresponding high-purity equipment. 

With the multi-bath ultrasonic cleaning systems consisting of standardized modules, here a UCM PerformanceLine, cleaning solutions can be individually configured, for example, for ultra-fine cleaning and high-purity applications. 

Modular solutions also for multi-bath ultrasonic cleaning 

In the area of multi-bath ultrasonic cleaning systems, solutions consisting of standardized modules are also offered in the form of the UCMBaseLine, UCMSmartLine, UCMPerformanceLine and UCMHighLine model series.

With the modules for the process steps cleaning, rinsing, PPC, drying, loading, and unloading, as well as a flexible transport system, cleaning systems for a wide range of applications can be configured and commissioned cost-effectively and easily. This is also supported by the fact that the electrical and control technology is already integrated. For high-purity applications, the systems are designed with the appropriate equipment and for operation in or connection to a cleanroom. 

With its further diversified portfolio, Ecoclean enables companies from all industrial sectors to meet changing cleaning requirements not only in an economical and stable manner, but also in a resource-saving and future-oriented way. 

New replacement solvents excel for medical, aerospace, military, defense, automotive, and other precision/critical cleaning applications where the final product must be residue-free and applications where water will not work or is not desired. Photo Credits: Kyzen Corp.

Modern solvent cleaning systems are an efficient and safe way of performing cleaning while ensuring environmental health and safety (EH&S) compliance. However, numerous changes to the solvent cleaning market over recent years are now affecting end users. As some older-generation solvents are under review by the Environmental Protection Agency (EPA), Occupational Safety and Health Administration (OSHA), other health and environmental organizations as well as internal corporate EH&S bodies, solvents that are currently being used in a cleaning process may soon become unavailable because of the potential discontinuation by OEMs or phase-outs of these solvents by federal or state laws.

Finding and switching to a new solution is crucial for those who use solvent by choice or necessity. While this task may appear daunting to many, it is reassuring that alternative solutions are available. The question to ask in this case is, “How do I future-proof my choices?”

It is important to evaluate the viability of replacement solvents, and technical experts are available to assist with the evaluation process. Each solvent has its own characteristics, such as flammability, global warming potential (GWP), ozone depletion potential (ODP), occupational exposure limits (OEL), volatile organic compounds (VOC) classification, and other criteria to meet EPA/OSHA/end-user internal standards.

Chlorinated and brominated solvents

Older-generation solvents such as trichloroethylene (TCE), tetrachloroethylene (PCE), methylene chloride (MC), N-propyl bromide (nPB), and N-methylpyrrolidone (NMP) have been identified under the Toxic Substance Control Act (TSCA) for chemical risk analysis. There are many public documents from governing bodies that notify users of the risks involved with these solvents. More strict regulations for personnel exposure have been proposed and await enactment. The latest news about TCE is the EPA announcing a proposal to ban all uses of the solvent, which the agency describes as an extremely toxic chemical known to cause serious health risks including cancer, neurotoxicity and reproductive toxicity.

HFE and HFC solvents

With the decline of chlorinated and brominated solvents because of regulatory issues, the solvents of choice were fluorinated solvents and trans-dichloroethylene (t-DCE) blends. Common fluorinated solvent ingredients are hydrofluoroethers (HFEs) and hydrofluorocarbons (HFCs). These solvents provided acceptable cleaning results and improved EH&S properties over the older-generation solvents. However, they have recently been identified as creating environmental issues. These issues are global warming and per- and polyfluoroalkyl substances (PFAS) classification.

Based on this discovery, there are changes on the horizon for HFEs and HFCs. For instance, 3M announced it will exit PFAS manufacturing and work to discontinue the use of PFAS across its product portfolio by the end of 2025. The discontinued products include the company’s Novec solvents (HFEs).

Also, the EPA announced a framework to prevent new or foreign-sourced PFAS from entering the U.S. market without scrutiny. Therefore, HFC solvents will no longer be acceptable for use per Department of Defense (DoD), General Services Administration (GSA), and National Aeronautics and Space Administration (NASA) guidelines.

Modern, fully enclosed cleaning systems are an efficient and safe way of performing cleaning while ensuring EH&S compliance. Vacuum degreasing solvents were developed for operation under vacuum conditions in modern equipment to remove polar and nonpolar-based soils for a wide variety of manufacturing purposes.

The American Innovation and Manufacturing (AIM) Act enacted in December 2020 mandates a phase-down schedule of HFC production and imports through 2036 from baseline years 2011-2013. Beginning in 2024, 40% of HFCs will be removed from the marketplace, while by 2036, 85% of HFCs will be removed. Therefore, one can rule out future sustainability use with these solvents.

At this point, it is wise to determine if the solvent implemented in an application contains any HFEs or HFCs and then decide how to replace these solvents with safer options.

The quickest way to review the safety data sheet for a solvent is in Section 3: Composition/Information. This section contains information on the ingredients. However, proprietary ingredients may not be listed. If there are questions about a product, contact the solvent supplier for more information.

Next-generation solvents have superior EH&S features while offering similar operational performance as compared to other solvents. Newer generation solvents offer sustainable cleaning for the solvent user needing a viable replacement.

In most cases, the conversion to a next-generation solvent is simple and quick. Most of these solvents are designed as drop-in replacements in modern generation, open-top degreasers.

Because of the discontinuation of some solvents used in open-top vapor degreasers by the original manufacturer or phase out by federal and/or state regulatory agencies, these changes will require a replacement action to validate conversion results from several different aspects.

These new solvents are:

• Free from HFEs and HFCs
• Not classified as a PFAS by the EPA
• Non-flammable
• Non-ozone depleting
• Not classified as HAPs by the EPA
• Do not contribute to global warming
• Some are VOC exempt
• Most are compatible with a variety of metals and some plastic substrates
• Most operate from 120°F to 130°F

Listed below is a suggested matrix to assist in identifying the solvent to be replaced. Process evaluation is critical for success.

1. Identify potential replacement candidates.
2. Confirm “green” properties and regulatory approvals.
3. Match performance to production requirements.
4. Evaluate long-term future sustainability.
5. Determine true operational cost of each candidate.
6. Confirm local regulatory compliance.
7. Implement conversion.

The vacuum degreasing solution

For the production process that requires solvent, vacuum degreasing offers sustainable cleaning options that are not only a viable replacement, but the solvents they use will help future-proof cleaning operations.

Depending on the soil type and loading, modified alcohols and non-halogenated hydrocarbons offer cleaning performance with desired environmental compliance. They not only ensure dependable, efficient and sustainable removal of oils, coolants and solids, but also enable cleaning and a corrosion protection process (if required) in one machine.

Modern, fully enclosed cleaning systems are an efficient and safe way of performing cleaning while ensuring EH&S compliance. Vacuum degreasing solvents were developed for operation under vacuum conditions in modern equipment to remove polar- and nonpolar-based soils for a variety of manufacturing purposes.

Implementing the vacuum degreasing cleaning method and its solvents have many other benefits such as:

• Compatibility with a variety of materials. Unlike aqueous detergents, vacuum degreasing solvents are non-corrosive, do not cause oxidation, discoloration or other surface impairments for most metals and some plastics.
• Excellent degreasing performance. Low surface tension combined with the solvency power of these solvents creates soil removal effectiveness without leaving residues on the parts.

• Rapid parts drying. Evaporative properties of the solvent in a heated, vacuum-sealed chamber enable parts to dry completely, removing solvent from blind holes and hidden passageways. This process eliminates solvent carry-out.
• Low solvent consumption. Soils are automatically separated from the solvent inside the vacuum degreaser because of the distillation process. The reclaimed solvent is returned to the process tanks for consecutive cleaning cycles. Thus, the solvent life is extended for an indefinite period.
• Solvent stability. Does not turn acid like some other industrial solvents. Any acid formation is because of the sulfonated/chlorinated oils/coolants being removed and is easily monitored and controlled.
• Low toxicity and eco-friendly operation. These solvents are not listed as hazardous air pollutants (HAPs) under EPA guidelines. The allowable operator exposure limits (OEL) are much higher than traditional vapor degreasing solvents. Continuous vacuum operation minimizes worker exposure.
• ASTM compliance. Modified alcohol has been certified for specific metals/tests.
• In-vitro cytotoxicity (medical). Modified alcohol has proven compliant to ISO 10993-5.
• Low VOC emissions. These chemical cleaning products, in combination with current vacuum degreasing technology and equipment, produce extremely low VOC emissions and find extensive use in California and other areas with demanding VOC requirements.

About the Author

Photo Credit: Kyzen

Joe McChesney is the global product line manager – solvents for Kyzen Corp. Over 40 years of experience regarding solvent and aqueous cleaning processes from conceptual design through field operation. Contact: joe_mcchesney@kyzen.com

Hubbard-Hall is being honored with the Top Workplaces 2022 Award by Hearst Connecticut. The award is based solely on employee feedback gathered through a third-party survey administered by employee engagement technology partner Energage LLC. The anonymous survey measures 15 culture drivers that are critical to the success of any organization, including alignment, execution and connection. This is the seventh time the organization has received this honor.

“Earning a Top Workplaces award is a badge of honor for companies, especially because it comes authentically from their employees,” says Eric Rubino, Energage CEO. “That's something to be proud of. In today's market, leaders must ensure they’re allowing employees to have a voice and be heard.”

Hubbard-Hall’s roots go back to 1849 when Apothecary’s Hall, a neighborhood store which sold paints, fertilizers and sundries, opened its doors in Waterbury, Connecticut. Today, the company is a partner to more than 2,300 companies across many industries, including the military, medical, aerospace, automotive, hand tools and high-tech connectors. With personnel based out of Connecticut, South Carolina and Massachusets, the organization is poised to help manufacturers in the areas of cleaning (aqueous or solvent), metal finishing and wastewater treatment.

“The success and longevity of our company starts and ends with our people.  For anyone who works at Hubbard-Hall, we want the experience to be more than just a job,” says Molly Kellogg, Hubbard-Hall CEO and chairman. “It should challenge them to be curious, to have candid conversations and to have the courage to make decisions that move us forward.”

Manufacturers should choose a supplier that understands the dynamics between cleaning chemistry and cleaning equipment and has a laboratory support structure to support a smooth transition.
Photo Credit: MicroCare

Q: My vapor degreasing fluid is being discontinued. What should I do?

A: When a manufacturer learns that their trusted line of vapor degreasing cleaning fluids will soon be discontinued, they may be left wondering how to move forward. There are many factors to consider when choosing a replacement cleaning fluid, including the equipment and substrate being cleaned, the type of contamination being removed, the long-term availability of the chosen fluid, and the level of support available from the supplier. Here are the three important factors to consider when replacing discontinued vapor degreasing fluids.

When looking for a replacement cleaning fluid, manufacturers should first identify the type of equipment, substrate and contamination they are dealing with. This will help them narrow down their options and find a cleaning fluid that is tailored to their specific needs. It is also important to work with a supplier who has experience with similar equipment and substrates.

Manufacturers should ask potential suppliers questions about their cleaning fluid’s compatibility with their substrates and equipment. For example, if a manufacturer is cleaning steel parts, they should inquire about the cleaning fluid's ability to protect against corrosion. If a manufacturer is using a specific type of cleaning equipment, they should ask if the cleaning fluid is compatible or if the equipment will require upgrades or modifications.

Additionally, manufacturers should start to prepare for their transition now. This may involve testing new cleaning fluids on a small scale to ensure that they are effective and do not cause any damage to equipment or substrates. It may also involve training employees on how to use the new cleaning fluid and making adjustments to the cleaning process to ensure optimal performance.

When selecting a replacement cleaning fluid, manufacturers should choose a fluid with a proven track record and a long-term sustainability profile. This means choosing a fluid that has been on the market for a significant amount of time and has a proven record of effectiveness. Manufacturers should also consider the long-term availability of the chosen fluid. If a fluid is only available for a limited time, it may be difficult to find a replacement when it is needed.

Manufacturers should also consider the environmental impact of the chosen fluid. Many newer cleaning fluids are designed to be more environmentally friendly than older ones. This may include fluids that have a low global warming potential, or are free of hazardous air pollutants. Choosing an environmentally friendly cleaning fluid may not only benefit the environment, but also the health and safety of employees who work with the fluid.

Finally, manufacturers should choose a supplier that understands the dynamics between cleaning chemistry and cleaning equipment and has a laboratory support structure to support a smooth transition. This means choosing a supplier that offers technical support, troubleshooting and training on the new cleaning fluid. Manufacturers should also choose a supplier that has a long-standing, good reputation for customer service and is available to answer any questions or concerns that might arise.

In conclusion, replacing discontinued vapor degreasing fluids can be a daunting task. However, by considering the equipment, substrate and contamination being cleaned, the long-term availability of the chosen fluid, and the level of support available from the supplier, manufacturers can select a replacement cleaning fluid that provides optimal cleaning performance with the least impact on the environment and their cleaning processes.

About the Author

Photo Credit: MicroCare

Elizabeth Norwood

Elizabeth Norwood is a Senior Chemist at MicroCare, LLC, which offers precision cleaning solutions. She has been in the industry for more than 25 years and holds a BS in Chemistry from the University of St. Joseph. Norwood researches, develops and tests cleaning-related products. She currently has one patent issued and two pending for her work. For more information, visit www.microcare.com.

Fig 1: Open-top vapor degreasing

Vapor degreasers use a variety of solvents and have seen an evolution of useable chemistries throughout time, from CFC 113 (commonly referred to by the commercial name Freon and used prior to the Montreal Protocol that phased out chlorofluorocarbons (CFCs) and other substances responsible for the depletion of the ozone layer) to the designer vapor degreasing solvents used today. As the Environmental Protection Agency (EPA) and regulatory agencies continue to find probable cause to limit or ban specific solvents for environmental or human health reasons, the aerospace industry continuously needs to adapt to the ever-changing guidelines.

Today, the aerospace industry faces major regulations on three commonly used molecules. N-propylbromide (nPB), trichloroethylene (TCE), and perchloroethylene (PERC) are all seeing unprecedented pressure.

The EPA, under the Toxic Substance Control Act (TSCA), is required to evaluate chemicals under a three-stage process. The EPA has determined that nPB, TCE, and PERC pose an unreasonable risk to humans. The proposed limits of these three molecules will prevent any of them from being used in an open-top vapor degreaser.

Fig 2: EPA Toxic Substance Control Act (TSAC) evaluation process.

With these solvents becoming unavailable, the industry must look at alternative methods to clean parts. Three viable options are: Drop in solvents, aqueous, and vacuum vapor degreasers.

Drop in Replacement Solvents

There are fluorinated solvents that will be able to be used in an open-top degreaser that will allow the current modern vapor degreaser to be utilized. These fluorinated products are blended with trans-1,2-Dichloroethylene (trans-1,2-DCE, or trans). The trans provides a vast majority of the degreasing power which allows the solvents to be used in vapor only or immersion vapor degreasing processes. The boiling points of these solvents are considerably lower and the degreaser’s heat settings will need to be adjusted. The lower boiling points will prevent the cleaning of some soils with these types of solvents. Also, a consideration is the cost of fluorinated solvents as they are significantly more expensive. 

Aqueous

Aqueous cleaning will be a long-term solution for many aerospace manufacturing facilities. There are industry approvals in place that eliminate one concern, the ability to degrease OEM hardware. The chemical blends are seeing some EPA pressure currently. Today, this pressure is somewhat regional around the topics of phosphate and nonylphenol ethoxylate (NPE) surfactants. The NPE surfactants have been banned from use in the European Union (EU) as a part of the REAcH (registration, evaluation and authorization of chemicals) regulations as well as in a few other countries. There are, however, many drawbacks to cleaning with water. Complex part geometry proves to be difficult to clean with many aqueous systems. Aqueous systems require a high floor space cost, higher energy consumption and possible waste stream ramifications. Another significant drawback with aqueous systems is drying the cleaned parts. Drying is often the biggest hurdle in an aqueous process.

Vacuum Vapor Degreasing

Vacuum vapor degreasers are a viable alternative to open-top degreasers for many applications. They employ a closed-loop system that has a very minimal solvent loss. All the benefits of an open-top degreaser are present with the aid of vacuum drying. Vacuum systems, although a great alternative, do come with a significant upfront capital investment. Modified alcohol is one of the solvents used in these systems and lacks many aerospace approvals at this time. Hydrocarbons are another option in this equipment. Again, these lack OEM approvals.

Aerospace fasteners.

Fasteners

An excellent option for cleaning aerospace fasteners is to employ a vacuum vapor degreaser. Because of the small diameters, blind holes, and the need to clean parts numbering into the thousands at a time, a vacuum system is ideal. The struggle to clean these types of parts in an aqueous system is twofold. First, it will be a challenge to ensure all the soils are removed from the surface of each part. Secondly, drying becomes a major challenge.

Water-based cleaning is challenging for parts with complex geometry, making vapor degreasing a good option.

Complex Geometries

A drop-in replacement vapor degreasing solvent is a good option for parts with complex geometries. Water-based cleaning will be a challenge to get the cleaning chemistry to all the blind holes and hard-to-reach areas. As in the previous example, drying becomes a problem with water-based chemistries as well. The vapor from the degreaser will penetrate all areas of the part and will be able to remove the soil. Drying becomes a non-issue with any vapor process. As 3D-printed parts become more and more prevalent in the industry, the need for vapor cleaning will also be in continued demand.

Landing Gear

Large parts such as landing gear that are currently being cleaned in a vapor degreaser can be moved to a water-based cleaning system. The geometries are not overly complex, enabling these parts to be sufficiently cleaned and dried and ready for the next process.

The aerospace industry will no doubt need to adapt soon as commonly used vapor degreasing solvents may become highly regulated. It will be imperative that the correct process type and chemistry is implemented on a part-by-part basis. Lastly, waiting until the last possible moment to begin new process evaluations will be troublesome. Waiting too long will put you at the end of a very long line of new equipment orders already in queue.

Curtis Waters is a process specialist for Brulin Holding Co. Visit brulin.com.

Before and after the use of Ferrozinc. Photo Credit: HMG Paints

With its performance and ease of use, Ferrozinc from HMG Paints is a water-based solution, a manufacturer of high-quality coatings and paints, for rust conversion in areas where shot blasting or complete rust removal is impractical or impossible. Ferrozinc is available in multiple sizes — including a new 250 mL size. Ferrozinc’s water-based formulation not only provides rust conversion properties but also emits low odor, making it a more pleasant, user-friendly option compared to solvent-based alternatives.

“Ferrozinc has been a popular product for our customers for a number of years, and we’re proud to introduce the new 250 mL size,” says James Burton at HMG. “It’s such a handy product for users in a number of industries from decorators and industrial applicators to agricultural and classic vehicle restoration.”

Traditionally, rust removal has been a laborious, time-consuming process, involving hours of wire brushing or the use of strong, acidic chemicals that pose safety hazards. With HMG’s Ferrozinc rust converter, this task becomes a thing of the past, the company says, making the converter a well-suited solution for those working in the decorative or industrial markets. Ferrozinc can also be utilized for personal use — such as in the case of classic car enthusiasts.

A user removes loose debris and poorly adhered surface rust, and follows with a degreasing step to minimize any contamination that may interfere with the chemical reaction. Afterward, a thin coat of Ferrozinc is applied to the rusted area and within 30 minutes the surface transforms into a black/navy color, indicating successful rust conversion. Any excess product can be easily wiped off, HMG says. After three hours, the treated surface is ready to be overcoated with the user’s preferred coating system.

All automation connected to the iFP KP 100 vacuum degreaser is controlled by the management software. The software, programmed by iFP Europe, observes the procedures provided by the Industry 4.0 standard. Source: Gosiger

A lack of labor resources, difficulty reaching cleaning specifications and environmental standards are among the most common problems manufacturers face in their cleaning processes, according to Mike Bishop, east coast regional manager at Gosiger, and who provided information for this article.

AMPG (Accurate Manufactured Products Group) in Indianapolis, Indiana, was experiencing these frustrations with its cleaning process prior to implementing an automated vacuum degreasing system that positively influenced cleaning results, efficiency and costs.

This manufacturer of precision fasteners and components was using an immersion parts washer with a petroleum-based solvent. The process was not only labor-intensive, but ineffective and unhealthy for the machine’s operators.

When the shop began to search for a new way to clean its parts, an automated system was at the top of the list as well as one that could clean oils and chips off various metal types without the need for multiple cleaning chemistries. The management team also hoped to eliminate the use of compressed air to dry all part types and eliminate solvent mist. Ultimately, the shop wanted a long-term solution for cleaning without risk of future Environmental Protection Agency (EPA) solvent bans.

The iFP automated vacuum degreaser parts washer, distributed by Gosiger, checked all the boxes for AMPG. Most importantly, the machine washed 10 million parts at the shop in 2023, while saving the business from paying fees to plating vendors that charged for unclean parts.

The wash chamber of the iFP KP100 can hold two standard baskets (standard basket dimensions are 471 mm L x 321 mm W x 200 mm H). Source: AMPG

A parts washer that did not clean

Prior to the implementation of its vacuum degreaser in 2018, AMPG was not only struggling to keep up with a recent part volume increase with its purchase of more Swiss lathes, but its cleaning process was ineffective. The petroleum-based cleaning solvent used by the company’s immersion parts washer was not adequately removed from the parts being cleaned. When preparing the parts for shipment, solvent often dripped out of part cavities, leaking onto the shipping boxes. This issue often led to shipment refusals.

But even when shipments were successful, meeting the cleaning standards of the recipient often was not. Because the parts were still dirty with solvent, cutting oil or metal chips, the zinc and black oxide plating companies to which AMPG was shipping would charge cleaning fees prior to processing the parts.

The shop’s work environment was also compromised because of the inefficient cleaning process. To dry what were supposed to be clean parts coming out of the washer, operators used compressed air. This process created solvent mist and a large fog cloud in the shop that was unhealthy for the employees.

Out with the old, in with the new

The vacuum degreaser, considered an automated system, typically necessitates 20 minutes of operator attendance out of every hour. The operator places baskets of dirty parts onto the machine and then removes the baskets of clean parts. At the start of the cleaning process, the operator loads four washing baskets in a queue and then walks away from the machine. At that point, the system takes over and starts washing. Once complete, the system’s automation will unload the product and load the next queued wash load.

Besides the vacuum degreaser, the 130,000-square-foot headquarters houses nine large diameter turning centers with bar feeders, seven 20-mm Star Swiss lathes with bar feeders, 43 32-mm Star Swiss lathes with bar feeders, four 38-mm Star Swiss lathes with bar feeders, four thread rollers and two milling centers. The facility runs 24/7/365 with 63 full-time employees.

Clean, dry parts, finally!

Finally, AMPG could enjoy all the advantages this vacuum degreasing system provides. It not only cleans cutting oils and metal chips off the parts but leaves them bright and shiny, unlike the immersion cleaner’s results. And because this cleaning process has no air voids, cleaning chemistry can effectively access all complex parts features, such as blind holes and internal threads that are often challenging to penetrate and cleanse.

Vacuum drying is another benefit of the iFP system. By pulling a deep vacuum on the washing chamber, all the solvent is evaporated from the chamber and off the parts without creating fog in the shop. Not needing to dry the parts coming out of the system was a huge labor savings for AMPG as well.

By using modified alcohol as the cleaning chemistry in the vacuum degreaser, there were no concerns with the materials that must be washed, which include steel, stainless steel, aluminum, brass, titanium and Monel. And according to Gosiger, it is a future-proofed solvent. Modified alcohol is not classified as an HAP (hazardous air pollutant) by the EPA, it has low GWP (global warming potential), is halogen compound free, it does not contain CFC, HFEs, or HFCs substances, and it does not contain PFAS substances.

Although AMPG’s capacity has grown since it first implemented the iFP unit, the cleaning process has continued to provide the business with its cleaning needs. Now, the shop floor houses 70 lathes, and the one vacuum degreaser has no problem keeping up with the part volume increase.