In manufacturing, selecting the right cleaning fluids is a critical determinant of product quality, reliability, and environmental impact. As industries increasingly prioritize sustainability, the transition to environmentally friendly cleaning fluids is imperative. This article delves into essential considerations for adopting eco-conscious cleaning fluids, particularly focusing on vapor degreasing, a prevalent method in parts cleaning.
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Outdated solvents and emerging concerns
Traditional vapor degreasing solvents such as n-propyl bromide (nPB), perchloroethylene (Perc), and trichloroethylene (TCE) have been stalwarts in vapor degreasing. However, mounting environmental regulations and health concerns have cast a shadow over their use.
nPB was widely used as an effective and dependable parts cleaner inside a vapor degreaser. During the past 30 years, nPB replaced other environmentally questionable chemicals, such as CFC-113, methyl chloroform, hydrochlorofluorocarbons (HCFCs) and perfluorocarbons (PFCs), which are found in many cleaning solutions. However, nPB is now under review and restricted by global government agencies due to water and air quality concerns. For instance, European safety bureaus banned the use of nPB as an industrial cleaner in 2020, citing unreasonable risks to human health. Similarly, Canada, Japan, and the United States Environmental Protection Agency (EPA) and Occupational Health and Safety Administration (OSHA) are imposing stringent regulations, with complete bans imminent.
Along with nPB, other solvents in question include Perc and TCE, which are currently banned or restricted in some countries. In the United States, the EPA added TCE and Perc to its watch list.
These solvents will need to be replaced with greener alternatives. Furthermore, perfluoroalkyl and polyfluoroalkyl substances (PFAS), known for their persistence in the environment and associated health risks, are currently under scrutiny. It’s noteworthy that knowledge and regulations regarding PFAS are constantly evolving and are expected to change further as research and data expand.
With a heightened understanding of PFAS’ detrimental effects, numerous manufacturers are actively pursuing alternatives to cleaning fluids containing PFAS. A significant shift toward PFAS-exempt or PFAS-free cleaning fluids is underway. These replacements offer effective cleaning performance while mitigating environmental effects and addressing health and safety concerns associated with PFAS exposure. By choosing PFAS-free options, manufacturers show their commitment to sustainability, regulatory compliance, and the well-being of both their workers and the broader community. This transition is a crucial step toward reducing reliance on harmful chemicals and embracing greener, more responsible manufacturing practices.
The rise of sustainable solutions
Manufacturers are now faced with finding replacement fluids that must not only meet regulatory demands but also provide reliable and consistent cleaning in their existing vapor degreasers. Most significantly, the new cleaning fluids must also be safe for workers’ health and the environment in which we live.
Fortunately, modern vapor degreasing fluids offer a sustainable alternative to their predecessors. While older cleaning fluids were undergoing phase-out, some cleaning fluid manufacturers were proactively researching, developing, and formulating new cleaning-fluid options. Some of these new fluids are specifically blended for cleaning efficacy, yet are hydrolytically stable, nonflammable for safety, and meet emerging regulatory standards. Most are proprietary blends of multiple compounds with closely held patents and are sold under each supplier’s unique brand name.
After rigorous testing, many of these new fluids have been proven to clean parts surfaces just as effectively, if not more so, compared to past solvents. Their cleaning strengths, measured by their kB value, are comparable to those of legacy solvents. Moreover, these innovative fluids have similar or even superior viscosity, density, and solvency properties. This enables them to efficiently lift, dissolve, and remove contaminants from various part surfaces, ensuring thorough cleaning results. These fluids boast lower global-warming potential (GWP), zero ozone-depleting potential (ODP), and minimal volatile organic-compound (VOC) content. They follow strict environmental regulations, including those set forth by the EPA, and help ensure that sustainability and cleaning performance are upheld without compromise. Their adoption is a crucial step toward mitigating the environmental footprint of manufacturing processes.
Harnessing the power of vapor degreasing and modern cleaning fluids
Vapor degreasing, complemented by modern cleaning fluids, is a future-proof solution for achieving cleanliness while adapting to evolving standards. A vapor degreaser works on a thermomechanical principle and typically consists of two chambers: the boil sump and the rinse sump. In the boil sump, the cleaning fluid is heated, and the parts are immersed and cleaned. Subsequently, the parts are mechanically transferred to the rinse sump for a final rinse in pure, uncontaminated fluid. This process ensures that components emerge clean, dry, at room temperature, and immediately ready for packaging or further processing.
The advantages of parts cleaning with a vapor degreaser are many. These systems are fast, cost-effective, sustainable, worker-safe, and highly efficient at trapping and removing soils from even the most intricate part designs. In addition, many of the fluids used in vapor degreasers are compositionally stable and nonflammable, enhancing workplace safety standards. Further, modern cleaning fluids exhibit superior cleaning power, with low surface tension and reduced viscosity that enables penetration into hard-to-reach areas. They effectively dissolve contaminants, ensuring components are critically clean and free from residues that could compromise reliability. Their efficacy and efficiency make them indispensable in modern manufacturing operations.
Ensuring seamless integration and optimal performance
Before transitioning to new vapor degreasing cleaning fluids, thorough evaluation of compatibility with existing equipment, parts substrates, and contaminants is essential.
Equipment compatibility
It’s imperative to evaluate cleaning fluid compatibility with existing cleaning equipment. Manufacturers should inquire about compatibility issues and any necessary equipment upgrades or modifications. Fortunately, many modern vapor degreasing fluids are designed to seamlessly integrate with existing equipment, minimizing disruptions to production workflows. By choosing fluids that require minimal equipment adjustments, manufacturers can streamline the transition process and support operational efficiency.
Substrate compatibility
Another critical consideration is the compatibility of the cleaning fluid with the substrates being cleaned. With the increasing complexity of parts, including a variety of materials such as metals, ceramics, and plastics, selecting a cleaning fluid that effectively removes contaminants without causing damage is essential. Modern vapor degreasing fluids offer high solvency tailored to specific substrates, ensuring effective cleaning without compromising material integrity. Manufacturers should conduct compatibility tests to verify the suitability of the chosen fluid for their specific applications.
Addressing contaminants
Identifying and addressing the types of contaminants encountered in the manufacturing process is fundamental to selecting a suitable vapor degreasing fluid. Matching the cleaning fluid to the specific contaminant is essential for successful cleaning outcomes. Understanding whether the contaminant is particulate, polar (i.e., inorganic), or nonpolar (organic) is key.
Particulate contaminants, such as metal shavings, dust, surfactants, stearates, and polishing pastes, don’t dissolve in cleaning fluids. Instead, they are displaced from the part surface and washed away. The cleaning fluid penetrates under the particulate, dissipates any static charge holding it to the part, and eases its removal.
Inorganic contamination includes salts, soaps, emulsion residue, graphite, oxidation residues like rust and tarnish, heat scale, smuts, and carbonaceous and metallic compounds. These contaminants are soluble in water, making aqueous cleaners a better choice for their removal. Water-based detergents and surfactants emulsify and encapsulate the contaminants, allowing them to be washed away.
Organic contaminants consist of nonpolar halogenated, oxygenated, and hydrocarbon compounds, including machining and stamping oils, grease, corrosion protection agents, esters, and baked-on resins. Specialty solvent-based cleaning fluids can dissolve and remove organic contamination effectively.
Partnering for success
You should consult with a cleaning fluid professional to determine which cleaning fluid will work for you. Good suppliers offer technical expertise, in-lab cleaning trials, onsite process audits, and ongoing support to help you achieve the best cleaning results. Leveraging the ability of trusted partners eases a seamless transition and ensures your continued success.
Preparing for change
As the regulatory landscapes continue to evolve, manufacturers must take proactive measures to ensure compliance and future-proof their operations. Anticipating potential bans or restrictions on legacy solvents and transitioning to sustainable alternatives is imperative. When selecting replacement cleaning fluids, prioritizing sustainability and long-term availability is paramount. Opting for fluids with proven effectiveness and a history of sustainability mitigates the risk of future disruptions. Moreover, considering environmental credentials such as ODP, VOC content, and GWP is essential. By choosing environmentally friendly fluids that meet regulatory standards, manufacturers can minimize their environmental impact without compromising cleaning efficacy.
Transitioning to eco-friendly cleaning fluids requires a comprehensive approach, encompassing equipment compatibility, substrate considerations, contaminant removal, sustainability, and supplier collaboration. By addressing these factors comprehensively, manufacturers can navigate the shift toward eco-conscious practices while upholding product quality and compliance. Prioritizing sustainability, compliance, and worker safety not only future-proofs cleaning processes but also ensures the long-term reliability and integrity of products.
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