Analyzing, optimizing cleaning processes

Cleaning processes potentially make cleaning operations more reliable, economical, and sustainable. How efficiently the cleaning is carried out depends on the equipment, the process technology, the medium used, and factors relating to the cleaning process.

Cleaning experts from Ecoclean Akademie in Germany found a systematic process analysis can easily improve the process and solve other cleaning problems, allowing companies to efficiently meet cleanliness requirements.

Assessing the actual cleaning process, equipment, and manufacturing environment, they found the smallest change to the part, spectrum, or material, type of contamination, or modifications to upstream or downstream processes were enough to seriously impair cleaning results.

© Ecoclean GmbH 

When to use systematic process analysis

If there’s poor cleaning or one not meeting new requirements, Ecoclean suggests identifying the exact problem within the process. If staining is the problem, ask whether the quantity and composition of the contaminants (processing media and other substances) have changed, or whether the constituents and concentration of the cleaning medium are still appropriate.

If the cleanliness analysis after the cycle shows too many or too large particles are still adhering to the parts, this may also be due to the cleaning program and process sequence used. Possible causes include residual particles in the working chamber or on the part carriers, an unsuitable filtration system, or a clogged filter.

Modified cleaning programs can be a further reason for carrying out a process analysis. The aim is shortening process times or enhancing the cleaning result. The analysis starts by documenting the actual state, which includes verifying the process parameters, sequence, and times. Based on the analysis results, potential improvement can be identified and appropriate measures can be defined.

© Ecoclean GmbH 

Preventing mistakes

However, the cleaning process isn’t over when the parts reach their required level of cleanliness. To prevent recontamination or corrosion, which can occur even with preserved or passivated parts, it’s important to look at how parts are handled after the cleaning step. The following questions need to be answered:

●      Where, how, and for how long were the parts stored?

●      How will they be transported to the next processing step?

●      What kind of packaging is needed?

Qualified personnel

Raising staff awareness about cleanliness, as well as about the capabilities of the cleaning technology and the impact of parameter settings on the cleaning result, is a key factor. If there’s a personnel change, it’s also important that the knowledge of how the cleaning system works is passed on. Investing in the training and continuing education of cleaning staff is therefore a cornerstone in order to achieve reliable cleanliness requirements in an economical and sustainable manner.

Ecoclean GmbH