How to avoid car icing in winter?

Cars are increasingly freezing due to supercooled precipitation. In addition, the car can freeze due to sudden changes in temperature at night, as well as washing in frosty weather without complete drying.

In order to avoid freezing of rubber seals on the doors and trunk, they must be periodically treated with special auto chemicals containing silicone. After traveling in frosty weather, it is necessary to ventilate the car so that moisture does not accumulate inside, and dry the windshield.

It is not recommended to water an icy car with hot water, otherwise cracks may appear on the glass and the varnish coating may be damaged. Defrosters and plastic brushes should be used to clean the glass. However, ideally, the car should be in a garage or in a warm parking lot.

This is how the largest car wash in the world works

The German TV channel Welt published a film about the car wash company Dr. Wash, which he calls the largest car wash on the planet. Up to 4 thousand cars a day pass through the conveyors of the enterprise.

The car wash is located in German Stuttgart and, according to the authors of the film, does not lack customers. The area of the complex is 15 thousand square meters, which employs 110 employees. The washing conveyor moves at a speed of 1 km/h. The length of the chain of rotating brushes and sprinklers is 50 meters, and the car passes it in 3 minutes. In total, the body wash process includes 15 workstations.

In addition to the actual body wash, Dr. Wash is also engaged in cleaning interiors: the company is able to put in order the interiors of a thousand cars in a day. There are two interior conveyors in the complex, each employing 10 people with a strict distribution of duties: on average, it takes 8 minutes for one car.

Among other things, the complex has its own body polishing area, a gas station and an engine oil change station.

Industrial pumps are installed at the station, which pump water for washing from the city supply system, up to 350 thousand liters are consumed per day. However, there are also special tanks in which water is stored, already used, but passed through its own set of filters; purified water is reused. It is claimed that this not only reduces water consumption, but also reduces the burden on the environment.

The company needs a lot of electricity. For example, only the drying system spends up to 6 thousand kWh per day. This amount of electricity would be enough to cover the needs of two average households for a year.

The simplest body wash here costs 8 euros, and a range of services, including interior cleaning and manual waxing of the body, costs 40 euros.

In October, an American car wash equipment company posted a video illustrating the first car wash in 44 years, with an elderly Datsun 240Z sitting in a shed all the while.

A washing station equipped with brushes to remove fooling on boats

Using the same principle as car washes, a Swedish company has developed a machine that cleans the hull of boats using moving brushes. It allows to remove the fooling on the hull and is ecological, because it avoids the application of antifooling paints, harmful for the environment.

All boats are confronted with fooling, this natural phenomenon of spontaneous colonization of the submerged part of the hull by different types of organisms (bacteria, unicellular algae, green algae, etc.). It makes boats difficult to maneuver and increases the fuel consumption of motorized ones. To delay this process, the most commonly used technique is to apply antifooling paint to the hull. This contains biocides and is therefore harmful to the environment. Its use is furthermore limited by decrees. Faced with this problem, the Swedish company Rentunder AB has developed an alternative solution inspired by car wash stations.

A washing station equipped with brushes to remove fooling on boats

The process is purely mechanical and is based on brushes, the rotation of which removes the fooling. Installed in ports, it is in the form of a U with floating pontoons arranged on three sides. The boat enters through the open one, then a door closes behind it, according to the same principle as the sectional doors of car garages. Horizontal brushes are then positioned on each side of the hull to clean it and automatically adapt to its shape. This process is suitable for boats not exceeding 6 meters in length and a draft (vertical distance between the waterline and the bottom of the keel) of 2.4 m. An additional brush is also used to clean the waterline, and under the hull, brushes mounted on jacks have the function of cleaning the keel.

A retention basin is positioned under the brushes to collect the waste which is then pumped, then filtered, before being evacuated to a specialized sorting centre. “Initially, chips of antifooling paint come off with the organisms, but the long-term objective is to stop using paint and clean the hull regularly with this machine,” explains Gaël Minier, President of G&G Boatwash, the company that imports this equipment into France and several neighboring countries.

The washing station can adapt to the depth of the ports

This equipment won the innovation competition at the last Paris boat show in the Service category. For the moment, only one machine is installed in France, in Les Sables-d’Olonne. It was first assembled and tested in Sweden, then disassembled to be transported in the form of a module to its destination. The set weighs just under 5 tons, and transport is provided using two semi-trailers or two containers. “This brushing system is robust and weighs 800 kg, adds Gaël Minier. The standard machine has a draft of 3.2 m, but it is possible to adapt it according to the different depths of the ports. Hydraulic motors and hoses contain biodegradable oil so as not to pollute the water in the event of a leak. »

This process requires regular cleaning of the hull, the frequency of which depends on the type of water. For boats navigating on lakes or in cold waters such as those located in Sweden, it is necessary to wash the hull twice a year. In the waters of the Atlantic zone, the cleaning should be done between 6 to 7 times a year, and in warm waters like those of Miami, it should be done monthly. On the other hand, the process is not suitable for boats that have remained for example two years in the water and on the hull of which are glued 100 kg of mussels.

A washing station equipped with brushes to remove fooling on boats

Despite the need for this regular cleaning, this process nevertheless proves to be economical, according to Gaël Minier: “It does not cost more than the cost of the application of an antifooling paint carried out by the owner of his boat, because you have to count the cranage, the sanding and the painting. And it costs less than the professional solution of applying antifooling paint at a shipyard. In Les Sables-d’Olonne, unit washing costs between 40 and 210 euros depending on the size of the boats, and it is possible to subscribe to an unlimited number of cleanings per year for a price starting at 300 euros, for boats measuring 6 meters, to 1,750 euros, for those reaching 16 meters.

This cleaning takes a short time, about a quarter of an hour. It has the advantage of keeping the hull of boats permanently clean and thus saves fuel consumption. Currently, the machine is controlled by an operator using a wi-fi remote control, but the Swedish manufacturer is continuing its research and development work to make the station completely autonomous, like car wash stations.

Reduce water consumption in industry

Water is costly. All living beings need it to quench their thirst. However, people quickly realized that the seemingly limitless resource can also be used for many other purposes.

Gradually, water consumption in industry grew rapidly. At the same time, climate change means that water supplies are becoming scarce in many regions. Read here why companies need to reduce their consumption of this precious liquid and how this can be done.

Why climate change is causing water shortages

The fact that water regenerates itself again and again in nature is due to the ability of the air to hold water vapour. The amount of vapor depends on the air temperature. The warmer it is, the more moisture it can hold over open water and wet surfaces. Humid air is lighter than dry. It rises to higher layers of the atmosphere, is blown away by the wind and reaches places that are so cold that the air has to let go of the water again. It then falls back to earth as precipitation in the form of rain or snow. Global warming is increasing the water content in the atmosphere. To make matters worse, water vapor is one of the greenhouse gases and drives global warming. The earth is drying out more and more. The industry must adapt to reducing water consumption.

Water consumption in industry

The most effective way to reduce water consumption is where large amounts of this resource are used. This is the case when water is used as a solvent for surfactants, salts, acids and alkalis and as a means of transport for substances, mechanical energy and heat. It is used as a solvent on a large scale in the metal processing industry. There, water is a component of cooling lubricants that enable workpieces to be machined. Surface technology uses aqueous solutions to clean, pickle and coat parts. In the chemical industry, most of the water is used for cooling or heating the reaction mixture.

Ways to reduce water consumption

In order to reduce water consumption in industry, three main practices are used, depending on the area of ​​application:

  • closed water circuits
  • extension of downtimes
  • recovery from waste water
  • closed water circuits

Closed circuits are the means of choice when water is used as an energy source. The required temperature level decides which state of aggregation is required. Liquid water is used for cooling or heating in the range from 0 °C to 100 °C. Hot water can be used very well in heating circuits. For cooling water, it is more economical to release the heat extracted from the process to the environment via evaporation in cooling towers. In these open circuits, the evaporated water has to be replenished. Since the salt content of the water would continue to increase as a result of evaporation, it is also necessary to discharge a certain amount of water and replace it with fresh water. Water consumption is reduced if the desalination water is treated or used as process water.

Temperatures above 100 °C can be reached through the use of steam. As the steam gives off heat to the process, it usually condenses. The condensate can be returned and reused as boiler feed water.

Reduce water consumption in industry

Extension of downtimes

Water-mixed cooling lubricants and surface technology baths gradually lose their effectiveness over the course of use. They are therefore disposed of at certain intervals and replaced with a new batch. Water consumption can be significantly reduced if the service life is extended through maintenance measures. Water-mixed cooling lubricants can be maintained by regularly separating out tramp oils and filtering out fine chips and dust. This also applies to cleaning baths, in which the cleaning agents have to be added afterwards.

Recovery of the water from the waste water

Water consumption in industry can be significantly reduced if the waste water produced is treated and reused as service water. In wastewater treatment, valuable ingredients can often be recovered in addition to the water. Various processes are used for waste water treatment. It often takes place in several stages. Solids can be removed from the water with filters. Suspended matter can be flocculated. Skimmers and separators are used to remove oils. In addition, vacuum evaporation, ultrafiltration or reverse osmosis can be used for water treatment.

Vacuum evaporation

With vacuum evaporation, the heat is supplied at negative pressure. This results in a lower boiling point. The vapor then condenses at normal atmospheric pressure and a higher temperature. Due to the temperature difference, the evaporation heat can be recovered and fed into the process.

Ultrafiltration

With ultrafiltration it is possible to remove very small particles and macromolecules from the water. Membranes are used as the filter medium, the pores of which are adapted to the size of the substances to be removed.

Reduce water consumption in industry

Reverse osmosis

Reverse osmosis is a process in which natural osmosis is reversed using increased pressure. Natural osmosis is a process in which a solvent penetrates through a porous skin. Driving force is a concentration difference between solutions on both sides of this skin. The solvent penetrates into the area of ​​higher concentration until the resulting increase in pressure terminates the process or ruptures the skin. The process can be observed, for example, with ripe cherries that burst after a downpour. In reverse osmosis, stable membranes take over the task of the skin. The pressure is increased on the high concentration side until it exceeds the osmotic pressure. Then the solvent permeates through the membrane to the low concentration side.

Fungal infestation due to plant downtime

«Protect cooling lubricants from germs»

Water-mixed cooling lubricants are an ideal habitat for various fungi and bacteria. The microorganisms or their spores are ubiquitous. They get into the systems primarily through the air and through contact with human skin. Preservatives prevent many germs from multiplying. Others cannot tolerate oxygen and are deactivated by the circulation of the cooling lubricant. However, they come to life during a longer system downtime.

What do microorganisms do to cooling lubricants during system downtime?

Living microorganisms feed on components of the cooling lubricant, excrete metabolic products and multiply. During operation, the mixture of water and concentrate is constantly circulated. The intensive contact with the oxygen in the air and the effect of the preservatives prevent the metabolism of the organisms.

When the system is at a standstill, the liquid is still. Penetrated tramp oils collect on the surface, solid particles sink to the bottom. New conditions arise at the interfaces. Then the fungi and bacteria gather in the places that offer them comfortable conditions. Those who need oxygen stay on the surface. Those who are harmed by oxygen sink to the bottom. Fungi settle on the machine parts. When each has found its place, growth and reproduction begin.

Consumption of the cooling lubricant components

Water-miscible cooling lubricants are a carefully composed mixture of substances that fulfill very specific tasks:

  • Lubricants to reduce friction between tool and workpiece
  • Surfactants to form a stable emulsion of water and oil
  • Defoamers that suppress the foaming caused by surfactants
  • Inhibitors that ensure corrosion protection for machine parts and workpieces
  • Biocides to prevent the multiplication of germs

It is easy to understand that the whole system is no longer up to its task when individual components slowly disappear. In the event of a plant standstill, the degradation processes are intensified.

Test tube with fungal spores

Accumulation of metabolic products in the plants

The microorganisms break down chemical compounds into their components and convert them into other substances. Oils become carbon dioxide and water, and fragments of the long-chain compounds also remain. Strong-smelling hydrogen sulfide is formed from sulphur-containing molecules. Nitrogen compounds are converted to harmful nitrite.

The metabolic products accumulate in the cooling lubricant and throw the system out of balance.

Growth Of Biomass

The microorganisms themselves bring another problem. They form biofilms that clog the pipelines and parts of the systems can stick together. Initially, these are greasy, barely perceptible deposits of germs and metal abrasion. If countermeasures are not taken, biofilm mats develop over time that can be several centimeters thick. If this happens when the systems are at a standstill, they can no longer be commissioned properly.

Why not use effective biocides that kill all microorganisms – even when the system is idle?

The effectiveness of biocides depends on their concentration and their ingredients. It should be borne in mind that these are poisons that can also be dangerous for humans. Therefore, these substances are subject to the strict regulations of the Biocide Ordinance.

The permitted ingredients usually act selectively. That is, some kill fungi, others bacteria or algae. If the system is idle for a long time, germs can creep in that are not caught by the preservatives used.

As few biocides as possible are used. The concentration must be just sufficient to kill the target organisms. If the composition of the cooling lubricant changes, this also affects the biocide concentration. If it falls below a certain limit, individual germs can get used to the substances and develop resistance. Then the preservative no longer works.

Man with canister - he's wearing protective gloves

How can cooling lubricant emulsions be protected from infestation?

The concentration specified by the manufacturer must be strictly adhered to when preparing the water-miscible cooling lubricants. Then the preservative develops its full effectiveness. During operation, the composition must be checked regularly and the preservative must be replenished according to the manufacturer’s instructions. Special conservation measures are required before a longer system downtime. If a longer standstill is planned, contacting the manufacturer will help to find suitable means for preserving the systems.

The cooling lubricant concentration can best be determined with a refractometer. Depending on the result, the concentration is brought back into the required range by adding water or concentrate.

In addition to the concentration, the pH value and the nitrite content can be determined. Test strips that are dipped into the liquid are available from specialist retailers for both values. The discoloration of the indicator fields on the strips is compared with a scale on which the pH value or nitrite concentration can be read.

If it contains nitrite, if the pH value is below 7 or if the appearance and smell have changed, germs have probably developed. A suitable disinfectant should then be requested immediately from the manufacturer. If the microorganisms multiply in the systems for a longer period of time, the cooling lubricants cannot be brought back into a usable condition.

To prevent contamination, cooling lubricants must always be mixed with fresh drinking water. Regular machine maintenance and the ongoing separation of chips and foreign oils from the cooling lubricants in filters or separators are essential to protect against fungal infestation and germ infestation and also improve corrosion protection.

What to do if the cooling lubricant emulsion is contaminated after a system standstill?

If the cooling lubricant emulsion has “tipped over”, the only thing that will help is completely emptying the system, using system cleaners and thorough mechanical cleaning. Particular importance should be attached to the elimination of biofilms.

The main cause of film formation is the fungal attack on a system. The fungi grow on the surfaces of the plant components. They are often not detectable in the liquid. Other microorganisms, dust and metal debris accumulate on the fungal cultures. If the biofilms are not completely removed, the system will be contaminated again shortly after refilling. Cooling lubricant manufacturers have special chemical system cleaners available for cleaning systems after fungal infestation, which can also reach places that cannot be reached by mechanical means.

SOLVENT-BASED CLEANERS

The effort to get a plant ready for operation, in which germs have spread during a longer standstill, is considerable. Machine care, care of the cooling lubricants and preventive measures in the case of foreseeable system downtimes can avoid this effort.

How to protect a classic car against corrosion and restore the paintwork?

The classic car market has experienced phenomenal growth in the last ten years. A new record was set in August 2017 – Aston Martin DBR1 from the 1950s was auctioned for USD 22.55 million (PLN 91.62 million). In 2018 alone, around 30,000 jobs were delivered to Europe. classic American cars, which clearly shows that this extremely dynamic market needs the help of experts.

Standox, a paint brand from the German city of Wuppertal, has an established position as a professional partner for workshops specializing in classic car restoration. At the same time, in times of economic uncertainty, many people are looking for something specific to allocate funds. Therefore, over the past decade, the value of investments in cars has far exceeded the value of investments in coins, diamonds and old wine. This trend is an ideal opportunity for garages to improve their classic car restoration skills and develop in this market segment.

Olaf Adamek, Standox Brand Manager for Europe, Middle East and Africa – Renovation of classic cars requires both extensive technical knowledge and qualified employees. However, it can be a very lucrative source of income for workshops. The customer community is large, compact and resilient to economic changes. They are often people with extensive general knowledge about classic car restoration, who require professional help from workshops in the field of painting. They must feel that their valuable acquisition is in good hands.

When choosing the best method of restoring a classic car, you need to pay attention to details. Sometimes an order to remove a bit of rust turns into a complete renovation with painting the entire body. Therefore, access to professional support and the right products is the key to success.

Corrosion: the number one enemy of automotive classics

How to protect a classic car against corrosion

The main difference between the paint restoration of a classic car and a modern car is protection against corrosion. Until the 1980s, bodywork was mainly made of sheet metal, which is very susceptible to moisture.

Harald Klöckner, Standox Training and Technical Service Leader EMEA – There is no doubt that getting a complete repair quote is crucial. Once we come to an agreement with the customer on this topic, the main task of the painter is to protect the historic car against corrosion. First of all, it is necessary to ensure that the putty does not come into contact with the bare sheet metal, and to limit the risk of corrosion during the preparation of the substrate. Always use a thin insulating layer between the sheet metal and the putty. Otherwise, the putty acts like a sponge and absorbs water, which then ends up in the metal.

Standox recommends a three-step approach – after the surface has been properly prepared, insulate the sheet metal with a Standox acid-curing primer such as Etching Adhesion Primer U3100 and a VOC filler such as VOC Xtra Filler U7560. Of course, the specifications of the respective paint system must be followed. The VOC filler isolates sanding marks and pores, and helps to even out the surface, making it an ideal base for the topcoat.

Perfect color match

How to protect a classic car against corrosion

As in the case of refurbishing new cars, the digital color management process significantly facilitates color matching in classic cars and improves the accuracy of the entire process. Refinishers have Standox digital color tools at their disposal, such as the Genius iQ spectrophotometer and Standowin iQ software, to perfectly match the color and recreate the original shade and effect of a classic car.

When there is very little original paint left on the body of a classic car due to extensive damage, when the car has been re-painted and the original color has long since been lost under newer coats, or when the color code is unknown, Standox helps the workshop with every step of the color matching and uses its expertise in area of ​​car restoration to help pick the correct color.

– Thanks to the advanced technology of the Genius iQ spectrophotometer and Standowin iQ software, workshops have access to over 200,000 constantly updated color recipes, allowing them to perfectly match color every time. All information is transmitted wirelessly to the scale, explains Harald Klöckner.

Resources and technical support

– In addition to the practical support that our customers can count on, we also provide a wealth of technical knowledge online so that refinishers can develop their skills, adds Harald Klöckner.

Standopedia is Standox’s online guide that provides refinishers with technical information and expert advice on a variety of painting issues, such as refinishing special colors or using new products. Standox also offers an extensive collection of Standothek technical guides that provide practical information for refinishers who wish to develop their skills in classic car restoration.

– Classic car owners have a great passion for their cars, and if the car has been repaired well, the owner will probably come to the workshop with the rest of the cars. Workshops offering a personalized and professional service gain customer loyalty, gain an appropriate reputation on the market and develop their business – summarizes Olaf Adamek.

How to remove rust from metal?

Cleaning and protecting metal mechanical parts from rust is a common operation but also necessary in the industry to ensure the proper functioning of the parts and guarantee their durability. Many solutions using chemical and mechanical processes exist today to derust metal parts. However, in addition to being often time-consuming, they generate risks for: the health and safety of operators, damage to parts and the environment.

How does rust form?

Rust forms as a result of a so-called oxidation-reduction reaction, which is a slow chemical process involving the iron molecule (whether in pure iron or an iron-based alloy), present in the metal, exposed to air oxygen and water. It therefore intervenes when the metal is exposed to humidity for a long time.

Certain circumstances will also favor the appearance of rust, such as:

  • Different oxygen concentration conditions such as at sea, where the presence of salt water further accelerates the process
  • The presence of certain metals such as iron which is very easy to oxidize, unlike lead or stainless steel.

As soon as oxidation appears, it corrodes the metal, expands it and causes it to change its appearance. For example, copper turns orange then green on contact with oxidation. Then the oxidation will gradually spread, weakening the metal part until it punctures and crumbles.

Why remove rust from your metal parts?

The consequences of rust forming on metal parts are significant in all industries.

The embrittlement of mechanical parts due to rust can, under the pressure of production processes, reach their breaking point and cause stoppages in production lines or breakdowns in vehicles. This can lead to significant intervention costs, but also in terms of production losses, as well as leading to risky situations for the safety of operators.

The effects of rust thus lead to overconsumption of iron and steel production: more than 15% of steel production would serve only to replace parts damaged by rust, which can represent large sums for the company.

The consequences on the environment are also considerable in terms of the generation of waste from excessively damaged metal parts.

Implementing effective methods of rust removal as part of preventive maintenance along with protective coating can therefore help to ensure the durability of parts, saving money and saving new replacement purchases. expensive equipment.

remove rust from metal parts

How to effectively remove rust from metal?

A rustproofing process in industry always includes a process for cleaning mechanical parts and tools upstream, which are generally covered in grease and dust. The parts also require impeccable cleaning so that the adhesion of the protective coating takes place in the best conditions.

Removing rust from metal parts is a complicated task, especially when the surface of the part is not flat.

Fortunately, there are currently many solutions for derusting and degreasing metal parts:

  • some using chemicals such as phosphoric or hydrochloric acid baths
  • some of the multi-step mechanical processes such as sandblasting, shot-blasting or mechanical brushing followed by intense polishing of the parts
  • or other automated industrial cleaning machines such as ultrasonic tanks or immersion machines.

Chemical rust removal process

A chemical deoxidation process based on phosphoric acid, hydrochloric acid or caustic soda makes it easy to remove rust but presents many risks, both for the operators and for the parts.

These products will stop oxidation and remove rust but are highly corrosive and irritating to the skin, eyes, respiratory and digestive tracts if exposed. It is therefore necessary to consult the Safety Data Sheets (SDS) of these products before handling them as a precaution.

They are also dangerous for the environment, especially for the fauna and flora of aquatic environments because they increase the pH of waterways. They are also very aggressive on metal parts and risk damaging them, in particular for precision mechanics where these processes are to be banned. It is also mandatory to trace the end of life of these products according to the regulations.

Mechanical process to derust mechanical parts

remove rust from metal parts

The mechanical way using pickling techniques is the most common way to remove rust from mechanical parts, although they can be time consuming and often tedious for operators.

This includes sandblasting and shot-blasting, which consists of projecting jets of sand or high-pressure iron shot onto metal parts. These surface treatment operations expose operators to risks with the exposure of dust generated and dispersed in the air, which can cause respiratory tract disorders. High-pressure abrasive blasting can also cause severe pitting to appear on the surface of the metal and damage the more delicate parts of the components beyond repair.

There are also techniques using abrasive sandpaper or metal radial brushes but they cause traces of more or less deep grooves in the metal.

All these mechanical operations must often be followed by intensive polishing to achieve a satisfactory finish of the metal parts in order to be able to coat them with protection.

Process using industrial cleaning machines

Faster, simpler, more efficient, industrial cleaning machines can both clean grease and dust from your metal parts but also remove rust effectively.

For this, ultrasonic cleaners are the best solution for degreasing and completely eliminating rust while preserving metal parts, even their most fragile elements. Ultrasounds form pressure variations which propagate in materials immersed in a liquid. These high-frequency vibrations produce millions of tiny microscopic bubbles whose particularity is to immediately implode on contact with the part, releasing high energy which causes the oxides to detach even in inaccessible corners. At the same time, the implosion of these bubbles generates movements in the bath, conducive to cleaning. Thanks to fully automated cleaning cycles, operators can also concentrate on other key tasks.

Cleaning machines using immersion/agitation baths can also be used to remove rust, while keeping the parts intact and without operator intervention.

Industrial parts cleaning

How to optimize the bath service life

Quality-oriented industrial parts cleaning is the prerequisite for the success of downstream processes and ensures the proper use of finished products. The specific requirements for cleanliness determine which technical requirements must be created for cleaning. Economic considerations when making an investment should also include ongoing operating costs. Modern equipment for process monitoring and bath care can, for example, extend the service life of baths.

Parts cleaning process with aqueous cleaners

Industrial parts cleaning is often done with water in which washing-active substances are dissolved. These bind the impurities from previous processing steps. The water absorbs the dirt load. When the ability to absorb contaminants is exhausted and the cleaning effect is no longer sufficient, the bath is changed. The period between two bath changes is often determined on the basis of experience. If the period of time selected is too long, there will be a loss of quality in the subsequent process steps. To rule this out with certainty, the bath liquid is often changed too early.

The right time can be determined by clearly defining and monitoring parameters that describe the condition of the pool. This point in time can be greatly delayed by using modern processing technology. The aim is to eject the dirt load and used cleaning agents from the bathroom. A number of material separation processes are available for this purpose. The type of contamination and the cleaning agents used are decisive for the selection of suitable processes.

Industrial cleaning of metals

In most cases, metals are machined using cooling lubricants. An oily film remains on the surfaces on which fine chips and dust accumulate. Other contaminants from which metal must be cleaned can be deep-drawing oils, rolling oils and polishing pastes.

Contamination also includes oxidation products such as rust on ferrous metals or verdigris on copper alloys. The agents for industrial parts cleaning must be tailored to the materials of the components.

Processing techniques

The dirt that is removed from the surfaces during parts cleaning can be roughly divided into solid, non-water-miscible liquid and water-miscible substances. The processing methods used to extend the bath service life are based on the state of aggregation and the miscibility with the cleaning solution. Often used:

  • gravity separation,
  • coalescence separation,
  • centrifugal separation and
  • filtration.

If special requirements are placed on the cleanliness of the cleaning solution, more complex processes can also be considered, such as

  • microfiltration,
  • ultrafiltration,
  • reverse osmosis or
  • distillation.

The equipment used can be installed directly in the circuit that circulates the cleaning liquid (full-flow processing) or operated in a bypass independently of this circuit (side-stream processing). In order to optimize the processes that serve to extend the bath service life, both variants are often used side by side. The aggregates in the off-line processing can be switched on or off as required.

Gravity and coalescing separation

Free oils and coarse solids that get into the bath when cleaning workpieces can be physically separated due to their different densities. The advantage here is that the process does not affect the composition of the cleaning solution. The separators consist of a container in which the liquid can rest. Light oils float to the surface and can be sucked off or drained from there. In coalescence separators, this process is supported by built-in components on which the oil collects.

Heavy components from the parts cleaning sink to the bottom as sludge. From there they can be removed with screw conveyors. In three-phase separators, both processes take place in parallel.

Extend bath service life through centrifugal separation

Solids or oils can be removed from the cleaning liquid faster in centrifugal separators, also known as separators, than in gravity separators. The principle is also based on the different densities of the phases. The heavy components are flung against the outer wall by fast rotating movements, while the lighter phase collects in the middle. Both phases are collected and drained separately. The shorter processing time is offset by higher acquisition costs.

Filtration for a longer service life

Industrial parts cleaning often produces dirt in the form of suspended matter, which can be retained in filters. In order to avoid clogging of the pores in the filter material, coarse-pored filters are used first, followed by devices with increasingly smaller pores. Due to the good cleaning performance of the filters, significantly longer bath service lives can be achieved. The disadvantage is that the filter material has to be disposed of together with the dirt.

Microfiltration, ultrafiltration and reverse osmosis

Microfiltration, ultrafiltration and reverse osmosis are among the membrane technologies. The nature of the membranes means that the smallest particles, organic molecules or salts can be removed from the cleaning liquid. In the preparation of baths for industrial cleaning, these techniques only play a role if ultra-fine cleaning with very small particle sizes in the residual dirt is required.

Distillation for water recovery

Distillation is mainly used in the treatment of bath liquids for industrial parts cleaning to recover the water. The process is based on the different boiling points of the components. With this technique, substances dissolved in the water can be separated. It helps to extend the bath service life because the concentration of these substances can be limited to a permissible level.

Monitoring of the bath condition

When monitoring the condition of the bath for industrial parts cleaning, the concentration of the cleaning agent and the amount of dirt in the bath are determined regularly. If the value falls below or exceeds the previously specified limit value, measures are required to restore the permissible operating conditions.

This includes the automatic or manual dosing of the cleaning agent or the commissioning of cleaning stages for the bath liquid that are temporarily used in the bypass. In addition to the bath control, checking the residual contamination on the cleaned parts provides information about the condition of the bath and the effectiveness of the process.

Dry car wash: all the pros and cons

What to do if you really need to wash your car, but there is no possibility to do it at a car wash? In this case, car chemistry comes to the aid of motorists, with the help of which it is possible to put on the marble without using water: the so-called dry car wash. A blurb tells that the method works and is effective, and the main thing is that it is cheaper than usual “car wash”. But do not be flattered and believe everything what they tell marketers.

At one time, this service was offered by enterprising young people in the parking lots of shopping centers. Which, in principle, was quite convenient – while the owner of the car is exploring the galleries of hypermarkets, his car becomes clean in minutes. The method is also used by those who live far away from traditional car washes or simply to save money. But as with everything, washing without water has both pros and cons, which prevail.

Let’s not go into the chemical processes that occur when applying detergent to a dirty body – advertising says something about molecular interactions. But the dirt is really washed off. In addition to everything else, the tool is suitable for cleaning the interior and even the under-hood (before using it, however, it is worth carefully reading the instructions). And after washing, a protective layer is formed on the bodywork, similar to the one that occurs during polishing. However, this is where the advantages of dry cleaning come to an end.

In rainy-snowy season, when roads are muddy and wet, a pretty decent deposit is formed on the body, against which a dry car wash is powerless. And the attempts to take the dirt by brazen force lead to damage of varnish-and-paint covering. And people who are too diligent will be able to prepare a body for painting, using just a microfiber cloth.

It also does not work with bitumen stains. So if you have driven over the repaired section of the road and have stuck them on the body, it is necessary to spend another special means.

But especially intensive dances with tambourine begin when it comes to how to wash the joints of body parts, where traditionally there is an abundance of dirt. The same method of washing doesn’t work here as well. The reason is the inability to wash out the detergent and the amount of dirt that it has collected.

Dry washing is like a crutch – the problem of cleanliness is solved selectively and not always qualitatively. Of course, the method has the right to life, but only if the dirt on the body of your car is not old. For example, on the way to work, the “swallow” was poured with water by a cleaning machine. But even here there is a risk of spoiling the paintwork, for polishing which even at a cheap car wash you will be charged a decent amount of money.

Why do you need a parts washer?

Every workshop is always busy with customers, as vehicles are always in need of maintenance. Small or major breakdowns are always taken care of by the workshop technician, and besides the breakdown of one part or another, vehicles also need routine maintenance.

For service stations an indispensable part of equipment is a parts washer, the productivity of which at times reduces the discomfort of working moments. This equipment saves an enormous amount of time, which is very handy at times of high workload for craftsmen and others.

What parts washing equipment can do

Parts washing is sometimes necessary for small parts, and sometimes entire assemblies require complete cleaning without detailed disassembly. A part washer is tailored for just about every purpose, and can be used to clean a number of parts at once.

There are two varieties of workshop washers. One is a stationary type for procedures of large assemblies and parts such as gearboxes or other large parts. The second type is mobile – which allows you to wash parts directly on the lift, without removing them. The mobile units are also suitable for cleaning of very small parts.

Cleaning chemicals for parts

Parts washers are used in different ways. For instance, for mobile parts washers, adding detergent will be enough, while stationary parts washers need special cleaning chemicals which can wash away rust, oil and other traces of use.

It is worth noting that the chemicals do not spoil the metal, but they are too toxic. Therefore, the liquid should be drained off after washing, so as not to damage the general drainage system or the environment. This liquid must be disposed of in accordance with chemical waste regulations.

The operation of sinks should be carried out in a safe manner, and above all the use of chemicals should be remembered. Hands, eyes and breathing protection should be ensured, and by all means no unauthorised persons should be present in the area.

How to buy a vehicle parts washer

When selecting equipment for washing vehicle parts, you must be aware that sink sizes vary. A single unit or several units may be suitable for a workshop, depending on the tasks and workload of the workshop.