A BLAST OF DRY ICE

Replacing manual and abrasive cleaning and finishing processes with dry ice blasting delicately and efficiently removes residue from parts and equipment.

When it comes to medical device manufacturing, precision can be an understatement. Paying attention to the intricacies in molding catheter tips and surgical equipment, grinding needles and tubes, or coating stents is critical - as the end product must be pristine and uncompromised.

Like the end product, the tools and equipment used in the manufacturing process must also be maintained, and the finishing process must ensure that the products are delivered without flaws or excess material, and are ready for use.

Many of the innovative par ts and products produced by manufacturers are small and the equipment is finely detailed and expensive. Residue build-up in the extremely small mold cavities and on the expensive tooling during the production of the high tolerance medical device parts can impact the quality of the end product. Residue build-up results in par ts not meeting tolerances and can also prevent the imprinting of small, yet critical details.

To clean and maintain the equipment and parts, manufacturers try a variety of cleaning and finishing methods. Quite often, manufacturers end up replacing their manual and abrasive cleaning and finishing processes with an alternative cleaning method called dry ice blasting. The precision cleaning method uses recycled CO2 in the form of dry ice pellets or pieces, accelerated at supersonic speeds to delicately remove residue from par ts and equipment. The process is helping medical device manufacturer s improve quality, increase production, prolong equipment life, improve worker safety, reduce costs and support environmental initiatives.

Cold Jet pelletizers can be equipped with multiple dies to produce various extrusion sizes.

UPPING QUALITY, PRODUCTIVITY

As previously mentioned, manufacturers try a variety of cleaning methods, from sandblasting and chemical solvents to manual scraping, chipping, drilling and scrubbing with brushes. These methods are time consuming as a single mold can require up to an hour or more, including the disassembly and reassembly of equipment. In addition to being physically demanding on maintenance workers, these traditional cleaning methods can damage the equipment and are not completely reliable.

Dry ice blast cleaning can be used to clean the majority of the molds used in medical device manufacturing, and is effective in removing burrs. Utilizing a dry ice blast cleaning solution can help to ensure quality and the nonabrasive process also will not damage products during the finishing process.

Medical device manufacturers are discovering that cleaning with dry ice blast cleaning systems can reduce cleaning time by as much as 75% because the cleaning of molds and equipment is simplified with dry ice blast cleaning. Unlike abrasive cleaning methods, the combination of the kinetic and thermal gradient effects breaks the bond between the residue and the surface. When the dry ice hits the surface, it returns to its gaseous state, eliminating any secondary waste. After hitting the surface, the dry ice particles sublimate, and the miniscule contaminants fall to the floor, or are captured in a HEPA filter.

Cleaning can be integrated into the overall production process with dry ice blasting. Additionally, dry ice blast cleaning allows manufacturers to do frequent preventive maintenance and spot cleaning without impacting production.

ADDITIONAL BENEFITS

Dry ice blasting delivers a complete clean without the abrasiveness of more aggressive or corrosive methods and equipment life is extended as regular; thorough dry ice blast cleaning does not carry the risk of damage that often occurs with disassembly and transportation of equipment to designated cleaning areas.

The nozzles used in dry ice blast cleaning systems come in a variety of shapes and sizes, and some systems allow for varied pressure controls for more precision and delicate cleaning.

As a result, operators have more control and can perform a more complete clean. Dry ice blast cleaning is a dry process, meaning that it will not wet the surface and is therefore non-conductive, which reduces the risk of rust or possible damage to electrical components and wires.

Additionally, dry ice blast cleaning is safe for operators and eliminates unnecessary exposure to harmful solvents and the need to work closely with extremely hot equipment.

Labor costs for cleaning delicate molds are also reduced by using dry ice blasting. Cleaning molds and associated equipment by hand frequently requires more than one person spending extended periods of time. With dry ice blasting, the cleaning can be done by one person with a single cleaning system.

A catheter tip manufacturing company in Minnesota that uses dry ice blast cleaning to clean molds experienced a 40% reduction in total cleaning time while another device manufacturer saved more than $75,000 by eliminating the need to replace expensive clamps that were destroyed following two to four cleanings with a sandblast cleaning system.

ENVIRONMENTALLY-SAFE

Dry ice blast cleaning is an environmentally-responsible cleaning process that supports the green initiatives of medical device manufacturers. Dry ice blast cleaning eliminates the need for chemical solvents, and because the process does not produce any secondary waste, it also reduces the possibility of downstream contamination.

Example of how Cold Jet dry ice blasting can clean a medical mold.

Dry ice blast cleaning allows manufacturers to clean faster and more frequently, which will help them to consistently produce high quality results while also extending the life of their most valuable and expensive equipment. Most importantly, the ability to clean quickly and in less time allows manufacturers to get back to producing products and growing the bottom line.

Dry ice blast cleaning has proven to be faster, safer and more effective at removing materials used during the manufacturing process. It will not wear away at metal surfaces, alter the shape or fit of molds, or damage the equipment in any manner. The process is providing manufacturers with a more effective cleaning option to replace messy sandblasting and the arduous task of manually scraping or drilling. Manufacturers that have already integrated dry ice blasting into their cleaning processes have experienced a reduction in labor time and costs, eliminated secondary waste and implemented an environmentally responsible process that promotes a safer and healthier work environment for their employees.

Cold Jet
Loveland, OH
coldjet.com