The Science Lab
The Importance of Remanufacturing Cleaning
Remanufacturing is defined as the process of returning a used product to at least its original performance level with a warranty that is equivalent to or better than that of a newly manufactured part. There are several benefits to remanufacturing, including:
- Economical method to maintain vehicles
- Quick method to get equipment back in operation
- Performs in the same manner as the original parts
- Reduce raw materials consumption (carbon footprint) vs original production of new parts
- Reduces GWP (Global Warming Potential) from fugitive emissions generated during original manufacturing
Upon receiving engines, transmissions, cores, and other miscellaneous components, the initial action is cleaning. The attached soils must be removed to disassemble and inspect parts. Poor cleaning can require additional time/reruns to achieve desired results as well as affect work area housekeeping. Difficult to remove soils such as burned-on oils and carbon, oxidation, and grime are quickly removed without damage to the parts when using KYZEN METALNOX products.
These products are formulated for maximum cleaning power while being environmentally safe. Furthermore, they are designed to provide exceptionally long bath life which lowers operational costs! Take a look at what products KYZEN offers for remanufacturing by downloading this brochure or learn more by watching Ethan Mueller’s Tech 2 Tech session on this topic here.
Corrosion Protection for Brass Metals – A Case Study
Cleaning Requirement:
A large manufacturer needs to remove screw machine oils from a variety of brass screw machine parts and provide three months of corrosion protection in open-air warehousing after cleaning.
Situation:
The large manufacture of brass screw machine parts consists of pipe/tubing fittings for applications including hydraulic, pneumatic and refrigeration. The parts are cleaned in a large number of Ransohoff Immersojet washers which incorporate spray-in-air, spray under immersion, and basket rotation. They range in size from single to six basket systems, and all incorporate a wash – rinse – dry process.
The customer had experienced a very costly corrosion problem during the summer of 2006 when black corrosion pits developed on finished goods inventory after leaving the customer’s plant. As a result, the customer switched to a neutral pH cleaning chemistry which only partially cleaned the parts leaving a protective coating on the parts. The two resulting problems were (1) the oily parts did not appear as bright and clean as competitors’ similar parts, and (2) the residual oil layer was difficult to control and resulted in sporadic corrosion problems.
Parts were test cleaned using various chemistries at KYZEN’s Nashville, TN Technical Center where the customer’s cleaning process was simulated. The cleaning/corrosion problem was duplicated using cleaning chemistries similar to those which the customer had used.
- Parts cleaned in this neutral pH chemistry were left oily but did not corrode during accelerated humidity chamber testing.
- Parts cleaned in mild alkaline chemistries displayed no signs of residual oil, but corroded severely in the humidity chamber, very similar to what the customer was experiencing with the alkaline chemistry they had used previously.
The product which proved to successfully remove the machining oil and provide protection for the brass parts was METALNOX M6310, a mild alkaline cleaning chemistry that contains corrosion inhibition components that are effective on brass, copper and aluminum. Several months of testing at KYZEN’s Technical Center provided assurance for both the customer and KYZEN to begin converting the Immersojet washers to METALNOX M6310.
Results and Conclusions:
The customer implemented M6310 in all 16 Immersojet Washers. During a 3-month period of time, KYZEN conducted bi-monthly humidity chamber accelerated corrosion tests on parts cleaned at the customer’s plant, with no failures. No parts were returned from the field for corrosion. The customer claims parts are cleaner and brighter, and they are now more competitive in their marketplace. M6310 demonstrated improved bath life and increased cycles between chemistry changes from approximately 150 to 180.
To read more case studies like the one above, visit our E-Knowledge center today. Additionally, learn how you can take advantage of our services like the ones mentioned in this study by visiting here.
Debbie Carboni – Product Line Manager – Electronics
Chuck Sexton – Global Product Line Manager – Industrial
