How Clean is Clean?  

For manufacturers that wash parts during the production process, cleanliness requirements depend largely on the product's function, material, and subsequent production steps. Defining how clean is "clean enough" typically involves:

• Industry Standards: Some industries, like aerospace, automotive, and medical devices, have strict cleanliness specifications. These standards may require testing for particles, oils, or other contaminants.

Example: The automotive industry may require that parts be free from dirt, oil, and metal shavings that can affect later steps such as coating or painting.

• Surface Requirements: Depending on the next process, such as coating, welding, or heat treatment, parts may need to be free from oils, dirt, or even microscopic particles. Contaminants can reduce adhesion, lead to corrosion, or compromise the quality of a finish.

Example: In painting, even microscopic debris can affect surface adhesion, causing peeling or other defects.

• Component Functionality: For parts used in critical applications (like hydraulic systems or precision instruments), cleanliness must meet high standards to avoid contamination that could result in performance failure.

Common methods to assess or measure cleanliness of a part after passing through a Washer include:

• White glove test. Just as it sounds, run a dry white glove or cloth over the part surface. If there is any reside on the fabric, the part is not clean.

• Water break test. A small amount of distilled, DI or RO water is poured onto the surface of a part. If the water doesn’t flow off the part as a well-defined sheet, the surface is clean. If it breaks into separate droplets, the surface is still contaminated by a hydrophobic film (e.g. oil).
• Millipore test. The part is rinsed with a cleaning solvent. Residue on the surface will be removed and suspended in the solvent. The cleaning solvent is collected and poured through filter paper with a known pore size. Any residue larger than the pore size of the filter collects on the filter paper. The filter paper and residue are dried and weighed. The mass of the dirty filter paper is compared to a similar area of clean filter paper. The difference is the mass of the contaminants which quantifies the level of cleanliness.

In summary, "clean enough" is determined by a combination of industry standards, downstream processes, and the specific role of the part in a system. Manufacturers often define cleanliness in terms of acceptable particle size, chemical residues, or biological contaminants.

How Do Industrial Washers Work? What is Torrent Technology™ and How is it Different?

Industrial washers are engineered to clean parts as part of the manufacturing process. However, Torrent Technology™, featured in the Torrent Washer™, offers a significant improvement over traditional washers by maximizing cleaning efficiency while reducing environmental impact and costs. Here's how Torrent Technology™ stands apart:

Types of Industrial Washers:

• Spray Washers: These use high-pressure jets of water or cleaning solutions to blast off contaminants.
• Rotary Drum Washers: Parts are loaded into a rotating drum where they are tumbled and cleaned through spraying or immersion.
• Conveyor Washers: Parts move through different washing stages (like prewash, rinse, and drying) on a conveyor belt, ideal for continuous production processes.

Why Torrent Technology™ is Superior:

• Torrent Technology™ employs patented rotating riser bars and nozzles that move in a circular pattern, providing 360-degree cleaning coverage. This results in more complete cleaning, especially for parts with complex geometries. Compared to traditional washers, the targeted spray pattern of Torrent Technology™ uses 75% fewer nozzles, leading to:

• Water and Chemical Savings: Torrent Washers use up to 75% less water and chemicals than conventional washers, reducing the environmental footprint.
• Energy Efficiency: The process requires less pump horsepower, saving energy and reducing operational costs.
• Reduced Treatment and Disposal Costs: By using less water and chemicals, the washer minimizes the amount of wastewater and chemicals that need to be treated or disposed of, further lowering costs.

Overall, Torrent Technology™ maximizes performance while reducing energy consumption, chemical usage, and water waste, making it an eco-friendly and cost-effective solution for manufacturers.

Cleaning Methods:

• Water-Based Cleaning: This is the most common method. Detergents, surfactants, and sometimes solvents are added to water to break down oils, dirt, and contaminants.
• Ultrasonic Cleaning: High-frequency sound waves generate cavitation bubbles in the cleaning liquid. These bubbles implode, dislodging contaminants from the surface and crevices of parts.
• Solvent-Based Cleaning: For more challenging contaminants (like heavy oils or grease), solvents may be used to dissolve and remove residues.

Rinsing & Drying:

After the wash stage, parts are rinsed with fresh water or a solvent to remove any remaining cleaning agents. Drying typically occurs via hot air blowers, infrared heaters, or vacuum systems to ensure no residual moisture remains.

Steps to Assure a Thorough Clean for Quality Production

1. Pre-Cleaning Inspection: Start by identifying potential contaminants (e.g., oils, grease, or metallic debris) on parts to ensure proper cleaning methods are used.

2. Choose the Right Washer & Method: Torrent Washers with Torrent Technology™ offer superior cleaning for complex geometries and hard-to-reach areas with fewer nozzles and less water.

3. Monitor Key Cleaning Parameters:

• Temperature: Higher temperatures can improve the effectiveness of cleaning solutions.
• Detergent Concentration: Maintain the proper chemical-to-water ratio to maximize cleaning without leaving harmful residues. Wash Cycle Time: Ensure the cleaning cycle is long enough to fully remove contaminants without compromising the part.
• Mechanical Action: With Torrent Technology™, the rotating riser bars and nozzles provide enhanced mechanical cleaning action, further boosting efficiency.

4. Inspect Parts After Cleaning: Use methods like particle counting, white-glove tests, or chemical analysis to ensure that parts meet cleanliness standards.

5. Final Rinse with Purified Water: In some industries, using purified or deionized water for the final rinse ensures that no minerals or other contaminants are left on parts, which is crucial for high-precision applications.

6. Drying Properly: Ensure thorough drying to avoid issues like water spots, corrosion, or rust.

7. Post-Cleaning Protection: If parts are clean but vulnerable to re-contamination, consider protective steps like immediate packaging or using clean-room environments.

By combining advanced cleaning technologies like Torrent Technology™ with thorough inspection protocols, manufacturers can ensure parts are not only clean but ready for high-quality production, all while reducing costs and environmental impact.