How to Use Water-Based Cleaning Agents
Traditionally, industrial cleaning has relied heavily on solvent-based cleaning agents. Unfortunately, harmful substances like trichloroethylene have been phased out due to their toxicity. In their place, eco-friendly solvent cleaners have stepped in, with hydrocarbon-based cleaners becoming quite popular. However, as companies seek to cut costs, new water-based cleaning agents are gaining traction. These agents are praised for their environmental friendliness, lower costs, and efficiency.
If you’ve been using solvent-based cleaners, what factors should you consider when switching to water-based ones? And how do you select a cleaner that fits your company’s needs? Let’s break it down.
Firstly, the materials used in industrial production vary widely, including stainless steel, copper, aluminum, iron, alloys, and plated surfaces. Is your product material compatible with water-based cleaners? Will the cleaning process affect the material? For instance, iron might rust easily when exposed to water, and copper or aluminum could oxidize and discolor. Many companies hesitate because of these concerns, but rest assured—water-based cleaning agents have come a long way. Developed over time, these agents now protect metals like cast iron from rusting during cleaning. Some even maintain the integrity of copper without causing discoloration. The key is selecting the right formulation for your specific needs.
Next, consider your enterprise's application conditions. Do you need specialized equipment for water-based cleaning? Most often, water-based cleaners require heating, and sometimes ultrasonic devices enhance cleaning efficiency. Yet, depending on your product’s surface and client demands, equipment isn’t always necessary. Assess whether your company has existing cleaning gear. Ideally, consult with water-based cleaner suppliers to determine if equipment is essential. If you already have an ultrasonic device, say with three internal tanks, it can still be adapted for water-based cleaning. For example, divide the tanks into three stages: one for initial cleaning, followed by rinsing, and finally drying. This setup works well with existing equipment. Conversely, if you lack equipment, buying new gear becomes a cost factor, which we’ll address further down.
After choosing the cleaner and assessing equipment, the next critical step is verifying the practicality of water-based cleaning for your business. Is it truly suitable? The answer lies in trial and error. No water-based cleaner is perfect for every scenario due to varying product types. Each application requires a tailored detergent formula. Thus, partner with a manufacturer offering R&D support to test product suitability and guide your cleaning process. Remember, theory alone won’t suffice; practice proves all.
Here’s a real-world example:
A metal stamping factory in Shenzhen’s Longgang district recently received an order for stainless steel stamping parts. The customer demanded flawless surfaces, free of dirt, scratches, or deformities. Through referrals, the factory reached out to our company, Changlufeng Chemical, to discuss their cleaning needs. Our team immediately sent a customer service representative to the factory for direct consultation. Once on-site, our rep spoke with Manager Lin.
Initially, we discussed that the batch consisted of SUS304 stainless steel with visible surface grime and residual oils from processing and molds.
Our customer service explained two cleaning methods: solvent-based and water-based. Since the factory lacked prior experience with cleaning processes, Manager Lin asked which method was superior, comparing effectiveness, cost, and required equipment.
Our rep gave a candid response. For long-term projects requiring frequent cleaning, water-based cleaners are preferable. These agents are diluted to a 2-5% concentration, keeping costs low. However, the process is more involved, particularly since customers demand spotless surfaces under intense lighting. This necessitates multiple rinses, including with industrial-grade purified water. Therefore, water-based cleaners are cost-effective for long-term needs but less so for short-term, smaller batches. For smaller quantities or short-term orders, solvent-based cleaners are more economical, given their higher per-unit cost but fewer steps.
Manager Lin mentioned the order would be ongoing, with approximately 100K pieces cleaned daily. Thus, the rep suggested water-based cleaning. Considering the company’s setup, a multi-stage process was proposed: ultrasonic heating for coarse cleaning, followed by another ultrasonic stage for fine cleaning, municipal water rinses, then a final purified water rinse before drying. Additional enhancements, such as spray rinsing or air-drying, could boost effectiveness if needed. Experiments showed one ultrasonic cleaning stage sufficed in some cases. The final purified water must be sourced from an industrial purifier, though filtered tap water might suffice for certain clients.
Following this discussion, Manager Lin understood the approach. Our team remained committed to transparency, encouraging hands-on testing. After agreeing to a trial, we conducted a time-based simulation experiment.
At the test site, we followed the typical cleaning procedure, achieving satisfactory results. Manager Lin confirmed the product met cleanliness standards. Further simplifying the process to just one ultrasonic cleaning stage yielded equally favorable outcomes. Ultimately, the factory adopted a streamlined water-based cleaning protocol: ultrasonic cleaning, rinsing, purified water rinse, and drying.
This collaboration proved mutually beneficial, strengthening our partnership.
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