Ecoclean India Blog

Thank you for your interest in our company and products. In our Ecoclean India Blog you will find latest information about the company, the people behind the scenes and of course all about our innovative systems and solutions for industrial parts cleaning and surface processing.

Cleaning of Shock Absorber Parts

Elimination of TCE (Trichloroethylene) and compliance with Safety Norms

Ecoclean’s Minio 85C helps in Elimination of TCE (Trichloroethylene) and compliance with safety norms. This environment friendly compact machine takes minimal space on the shop floor and helps in reduction of overheads; while it achieves stringent cleaning results consistently. With its Minio 85C for cleaning of shock absorber parts Ecoclean in India has been able to win the patronage of its esteemed customers. The Customer is a leader in Indian auto components industry. The company provides widest range of Ride Control Products in India namely shock absorbers, struts, and front forks catering to Passenger cars, Utility Vehicles, Commercial Vehicles and Two wheelers.

 

Background:

'Cleaning' is very critical in the manufacturing process of shock absorbers, dust or oil contamination on the parts results in improper performance of the parts”. Customer therefore demanded an alternative to their existing trichloroethylene-based machine with a smaller footprint, achieving better cleaning results.

 

Challenge:

Customer’s range of products includes various types of shock absorbers, front forks and struts. These components are internal valving components. The major reason for the failure in valve systems is due to improper cleaning of parts before assembly.

  • Cleaning of sintered metals which are porous in structure.
  • Replacement of TCE (Trichloroethylene) in the new machine.
  • The type of contamination is in the form of oil and dust.
  • stringent cleanliness level not exceeding 100 microns and no contamination more than 0.1 milligrams. 
  • 100% dry parts to avoid damping of the parts.
  • Footprint of the existing machine

 

Solution: Ecoclean’s Minio 85C fulfilled customers requirement for a compact, cost effective, hydrocarbon machine that eliminated the use of trichloroethylene. Minio 85C - hydrocarbon machine is not only an environment friendly solution but also has a very high built-in quality to meet the safety norms for the customer.

 

 

Features:

Minio 85C is a Compact modular design This system sets new standards as a result of features such as:

  • Efficient high-power injection flood wash, two flood tanks and filters contained in the basic system
  • Redundant safety equipment
  • Use of vacuum technology during cleaning, drying, distillation
  • Cleaning above flash point
  • Double full stream filtration
  • Eight cleaning programs
  • Inert gas welded pipelines

 

Benefits: Thus, we conclude that the customer benefited in many ways with the replacement of the new hydrocarbon machine.

  • It helped in increasing the productivity virtually by replacement of the old machines (complex handling mechanism) by one single machine, reduced material rejection due to consistent cleaning results. Reduced maintenance and higher uptime (~ 95%), no need to change cleaning media due to excellent regeneration system (online distillation). Electrical energy conservation by heat recovery Less energy consumption (< 9 kWh)
  • The hydrocarbon machine delivers repetitive and consistent cleaning quality.
  • The controlled emissions results in virtually zero solvent emission, use of hydrocarbons as cleaning media is less harmful to human and environment as compared to use of TCE, thus helped in compliance with environmental health and safety norms.
  • Moreover, the important fact that the replacement of the new machine has helped the customer in reducing the operating cost as compared to previous TCE based machine.
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Contact

Monika Bahuguna
Phone: +91 (0)20 4620-5007
Email: marketing.india(at)ecoclean-group.net 

Methods of Cleanliness analysis

Gravimetry test and Particle analysis

Best Technology experts often asks, “How clean do your parts need to be?” but many times our customers just know they need to be “clean”.  Since clean is relative for every application, it is important to understand part cleanliness and various clean test specifications.  The important aspect in parts cleaning systems is understanding the post cleaning process which the part will endure after cleaning: passivation, welding, assembly, medical device implant, IC circuit board final assembly, etc.


Steadily increasing requirements for technical cleanliness demand new cleaning analysis techniques.

  • Gravimetry method, famously known as Millipore test

Gravimetric (also referred to as Millipore) Testing is one method by which a manufacturer can have their parts checked for cleanliness. It is an objective, scientific method that helps to take the guesswork out of meeting cleanliness specifications. Using a flushing solvent and filters, the amount of contamination on a part can be weighed to produce an accurate account of how much contaminant is left after the production washing of the part.


Also called a solvent extraction test, the particles are flushed off the part and collect on the filter membrane paper can be analyzed microscopically using automated scanning particle counters such as a Leica to characterize the size and amount of particulate collected.  ISO 1632-10 is one such spec which determines part cleanliness based on particulate size and quantity.

  • Particle Analysis

High resolution scanner for particle analysis: Measuring quantity, size, shape and reflection of residual contaminant particles all in one place. Scanning is done in reflected and transmitted light and includes software generated reports analyzing component cleanliness.

 


Advantages of these Cleanliness
testing methods at Ecoclean’s Technology Center:

  • Time and cost savings as a result of immediate analysis on-site
  • Expert advice and active support on technical cleanliness and it’s different aspects
  • Component cleanliness analysis of different components based on VDA 19 and ISO 16232
  • Process chain analysis as a basis for optimizing production processes with regard to technical cleanliness


Note: Standards for Analysis should allow a Unification of the practical Performance and improve the Reproducibility and Accuracy of the Results.

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Contact

Monika Bahuguna
Phone: +91 (0)20 4620-5007
Email: marketing.india(at)ecoclean-group.net 

Parts Cleanliness and Analysis

Meeting highest cleanliness requirements

According to the Specifications of Cleanliness limit, Test methods are defined for residual dirt.


Specification of Cleanliness Limits

  • Weight of Particles (Gravimetry)

  • Distribution of Particles

  • Size of greatest Particle


Types of Test methods to determine above specifications:

  • Approximate Degree of Contamination

    > Visual Inspection (e.g. Wipe Test, Knock Test…)

  • Amount of Contamination e.g. per Part, per Surface

    > Quantitative Determination of the Particle Contamination (Cleanliness Analysis)

  • Optimal activation of surfaces, e.g. Surface Tension test


Visual Inspection
is defining the cleanliness of a cleaned part by visual means, i.e. wipe test, knock test or looking the part over thoroughly.


Quantitative Determination of particle contamination
: to analysis the cleanliness of a cleaned part, by measuring the dirt remaining on the component. It also helps in adhering to the cleanliness standards under VDA and ISO. 


A few methods of Cleanliness analysis:

  • Gravimetry method, famously known as Millipore test

  • Particle analysis

In our Technology center, we follow the directives laid down in VDA Vol. 19 and the international ISO 16232, and document the technical cleanliness of components.


Points to consider while conducting Tests:

  • Testing of cleanliness: Millipore laboratory
  • The part for cleanliness analysis must be protected properly and immediately shifted to grey room

  • The cleanliness laboratory must be in the closed room

  • Limited Entrance (only for the staff who is responsible the cleaning system)

  • Trained people in handling and testing after cleaning

  • Validated test method to be used!

  • Person handling the parts must wear powder free gloves

  • The dirt level of apparatus and testing liquid must be controlled: blank value < 0.1 mg

  • Blank test to be performed every time after preparation of the testing media

  • Soft particles including fibers are normally coming from the ambience or handling of the parts before cleaning

  • Important to understand that the hard particles are usually the metallic particles

  • Preservation of tested Millipore filter is important for future reference

  • Avoid Contamination, e.g.

    > No Cotton gloves

    > Handle tiny parts with Teflon tweezers

    > Pack parts into a clean Bag / Box

    > Prevent rubbing in Bag / Box

    > Seal Bag / Box

    > No use of Paper boxes

  • Keep an eye on correct surface appearance (e.g. No Burr or stuck Chip)

  • Clear Labeling (Traceability to Load/Cycle)

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Contact

Monika Bahuguna
Phone: +91 (0)20 4620-5007
Email: marketing.india(at)ecoclean-group.net 

Why Parts Cleaning?

Increasing cleanliness requirements of machined parts and components

Industrial parts cleaning is becoming increasingly important for the foundation of modern production processes in almost all the sectors of industry e.g. hydraulics, automotive and production systems, to name a few. Phrases such as 'reduction and avoidance of start-up breakdowns' and the difficulty of ever-increasing warranty periods are driving the demands for component cleanliness.

Following are the two broad targets for parts cleaning:


Ensure an optimal component surface for further manufacturing steps

  • Cleaning of undesired material (oil, emulsion particles,…)
  • Removal of passive layers (removal of rust protection oil,…)
  • Activation of surfaces
  • Protection against corrosion (applying the rust protection oil)

Compliance with cleanliness standards

  • VDA 19: Testing of technical Cleanliness - Particle Contamination of functionally-relevant automotive Components
  • ISO 16232: International standard - Road vehicles – Cleanliness of components of fluid circuits
  • NAS cleanliness codes and
  • Company specific customized standards

Technical cleanliness

In past what was known as residual contamination method has evolved into “technical cleanliness” in recent years to become an important measure of quality in the automotive and other industrial sectors. Technical cleanliness of a cleaned part is defined to ensure an optimal component surface for further manufacturing steps. The main reason to outline cleanliness is that the hard, inorganic particles cause severe damage and drastically shorten a product's lifetime. Furthermore, filmic impurities impede subsequent coating processes. To ensure an optimal component surface to deliver the desired performance and life of the end product, conforming to predefined cleanliness is required.


So how is the Technical Cleanliness defined?

Technical cleanliness is defined by the amount of contamination on the surface of a component after the cleaning process is performed. To describe the state of cleanliness, particle contaminations are determined in followings terms:

  • Mass of Particles (Gravimetry)

  • Size of Particles

  • Distribution of Particles

Particle contamination is the contaminants that remain on a component's surface. It can be:

  • Solids  

  • Metallic particles and chips

  • Broken Burrs

  • Dirt and dust

  • Organic, non-polar e.g. oil, fat

  • Organic, polar e.g. emulsion

  • Inorganic, polar (Salts)

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Contact

Monika Bahuguna
Phone: +91 (0)20 4620-5007
Email: marketing.india(at)ecoclean-group.net 

EcoCtwin – Twin chamber Cleaning Machine

Innovative Cleaning Technology Made in India

EcoCtwin Twin chamber Cleaning Machine

The EcoCtwin cleaning system is a low-cost, highly efficient system which, owing to its modular design, can be used for a very wide range of applications in cleaning parts with 50% less cycle time. Depending on the features installed the EcoCtwin is suitable not only for removing oil and emulsion from mass-produced parts but also for the fine cleaning of assembly parts.

All the cleaning stages are divided into two categories and uses an immersion process and aqueous media. Removal of large quantities of swarf from mass-produced parts and particles of dirt with a defined size in fine cleaning can be achieved by selecting the appropriate filtering system and other application- dependent optional extras. Different types of optional equipment make it possible to use the EcoCtwin cleaning system in numerous areas of metal processing.

The special feature of this machine is it’s two chambered cleaning system, which reduces the cycle time by 50%. The entire process is divided into two chambers while maintaining all the advantages of single chamber systems. For example, cleaning and rinsing respectively with Tank 1 & Tank 2 media will take place in first working chamber. While rinsing or passivation with Tank 3 along with hot air and vacuum drying processes are carried out in work chamber 2. Both the work chambers will be equipped to perform the cleaning processes like spray, Ultrasonic and Injection Flood Wash.

Equipment Features

  • Cleaning and drying process in a vacuum tight work chamber
  • 2 stage or 3 stage immersion and spray cleaning
  • Closed loop filtration with high power injection flood washing
  • Bag & candle filtration for best cleaning results
  • Integrated, efficient oil separator
  • Automatic work chamber door locking
  • Waste water free operation possible with AQUACLEAN
  • Innovative cross contamination reduction system
  • Automatic loading of basket possible
  • Rotation and swivel movements of the parts baskets
  • All parts in media contact are made of SS 304
  • Siemens S7 PLC control
  • Advanced Interactive HMI
  • Optimum maintenance access

 

Process

  • High power injection flood washing
  • Spraying
  • Ultrasonic cleaning possible
  • Hot air drying
  • Intermediate drying possible
  • Vacuum drying for 100% dry parts

 

Applications

Application for EcoCtwin is in all industrial sectors, to name a few:

  • Automotive
  • Aerospace
  • Fasteners
  • E-mobility
  • Metal Working
  • Railways
  • Machine Tools
  • and many more
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Contact

Monika Bahuguna
Phone: +91 (0)20 4620-5007
Email: marketing.india(at)ecoclean-group.net 

Advantages of single chamber cleaning machines over multi chamber systems

For the safe and reliable removal of oil, grease and chips.

EcoCmini Cleaning Machine

Single Chamber machines are those which complete all stages of cleaning in one chamber. The stages in single chamber machines, manufactured by Ecoclean India, are High power Injection Flood Wash (IFW), full immersion of parts, Spray Wash, Ultrasonic (US) washing, and then drying with Hot air and vacuum dry for 100% dry parts.

Multi Chamber Machines are those which have a different chamber for the above-mentioned different processes. This results in moving parts chamber to chamber or/and some processes which work good in combination are separated in multi chamber.

Following are some advantages of Single chamber Cleaning machines over multi chamber cleaning machines.

  • Different movements: In single chamber concept, rotation mechanism is simple, viz. complete rotation (3600); Oscillation, indexing possible; as compared to more complex mechanism in multi-chamber systems. It ensures thorough cleaning from all sides of basket and more uptime.
  • Machine footprint: By design, Single chamber machines are more compact as compared to multi-chamber machines. This results in more production per sq. feet of area, plug and play system, and adequate maintenance access.
  • Easy separation of water and oil: Unlike multi-chamber systems, in single chamber system every storage tank gets sufficient time to get stagnant, resulting in separation of water and oil by gravity. Oil separation in turn results in better cleaning results, less maintenance efforts, and high uptime.
  • Improved bath life: in single chamber, media coming from working chamber is filtered before putting back to storage tanks whereas in multi-chamber machines, by-pass filtration is used which means dirt is first put into the tanks and is filtered thereafter. Filtering the media before, results in better cleanliness quality, improved bath life, 100% filtration, low running cost, less maintenance efforts.
  • Cylindrical shape of work chamber in Single chamber: Improves efficiency of cleaning processes like Spray, Injection Flood Wash (IFW) and Ultrasonic (US); Easier to create air tight chamber. This results in generation of vacuum as less as 50 mbar; better drying efficiency; no accumulation of dirt / chips on tank walls.
  • No need of overhead conveyor for basket movement: Instead of moving basket from one tank to another as in multi-chamber machine, single chamber machine works on concept of moving media from different tanks to work chamber. This results in decreased maintenance efforts, no need of overhead conveyor / gantry for basket movement (which is difficult to maintain over time), easy draining of work chamber.

In conclusion Single chamber Cleaning machine achieves all the functional advantages of Multi Chamber Cleaning machine.

Although there is one disadvantage to consider which is longer cycle time. No other batch can be uploaded till one batch is being cleaned.

At Ecoclean India although all our machines are single chamber, however, customers looking for shorter cycle time have an option of choosing EcoCtwin, twin chamber machine.

EcoCtwin is a two chambered Cleaning machine, which reduces the cycle time by 50%. The entire process is divided into two chambers while maintaining all the advantages of single chamber systems. For example, cleaning and rinsing respectively with Tank 1 & Tank 2 media will take place in first working chamber. While rinsing or passivation with Tank 3 along with hot air and vacuum drying processes are carried out in work chamber 2. Both the work chambers may be equipped to perform the cleaning processes like spray, Ultrasonic and Injection Flood Wash.

We at Ecoclean are proud to provide a customized solution for our customers, keeping the trademark German Technology in place. Working within the frame of our parent company, SBS Ecoclean Group, and still providing the best suited solutions to our customers is our forte at Ecoclean Machines.

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Contact

Monika Bahuguna
Phone: +91 (0)20 4620-5007
Email: marketing.india(at)ecoclean-group.net