Controlled cleanliness of components and cleaning solutions

03_highlights_2011_RZ__ 29.05.12 21:08 Seite 26
Highlights 2011
Filtrate treatment
After the filtration process, a colorant
dosage can be added. The Villach Brewery
currently uses this for dark beer. There is
also the possibility of added ascorbic acid.
This is applied when filtering export beers.
Filtered beer is transported to a filtrate
buffer tank. It serves above all for
hydraulic decoupling of the filter system
and carbonising. The Innopro Carbamix
takes care of the fine adjustment of the
original extract. Degassed water is dosed
to the beer flow here, oriented on the tar-
get values for original extract. An afterfilter (Innopro Corvus) equipped with an
8μm depth filter cartridges ensures maximum safety of the filtration process.
Then filtrate is transported to the bright
beer cellar. Here, all tanks are equipped
with differential pressure volume measuring units. This clearly indicates how much
beer there is in each tank upon system
visualisation. Also newly installed by
KHS: a stacked pipe system with swing
bend plates, which replaces previous hose
connections. The advantages are: better
accessibility, clear arrangement and
hygiene. Plus KHS service: charging of
keg and glass bottle filling systems. This is
realised by newly installed pipelines with
the corresponding pumps and pressure
control. A new CIP system cleans pressure
tanks, pipelines and filling systems.
Another new CIP system takes care of
cleaning processes in the filter cellar.
Residual beer management is realised.
Mixed phases are transported to a residual
beer tank whose content is added to the
usual residual beer processing cycle.
Controlled cleanliness of components
and cleaning solutions
A report about the „parts2clean“ 2011
The quality and reliability of components in later operation just like the result of subsequent processes depend above
all on the cleanliness of the workpieces. In addition, increasing demands on component cleanliness have to be met in
almost all sectors. The cleaning efforts increase substantially. To be on the safe side, the solution is often „as clean as
possible“. However, this reduces profitability and thus competitiveness in most cases. In the maintenance, repair and
overhaul (MRO) sector, cleanliness of components and surfaces also play an increasingly important role. In many cases,
cleaning work is performed manually here. Apart from non-reproducibility and missing reliable results in the process,
this is associated with high costs. The industry fair parts2clean informs about cleaning methods and ways to control
the cleanliness of cleaned parts as well as cleaning solutions efficiently and demand-conform. The trade fair for
industrial component and surface cleaning took place in October 2011 at the Stuttgart exhibition center.
Demand-conform cleaning in production
Depending on the production level, the cleaning tasks in component production range from primary and interim up to superfine
cleaning. However, the respectively relevant parameters like component geometry, material, type of contamination and cleanliness
requirement are usually known. This makes it possible to pick the
one optimum solution among the numerous available cleaning
methods with respect to cleanliness and profitability. This may be
a wet chemical procedure with a hydrous cleaner or solvent. These
procedures are often also used as a local solution for interim cleaning, for example directly after a machining process in production.
Amongst other things, this avoids mixing of different processing
media, which may lead to cleaning problems and thus higher
expenses later on. Advanced developments of cleaning media
result in a higher degree of profitability, environmental compatibility and shorter process times. Media treatment also has a significant influence on the quality and costs of the cleaning process.
Effective filtration and separation systems (e.g. oil separators, particle filters, membrane filters, water treatment) help to increase the
service life of the baths and reduce disposal costs.
Cleaning technologies like hydroblasting and dry methods,
among them CO2, plasma, blast or vibration cleaning, are frequently used for cleaning individual components. They generally
have a high degree of automation, which simplifies productionintegrated cleaning. Depending on the task, it may also be expedient to combine different cleaning technologies, for example if
functional surfaces must have a higher degree of cleanliness for a
subsequent production step than the rest of the workpiece.
Cleanliness of workpieces
Residues, for example particles, burrs, dusts as well as oils,
emulsions and separating agents on workpiece surfaces cannot be
avoided during production and processing. Demand-conform
degrees of cleanliness must be achieved in the cleaning process so
that these contaminations do not have a negative effect on subsequent processes like coating, curing, welding or gluing and also do
not impair the function of the component in later use. In addition,
the achieved degree of cleanliness must be checked and documented in more and more sectors. Continuous monitoring of cleaning and rinsing baths is also becoming increasingly important.
The automotive industry has developed a standard work with the
VDA volume 19 („Inspection of Technical Cleanliness Particulate Contamination of Functionally Relevant Automotive
Components“) respectively the international equivalent ISO
16232, volume 1 to 10 („Road vehicles – Cleanliness of components of fluid circuits“) for checking whether particular cleanliness
specifications were observed. The aim of the guideline is to be able
to objectively assess and compare the technical cleanliness of a
component by means of clearly described procedures and methods
for obtaining and analysing particle contamination in production
and surroundings. These days VDA 19 is also met with great interest in numerous other industries, for example medical and precision engineering and the optics and hydraulics industry.
F & S International Edition
No. 12/2012
03_highlights_2011_RZ__ 29.05.12 21:08 Seite 27
Highlights 2011
The exhibitors at the parts2clean presented diverse systems for cleanliness
analyses in acc. with VDA 19/ISO 16232.
These include so-called extraction modules used for the different methods of particle extraction. With respect to the subsequent analysis of the particles retained in
the filter, the offer ranges from laboratory
scales for gravimetric determination and
particle scanners as well as light-optical
microscopes up to scanning electron
microscopes and microtomographs. The
device manufacturers offer systems specially
designed for automated analysis of residual
contamination filters. They can usually also
be adapted to individual in-house standards.
Companies for which an internal cleanliness control is not economic or which do
not have the personnel for this can rely on
experienced and certified service
providers in this sector.
When using liquid particle counters,
e.g. extinction particle counters, an analysis filter as used in gravimetry and
microscopy can be omitted. Prerequisite
for reliable results is that the test fluid does
not contain any gas bubbles or droplets of
external fluids when measuring.
If residues of processing media are
encountered on the surface after cleaning,
these may impair the quality of subsequent
processes like coating, lacquering, gluing,
curing and welding. Different test methods
are available in order to detect these. Test
inks are probably the easiest method.
Inline systems are also available. These
use different methods, for example the relative change of luminance resulting from
thin layers on the surface, or laserinduced, time-resolved fluorescence spectroscopy. Beyond that the exhibition spectrum also includes systems for contact
angle measuring. These are also available
as mobile devices.
Monitoring of cleaning and
rinsing baths
A premature exchange of baths results
in unnecessary costs. If cleaning and rinsing baths are exchanged too late, the cleaning quality is off, which results in expensive follow-up work. Therefore, bath
monitoring and media treatment is an
important factor in quality and cost-optimised production. Different systems are
available for continuous monitoring of the
cleaning baths featuring manual measuring
devices as well as fully automatic systems.
The latter determine the presently available cleaning power in the running process
and dose the cleaning medium automatically depending on consumption or indicate a required bath exchange in due time.
In addition to the information provided
by the exhibitors, the German-speaking
industry forum provided a lot of knowhow concerning analysis methods and
technical cleanliness.
F & S International Edition
No. 12/2012
through experience
From yarn
to filtration
– Belts for vacuum belt filters
– Belts for drum filters
– Filter cloths for filter presses
– Liners for filter centrifuges
The world forum of the process
industry and the trend-setting
technology summit for chemical engineering, environmental
protection and biotechnology.
Visit us at our booth in
Frankfurt am Main, Germany
18 – 22 June 2012
Hall 5.0 Booth D60
Sefar AG
Hinterbissaustrasse 12
9410 Heiden
Phone +41 71 898 57 00
+41 71 898 57 21
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