Hubbard-Hall has developed an emulsified cleaner that is optimized for filtration. Combined with its membrane filter, this solution enables users to regenerate the cleaning solution.

The working principle of the parts cleaning system is to transfer dirt to the cleaning solution. These solutions have limited capacity and must be replaced regularly. This process can be costly and destructive, but until now, alternative methods of regenerating cleaning solutions through filtration have been difficult to achieve on a reliable and cost-effective basis.

The emulsified cleaner developed by Hubbard-Hall (Waterbury, Connecticut) solves this problem through a formula combined with proprietary membrane filtration technology. This matching of cleaner characteristics and filter design provides a way for parts cleaners to reduce downtime, increase efficiency, and reduce costs.

Like customers and end users, finishing processes such as electroplating, galvanizing, paint, and coating require clean surfaces. To achieve this, industrial parts cleaning systems are incorporated into the manufacturing process. These systems are designed to remove fouling on the feedstock or fouling added in previous manufacturing operations. The soil includes mapping compounds, polishing compounds, processing oils, corrosion inhibitors and even fingerprints.

Two cleaning methods are used in the manufacturing process: immersion type (rack type or barrel type) and impact type (spray type). Both combine a cleaning solution with agitation, usually heating, to remove dirt on the surface of the part.

The cleaning solution combines solubilization, wetting, emulsification and saponification to suck dirt away from the place where it is attached.

During the dissolution process, the detergent will dissolve the dirt. An example is the use of acid to dissolve rust on steel.

Wetting uses the difference in surface tension to pull the soil from the surface into the solution.

Used when the dirt does not dissolve, the emulsifier is a surfactant or emulsifier with hydrophobic and hydrophilic elements to pull the dirt from the surface. Surfactants are characterized by their hydrophilic-lipophilic balance (HLB), which determines their relative attractiveness to oil and water. A high HLB value indicates a greater tendency to solubilize, while a low value indicates more emulsification.

Saponification is a chemical process in which fatty acids (such as lard on stamped steel) react with alkali to form soap. Because it is water-soluble, this makes it easier to remove dirt.

Through emulsification and saponification, the soil remains in the bath. After a few days or weeks, the solution will become saturated and less effective, increasing the risk of re-staining the parts as they pass. When this happens, the only option is to dump the bathtub.

Non-emulsifying cleaners avoid this problem by using an oil separator-coalescer or oil skimmer-to remove the oil. However, these cleaners cannot remove all types of dirt. In addition, some dirt will emulsify without the help of a solution.

A good filter must be able to withstand high temperatures, pH values ​​ranging from strong acids to strong bases, and thermal shocks. It should be durable to minimize the frequency of replacement, and it must have pores sized to remove oil but not surfactants.

Three types of filters are used with emulsified cleaners. these are:

Each type has its own advantages and disadvantages. Ultrafiltration used in reverse osmosis works by molecular weight cut-off. The disadvantage of this is that it removes the surfactant from the cleaner, making it ineffective.

Polymer filters have limited capacity within the necessary pH and temperature ranges. They are also easy to damage, cannot back pulse, and need to be replaced frequently. The ceramic filter can handle a wider range of pH and temperature, can back pulse, but is fragile and susceptible to thermal stress cracking.

Hubbard-Hall's complement to filtration technology is a combination of stainless steel and metal oxide membrane (MOM) filters. The use of MOM-coated 316 stainless steel can form a filter with a controllable pore size. It can withstand temperatures exceeding 200° F and pH values ​​from 0 to 14. It is durable, can reverse pulse and can be cleaned instead of replaced.

The matching of the characteristics of the cleaner and the filter design provides a method of regenerating the aqueous cleaning solution for the parts cleaner.

When dirty detergent is pumped onto the membrane, two things happen. First, the cleansing liquid is cleaned through the pores, while the larger emulsified oil molecules are eliminated. Secondly, the membrane destroys the emulsion between the cleaning agent and the oil, so that more cleaning agent can be recycled.

Improving filtration is only part of improving bath repair. Another ingredient is a cleaning agent that can be used in conjunction with stainless steel MOM filters.

Demulsification requires precise control of HLB value, cloud point (water solubility of surfactant at temperature), charge and micelle formation. Aquaease-Infinity in Hubbard Hall has all these features.

Aquaease is designed to allow the cleaning fluid to flow continuously from the parts cleaning tank to a separate process tank without stopping the cleaning line. From here, it is pumped into the membrane filter. The waste material (soil) is returned to the treatment tank, and the recycled cleaning agent is returned to the cleaning tank.

With Aquaease, the dirt will be returned to the treatment tank, and the regenerated detergent will be returned to the washing tank.

The benefits of this system include extending the life of the cleaning solution by three to four times. By reducing the frequency of bath repairs, it can also reduce downtime, halve the consumption of cleaning solutions, and save energy and water. Eliminates the re-soil waste and problems of downstream operations (or customers) and reduces the amount of waste to be disposed of or processed.

A typical large-scale clean production line may consume US$100,000 worth of cleaning agent per year. Dragout usually accounts for 35% of the loss. Among the other 65%, 95% can be recovered by using Aquaease. This can reduce annual cleaning agent expenditures by as much as $62,000. Reducing downtime and reducing hazardous waste disposal costs may also help save costs.

Emulsification and saponification cleaning processes are essential in many industries and enterprises, but they will increase management costs and complexity. Switching to water-based cleaners that are optimized for use with the new filtration technology can extend the time to change cleaners. This leads to higher operational efficiency and lower costs.

How to use it for planning, preventive maintenance and troubleshooting.

Cabinet manufacturers say that powder coatings provide more benefits.

Powder coatings are one of the most durable finishes that can be applied to industrially manufactured products. They provide excellent corrosion protection and are very safe because they do not contain volatile organic compounds.

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