Bath exchange is an important consideration for your cleaning process. Why? Because bath exchange means cost, time, and efforts.
The frequency of bath exchanges largely depends on the type of cleaning system in use. Below, we will explore the key differences between solvent-based and water-based cleaning systems and how they affect bath exchange requirements.
Solvent-Based Cleaning: Continuous Solvent Recovery Through Built-in Distillation
In a closed solvent cleaning machine, oils can be effectively separated from the solvent thanks to the built-in distillation unit. This purification process allows the solvent to be reused across multiple cleaning cycles, significantly reducing the need for frequent bath exchanges.
Nevertheless, as used solvent is constantly re-purified and recycled via distillation – meaning more work demand is made on less solvent input – the stress on solvents could increase. Where necessary, stabilizer concentrates can be added to counteract evolving acidity, prevent discoloration or metal catalytic effects, thereby extending the solvent lifespan and enabling process security.
Solvent lifespan will also depend on factors such as contaminations (type and amount of oils, fats, waxes, metal treatment fluids etc.), the type of solvent used, amount of water (humidity, emulsions) and the process parameters (time, temperature etc). In best case scenarios, the solvent can be re-used for hundred thousand of cleaning cycles.
Water-Based Cleaning: The Necessity of Regular Exchanges
Water-based cleaning systems typically involve multiple stages, beginning with a cleaning bath and followed by rinsing baths. This multi-step process introduces the risk of product carry-over, where residues and contaminants from one bath remain in the next, reducing overall cleaning efficiency. The cleanliness of the parts depends heavily on the quality of the last rinsing bath, and often, multiple rinsing baths are needed to fully remove both contamination and cleaner residues from parts.
Unlike closed solvent machines, most water-based cleaning systems do not feature built-in distillation units. The lack of distillation means that water baths have to be exchanged and replaced regularly to maintain cleaning quality.
Additionally, water-based systems are often open systems, which are prone to evaporation losses. These losses must be monitored, measured, and compensated regularly in order to maintain a consistent concentration of the cleaning agent.
Understanding the factors that influence bath exchange frequency is essential for maintaining an efficient and reliable cleaning operation. By factoring in the time, costs and effort involved in bath exchanges, you can more accurately assess and manage your long-term operational expenses.