Industrial part cleaning is the process of removing dirt, oils, particles and other contaminants from parts. This can be done with water, solvents or other media. The aim is to achieve a defined level of technical cleanliness, which can vary greatly depending on the requirements of the end product. A distinction is often made between pre-cleaning, intermediate cleaning and final cleaning in order to optimally adapt the cleaning process to the manufacturing steps.

Components are cleaned to maintain their function, service life and quality. Contamination can lead to malfunctions, wear or product defects. In particular, part cleaning is often a prerequisite for subsequent further processing steps – e.g. mechanical processing, welding, coating, painting, bonding, assembly, etc. In sensitive industries such as medical or semiconductor technology, clean components are often essential.

The objective is to remove contamination. Both particulate and film-like residues are removed. This ensures the quality and reliability of the end product.

Every cleaning task is unique and requires an individual solution. The decisive criteria here are: the geometry of the part, materials, processing condition, type and intensity of contamination, throughput (cycle time) and the particulate and filmic residual dirt requirements.

After this cleaning task, the cleaning process must be designed. According to Sinner's circle, four factors are crucial for the cleaning process: mechanics, temperature, chemistry and time.

Sinner's Circle is a model that shows which four factors are important for successful cleaning: mechanics, temperature, chemistry and time. It was developed in 1959 by Dr Herbert Sinner and is used today in many areas of cleaning.

Sinner's Circle helps to understand how cleaning processes work and how they can be optimised. It makes it easy to see which factor needs to be adjusted if a cleaning result is to be improved. Optimal coordination saves time and money.

Mechanics: The movement or force that loosens the dirt (e.g. brushing, spraying, ultrasound).

Temperature: The heat of the cleaning medium.

Chemistry: The effect of the cleaning agent.

Time: The duration of the cleaning process.

All four factors together form a circle. If one factor weakens, another must be strengthened to achieve the same cleaning result.

Yes, to a certain extent. Example: If the temperature cannot be increased, more mechanical action or stronger chemicals could be used instead to achieve the same result.

Then the contamination is not completely removed and the cleaning task is not fulfilled. This can lead to quality problems, failures or higher wear and tear on the components.

Essentially, a distinction is made between aqueous cleaning and solvent cleaning within wet chemical cleaning. There are aqueous cleaners, solvents (chlorinated and non-chlorinated), polar solvents (modified alcohols) and special media. The choice depends on the type of contamination and the material of the parts. Each medium has advantages and disadvantages in terms of the environment, costs and cleaning results.

Aqueous cleaning involves the use of water with suitable additives such as alkaline, acidic or neutral cleaners. It is well suited for many metallic and non-metallic materials. There are a variety of cleaning processes that ensure optimum cleaning results.

Solvent cleaners can be hydrocarbon-based or chlorinated. They dissolve oils and greases effectively and dry quickly. Chlorinated solvents must be used in closed systems.

Aqueous cleaning is considered environmentally friendly because it is water-based and is suitable for many metallic and non-metallic materials. With the right chemicals, it removes both polar and some non-polar contaminants. Disadvantages include the higher energy requirements for hot water and drying processes, the need for complete drying, and the theoretical risk of corrosion with sensitive metals.

Solvent cleaners impress with their powerful degreasing effect, fast and often residue-free drying, and good wetting of complex geometries. However, some of them are harmful to health and the environment, often require expensive closed systems and, in the case of flammable hydrocarbons, additional safety technology.

The choice between the two methods depends on the type of contamination, the material, environmental and safety requirements, and economic aspects.

Aqueous cleaning and solvent cleaning are the most common cleaning methods. There are also other cleaning methods on the market. These include plasma cleaning, laser cleaning, dry ice blasting and CO2 snow blasting.

Plasma cleaning uses an ionised gas to break down and remove organic contaminants such as fats or oils. Plasma cleaning can be used on various metals and plastics.

Laser cleaning uses short, high-energy light pulses to remove layers of dirt or oxide. The energy of the laser heats or vaporises the dirt without significantly affecting the base material. It can be used on various metals, plastics and ceramics. Laser cleaning is often used for spot cleaning before coating, bonding or painting to improve adhesion.

Dry ice blasting uses solid CO₂ in the form of small pellets, which are shot onto the surface with compressed air. Upon impact, they mechanically loosen the dirt and then evaporate without leaving any residue.

CO₂ snow blasting works with fine snow crystals made of CO₂, which hit the surface with compressed air. The combination of cold, mechanical impulse and loosening effect cleans very gently.

Filtration removes dirt particles from the cleaning medium. This prevents dirt from returning to parts that have already been cleaned. This increases process reliability and extends the service life of the media.

After cleaning, components must be thoroughly dried on a regular basis to prevent corrosion or water spots. There are various methods such as hot air, vacuum or infrared drying. The choice depends on the material, geometry and cleanliness requirements.

Dust and dirt from the environment can re-contaminate freshly cleaned parts. Cleaning areas should therefore be clean and controlled. For high requirements, work is often carried out in a clean room.

There are various methods, such as particle measurement, residual dirt analysis or optical inspection. The choice depends on the requirements for the part. Regular checks ensure consistent quality.

Common methods are spray cleaning (low pressure and high pressure), immersion cleaning, ultrasonic cleaning, flood cleaning, pressure flooding and pressure change washing (VIT).

In spray cleaning, the parts are sprayed with water or cleaning fluid under pressure. In low-pressure spray cleaning, pressures of 6 bar to 25 bar are common. The jet loosens dirt through its mechanical action. This method is flexible in its application. Nozzles that can be aligned with the part allow even hard-to-reach areas to be accessed. In addition, the nozzles or the part can be swivelled or rotated to enable cleaning of as many component surfaces as possible.

This involves spraying water onto the surface at very high pressure. This allows even stubborn dirt or deposits to be removed. The pressure is adjusted depending on the material. Pressures between 200 bar and 1,000 bar or even higher are common.

In addition to cleaning, the high-pressure jet can also be used for deburring, depending on the material and pressure.

In immersion cleaning, the workpieces are completely immersed in a cleaning bath. The cleaning fluid dissolves the dirt through chemical action. The mechanical effect is negligible. It is often combined with ultrasound to enhance the effect. Immersion cleaning tends to be used for parts with lower initial contamination, complex geometries and high residual dirt requirements. Immersion cleaning can be supported by oscillation.

During oscillation in immersion cleaning, the part is moved slightly up and down in the cleaning bath. This movement causes the cleaning fluid to flow constantly around the part, which accelerates the dirt removal process. It is particularly helpful for complicated shapes or cavities, because fresh cleaning fluid constantly reaches these areas and dissolved particles are removed more effectively.

Ultrasonic cleaning works with sound waves that create tiny bubbles in a liquid, known as cavitation bubbles. When these bubbles collapse (implode), they remove dirt from the surface of the parts through a mechanical effect. The sound waves are generated electrically and transmitted into the liquid as mechanical vibrations via special transducers – known as plate transducers or rod transducers. This process is particularly gentle and is well suited to sensitive parts. The frequency of the sound waves is decisive for the cleaning effect.

As a general rule, the lower the frequency, the larger the cavitation bubbles. Lower frequencies therefore have a higher mechanical cleaning effect than high frequencies. Common frequency ranges are:

Frequencies from 25 kHz to 40 kHz are suitable for cleaning grease, oil and particles. A frequency of 25 kHz should only be used on hard surfaces, as aluminium, for example, can be damaged by ultrasonic cleaning at 25 kHz. The frequency range from 25 kHz to 40 kHz is often used in the automotive industry and maintenance, for example.

Frequencies from 40 kHz to 132 kHz: used for precision cleaning. The mechanical cleaning effect is lower, but ultrasonic cleaning in this frequency range can also be used on softer and porous surfaces. The frequency range from 40 kHz to 132 kHz is used, for example, in the cleaning of optical components, medical technology parts, (ultra-high) vacuum technology and the semiconductor industry.

At frequencies above 132 kHz, fine and sensitive surfaces can be cleaned gently, for example in the semiconductor industry (wafers).

In flood cleaning, a part is completely immersed in cleaning fluid. This allows even hard-to-reach areas to be cleaned. Flood cleaning is used in immersion cleaning or in chamber cleaning systems. This method is often combined with other processes, such as ultrasonic cleaning, pressure flooding or basket rotation.

In pressure flooding, the parts are placed in the cleaning bath. Pumps draw liquid from the cleaning bath and return it at high pressure via nozzles. This creates strong currents and turbulence ("whirlpool effect") in the cleaning bath. This ensures thorough cleaning, even in areas of the part that are difficult to access.

The pressure change process Vacuum Impulse Technology © "VIT" from BvL uses targeted, repeated pressure changes to a defined negative pressure in a liquid-filled vacuum chamber. This creates microscopic gas bubbles that implode when the vacuum chamber is abruptly ventilated. The resulting micro-cavitation shocks remove particulate and film-like contaminants directly from the part surface – even in capillaries, blind holes and complex internal geometries. At the same time, each cycle generates an asymmetrical volume flow that flushes the medium deep into narrow structures and reliably removes detached particles. The process thus achieves a significantly higher level of cleanliness than conventional flood or ultrasonic cleaning and is suitable for both fine/ultra-fine cleaning and demanding industrial parts.

Steam degreasing is used in solvent cleaning. Steam degreasing involves generating solvent vapour, which comes into contact with the cooler components and dissolves grease. This process is very effective for oily or greasy contaminants. It usually takes place in closed systems.

After cleaning, parts must be thoroughly dried on a regular basis to prevent corrosion or water stains. If moisture remains on the parts, it can lead to quality problems during storage or further processing. In addition, complete drying ensures that the parts are immediately ready for use or prepared for subsequent processes such as coating or assembly.

In industrial parts cleaning, several methods are commonly used depending on the requirements, parts and type of system. The respective methods can sometimes be combined with each other or carried out one after the other. The main methods are hot air drying, compressed air blowing, infrared drying, vacuum drying, convection drying and condensation drying.

In hot air drying, warm air is directed over the part to evaporate moisture. The air can either be blown directly onto the parts or circulated throughout the drying chamber. This process is simple and suitable for many applications. Depending on the material, the temperatures must not be too high. Hot air drying can be supplemented with filters (e.g. HEPA H13 air filters) for high residual dirt requirements, e.g. in high purity and ultra-fine cleaning, to prevent the introduced air from contaminating (recontaminating) the part again.

In a cleaning system, a distinction is made between recirculating air drying and fresh air drying. In recirculating air drying, the already heated air is reused: it flows through the chamber, is then collected and reheated before being used again. This process is particularly energy-efficient and environmentally friendly, as less energy is required for heating. It is particularly suitable for low moisture levels.

In contrast, fresh air drying constantly uses new air from outside, which is heated and passed through the chamber. The moist air is then discharged to the outside. This process offers higher drying performance with high moisture input, but is more energy-intensive. The choice of process therefore depends on the drying requirements and energy requirements.

Compressed air blowing uses compressed air to blow moisture off the parts. The nozzles can be directed at cavities or hard-to-reach areas. This process is often used in combination with other methods.

Infrared drying is an efficient process in which heat is transferred directly to the part to be dried by means of infrared radiation. In contrast to conventional methods, the ambient air is not heated, but the radiation acts specifically on the surface, causing the material to heat up quickly and the moisture to evaporate. This enables particularly fast and energy-efficient drying. The method is particularly suitable for flat workpieces. Another advantage of infrared drying is that the heat transfer is contactless, which means that there is no risk of recontamination in the infrared drying process.

Vacuum drying is a drying process used in aqueous cleaning and solvent cleaning. The parts are dried in a vacuum-tight chamber under reduced pressure, i.e. in a vacuum. The negative pressure significantly lowers the boiling point of water, allowing moisture to evaporate even at low temperatures. This is particularly advantageous for sensitive materials that would be damaged or lose their quality at high temperatures. Vacuum drying enables gentle, even and effective drying, removing even deep-seated moisture from complex geometries and porous materials.

Condensation drying is based on a heat pump. It is an efficient process that enables fast, gentle and energy-efficient drying. Temperatures of 20°C to 90°C are common. In a closed circuit, extremely dry, unsaturated air is passed over the material to be dried, quickly absorbing the moisture. The air is then cooled so that the water it contains condenses. The condensate is removed from the system. The now dehumidified and cooled air is reheated to the desired temperature and fed back into the drying process. Condensation drying can also be used to cool parts.

Depending on the drying requirements, different drying processes can be combined in sequence or with each other. For example, compressed air blowing can be used to remove accumulated moisture from scooping structures. Hot air or vacuum drying can then be used to remove the remaining residual moisture.

It is not uncommon for vacuum drying to be combined with other drying processes. Vacuum drying requires that the part still contains sufficient residual heat. Either the part still have sufficient residual heat from the high-temperature cleaning process, or hot air drying is installed before vacuum drying. It is also possible and extremely effective to combine vacuum drying with infrared drying. This allows the infrared rays to continue to transfer heat energy to the part during the vacuum process.

A cleaning process usually consists of pre-cleaning, main cleaning, rinsing, drying, testing and clean packaging. Depending on the objective, a distinction is made between coarse, fine and ultra-fine cleaning. For extreme requirements (e.g. semiconductors and optics), this is referred to as high-purity cleaning with a clean room environment and strict media control.

Depend on the type of dirt: "Like dissolves like". Oils/fats (non-polar) can be removed effectively with solvents such as hydrocarbons or modified alcohols, salts/emulsions (polar) and particles with aqueous, mostly alkaline or acidic cleaners. For the most demanding requirements, very pure water (VE/UPW) and easily rinsable, partially HIO-element-free cleaners are used.

The cleaning process varies depending on the type of system. In a chamber cleaning system, for example, the cleaning process begins with the part being placed in the chamber and the chamber then being flooded. In addition to the cleaner used, the cleaning process is supported by the respective cleaning methods such as spray cleaning, pressure flooding, ultrasound or pressure change washing such as VIT©. The cleaning process in the narrower sense is followed by rinsing. The purpose of rinsing is to remove any dirt and cleaning agent residues that have been loosened from the part but are still adhering to it. Rinsing is essential for the cleanliness of the parts. Depending on the residual dirt requirements, different water qualities can be used.

A closed solvent system has proven effective: cleaning/steam degreasing, ultrasound if necessary, internal distillation of the medium and vacuum drying – fast and reproducible. Alternatively, aqueous, alkaline cleaning with pressure flooding and subsequent rinsing works well. It is important to use appropriate filtration to prevent high levels of dirt entering the medium.

Use vacuum flooding processes with pressure changes (e.g. VIT ©) to allow media to penetrate narrow channels and remove dirt. Ultrasonic cleaning can be used as a supplement if the part is robust enough. In medical technology (e.g. guide wires), this method enables verifiable cleaning down to the capillaries, followed by gentle vacuum drying.

This requires fine/ultra-fine cleaning with multi-stage immersion baths or chamber cleaning with a large number of tanks, deionised or ultrapure water rinses and very clean drying. Ultrasound at higher frequencies or megasonic ultrasound works gently and produces few particles. The "lift-out" from the last deionised/DI rinse helps to dry without leaving any stains.

Rinsing removes cleaning agent and dirt residues – the higher the purity requirement, the purer the water (deionised water or UPW) and the greater the flow rate. Multi-stage rinsing cascades save water and improve quality. A continuous, filtered rinsing flow in closed chambers is particularly effective. Depending on requirements, it may also be advisable to connect a rinse with municipal water upstream, as municipal water generally rinses off the cleaning agent better, and to connect a deionised or UPW rinse downstream as the final rinse.

Common methods are hot air, infrared and vacuum drying. Vacuum drying is particularly effective for complex geometries or sensitive materials. Water requires significantly more energy to evaporate than solvents; the drying strategy should take this into account. The drying process can also be equipped with filters (e.g. HEPA H13 filters) if the highest standards have to be met.

Visual and UV inspection reveal stains and fingerprints, while particle measurements and gravimetry evaluate residual dirt. For high-purity requirements, RGA measurements and XPS analyses are also used. In regulated areas (e.g. medical technology), a documented, validated test is mandatory.

Work in a clean room or under laminar flow from the last rinse to unloading. Pack immediately, often in double layers, and only open in the airlock or at the place of use. Clean workpiece carriers with few contact points and trained handling prevent recontamination.

Cleaning media dissolve dirt, oil, grease and particles from components. They can be liquid or gaseous and are selected according to the task at hand. It is important that the medium is suitable for the cleaning task, works well and can be rinsed off cleanly at the end. This keeps the surface functional and free of residues.

There are solvent media and aqueous cleaners. Solvents are particularly effective on oily and greasy residues. Aqueous cleaners (alkaline, neutral or acidic) are suitable for salts, emulsions and particles. Additional special processes such as CO₂ snow or plasma can help in special cases.

Solvents are often the best choice for turning and milling parts that are heavily contaminated with oil and grease. Closed systems with distillation maintain consistent quality and save on media. Ultrasound can increase the effect without damaging the parts. Finally, vacuum drying ensures that the parts are dry.

Aqueous cleaners are useful for inorganic residues such as salts or for heavy particle contamination. The processes can be combined very well with spraying, pressure flooding and ultrasound. Several rinsing stages reliably remove cleaning agent residues. This leaves the surface residue-free and wettable.

Aqueous cleaning is considered environmentally friendly because it is water-based and is suitable for many metallic and non-metallic materials. With the right chemicals, it removes both polar and some non-polar contaminants. Disadvantages include the higher energy requirements for hot water and drying processes, the need for complete drying, and the theoretical risk of corrosion with sensitive metals.

Solvent cleaners impress with their powerful degreasing effect, fast and often residue-free drying, and good wetting of complex geometries. However, some of them are harmful to health and the environment, often require expensive closed systems and, in the case of flammable hydrocarbons, additional safety technology.

The choice between the two methods depends on the type of contamination, the material, environmental and safety requirements, and economic aspects.

Rinsing media remove dissolved dirt and chemical residues after cleaning. Depending on the requirements, water of different qualities is used for this purpose: tap water (also known as municipal water), deionised water, deionised water and ultrapure water. The purity increases with each stage. For very high requirements, deionised or ultrapure water is often used in the final stage.

VE water stands for fully desalinated water and describes municipal water from which all dissolved salts have been removed by ion exchangers. This enables stain-free cleaning.

DI water stands for deionised water and refers to water that is produced by an ion exchanger, often combined with reverse osmosis or electrodeionisation (EDI). This water is purer than normal VE water, as even traces of ions are removed. It is used, for example, in medical technology or for cleaning electronic components.

UPW stands for ultrapure water. This water has extremely low conductivity and contains virtually no particles or organic contaminants. It is used in particularly sensitive areas such as semiconductor manufacturing, optics or in high-purity applications in medical technology.

Multi-stage rinsing cascades reduce the carryover of dirt and chemicals. The quality increases from stage to stage until the parts are spotless. Flow rinsing delivers consistent quality, while stationary rinsing is more economical but requires more control. The final stage should be very clean so that no residues remain.

Media treatment can extend service life, maintain consistent quality, reduce costs and conserve resources. Media treatment keeps cleaning and rinsing media clean and effective. Typical methods include filtration, oil separators and, in the case of solvents, distillation.

Industrial cleaning systems use proven filtration methods to remove dirt and foreign matter from the cleaning bath and/or rinsing bath. This maintains the cleaning quality and extends the service life.

Mechanical filters such as sieves or filter mats are often used for coarse contamination. Mechanical filters with fine mesh sizes can also remove small particles down to 0.5 µm from the liquid. Bag and cartridge filters are commonly used here. In so-called settling tanks, heavy dirt particles can collect at the bottom through sedimentation and be removed. Magnetic inserts help to remove ferritic particles such as chips. Special oil separators (coalescence separators) separate oils and fats that float on the cleaning fluid.

In some cases, centrifuges are also used to eject dirt particles from the liquid stream at high speed (centrifugal force).

Full-flow filtration means that the entire media volume flow passes through the filter before being returned to the tanks or to the chamber to the nozzles. The advantages are constant media purity and good protection for nozzles, valves and pumps. The disadvantages are higher pressure loss and faster filter wear with high dirt loads.

Bypass filtration (partial flow) continuously filters only a diverted portion of the circuit. The advantages of this system are stabilised bath quality that does not throttle the main process. In addition, bypass filtration is often more energy-efficient and cost-effective. The disadvantages are that bypass filtration reacts more slowly to peak loads and only achieves the target purity if the circulation and filter performance are appropriately designed.

In practice, spray systems usually use full-flow filters upstream of the nozzles, while immersion/ultrasonic baths often use additional bypass filters for bath maintenance. A combination of both concepts is often the most effective.

Important parameters are conductivity, pH value, oil content and particle content. Refractometers, titration or density tests, also inline, provide additional assistance. Limit values trigger treatment, re-dosing or replacement. All data should be documented in batch logs.

That depends on the volume of parts, contamination and treatment. With good filtration and monitoring, long service lives are possible. This saves energy and costs. Without maintenance, media age quickly and clean less effectively. Individually defined limit values and test plans determine when to change them.

Temperature is a component of the Sinner circle. A higher temperature reduces viscosity and accelerates cleaning. This makes it easier to dissolve oils and greases, for example. At the same time, material compatibility and energy consumption must be taken into account. The optimum temperature lies within the defined process window.

Stable concentration, good filtration and clean separation of the process steps keep quality high. Regular measurements and clear limit values control re-dosing and treatment. Reference parts and clean handling ensure reproducibility. This keeps the process economical, safe and reliable.

In aqueous industrial part cleaning, there are two main types of media monitoring: inline measurements directly in the system and offline measurements by sampling. Inline, turbidity sensors are primarily used to control particle content and fluorescence or IR sensors to monitor oil – these provide continuous values and are increasingly common in high-quality systems. pH, conductivity and concentration sensors are also commonly used inline to automatically monitor the chemical condition of the bath. Offline, on the other hand, laboratory or rapid tests are usually used: particles are determined using filter samples and microscopy or particle counters, oils often using IR analyses, hand-held fluorescence measuring devices or laboratory methods. Simple routine tests such as titrations, pH measurements or conductivity tests are also standard. Overall, inline sensors are mainly used for continuous process reliability, while offline analyses provide detailed and reliable evidence and are common in almost all operations.

In industrial parts cleaning, the cleaning agent concentration is monitored in two ways: inline and offline. Inline sensors are integrated directly into the system and measure continuously – e.g. via conductivity (good for alkalis/acids), refractometers (refractive index, universally applicable), ultrasonic sensors (very accurate but expensive) or surfactant sensors (via surface tension). They provide real-time values, enable automatic dosing and are particularly common in large or quality-critical systems.

Offline methods rely on sampling and subsequent testing. The most common are titrations (standard for alkaline/acidic cleaners), hand refractometers (fast, but prone to malfunction in contaminated baths), and rapid tests or laboratory analyses for specific ingredients. These methods are inexpensive and widely used, but only provide selective results and require more personnel.

In practice, a combination is usually used: offline analyses serve for validation and as a backup, while inline systems ensure constant process control and automatic re-dosing. Overall, offline tests are still the most widely used, while inline technologies are becoming increasingly important in automation and quality assurance.

High-pressure cleaning is a cleaning process in which water is sprayed onto parts at very high pressure. This allows stubborn contaminants such as oil films, particles or adhesions to be removed efficiently. Even heavily soiled surfaces can be cleaned thoroughly and gently with the right water pressure and suitable nozzles. High-pressure cleaning is used in industry wherever conventional cleaning methods reach their limits, for example with stubborn dirt.

High-pressure deburring refers to the removal of burrs from workpiece edges using a concentrated jet of water under high pressure. Typically, water pressures of up to around 1000 bar (and even higher in specialised systems) are used to cut off protruding burrs in a targeted manner. The water jet is directed precisely at the burrs via fine nozzles, so that they are knocked away by the high kinetic energy. The process is particularly suitable for parts with burrs that are difficult to access (e.g. internal bores or cavities) and often combines deburring with cleaning of the parts in a single step.

Advantages: One of the strengths of high-pressure deburring is its ability to reliably deburr even complex contours such as deep bores, cross-bore transitions or undercuts, and it is suitable for a wide variety of materials (metals, and to a limited extent plastics). Compared to alternatives, the process is gentle on materials, so that no mechanical damage occurs and sharp edges remain burr-free (no unwanted rounding). In addition, burrs and contaminants are removed in a single operation, so the part is cleaned at the same time.

Disadvantages: High-pressure deburring systems involve relatively high investment costs and require powerful pumps, which means considerable energy consumption. In addition, very solid or tough burrs cannot always be completely removed (e.g. root burrs). The water jet does not achieve a defined edge rounding. If a chamfer or radius is required, a subsequent process may be necessary.

High-pressure deburring is mainly used in industries that have high requirements for burr-free and technically clean parts. For example, the automotive industry, especially engine and transmission manufacturing and battery boxes, or the hydraulics industry rely on this process. Typical workpieces are hydraulic blocks and valve housings, engine and pump housings, transmission parts and battery boxes. Such parts often have internal bores and channels in which burrs or chips can accumulate. The high-pressure process reliably removes these before assembly. High-pressure cleaning and deburring is also used in the aerospace and other high-tech industries to remove the smallest particles and burrs in accordance with strict cleanliness standards (e.g. VDA 19).

The high-pressure deburring process takes place in a closed system. A high-pressure pump system forces water at several hundred to several thousand bar through special nozzles that are directed specifically at the workpiece. The nozzles are moved either by robots or by multi-axis CNC axes so that all critical areas (e.g. drill holes, edges, blind holes) can be reached. The high kinetic energy of the water jet breaks off the burrs and flushes them out of the part toge ly with dissolved dirt particles. The draining water is then filtered to collect the removed particles and is often reused in the cycle.

The high-pressure process effectively removes burrs that arise during machining, e.g. drilling burrs, milling burrs or turning burrs. Even fine casting burrs (flitter) on die-cast parts can be removed by the water jet, as can chips stuck in drill holes. Typically, adhering residues can also be removed in addition to burrs. The directed jet can even reach and remove contaminants in very narrow cavities. However, high-pressure deburring has its limits when it comes to very large, solid burrs and root burrs. In such cases, the root of the burr often remains and may need to be reworked mechanically.

The required pressures depend heavily on the application. For cleaning processes without deburring, lower high pressures in the double-digit bar range are often sufficient. However, significantly higher pressures are required for deburring tasks: in practice, the working pressures are usually in the range of about 300 to 800 bar. Pressures of 500–1000 bar are often used to reliably remove stubborn burrs. For particularly stubborn tasks, pressures of up to 2,500 bar can also be used in special cases. The material is also a decisive factor. Aluminium parts are processed at a lower pressure than steel and stainless steel parts.

Modern high-pressure systems for parts cleaning and deburring are usually designed as closed cabins or cells and can be flexibly adapted to the production process. Many systems work in a similar way to machine tools: they have multi-axis nozzle guides or robots that either position the part in front of stationary nozzles or guide the nozzle along the fixed part. Rotating lances are often used for internal contours such as deep bores, in which a nozzle rotates 360° inside the bore and thus deburrs all around.

In addition, high-pressure deburring can be integrated as a module into a complete cleaning system, e.g. in combination with pre-cleaning, fine cleaning, rinsing processes and final drying, to obtain a fully automatic complete package.

When used properly, the high-pressure jet only removes burrs and contaminants without removing or damaging the base material of the part. The surface quality is maintained. The water jet does not cause any significant material removal on the workpiece surface. However, it is important to adjust the pressure to the material: excessive pressure can damage sensitive materials or leave erosion marks on surfaces. In normal cases, however, high-pressure deburring is considered to be very gentle on materials compared to alternatives.

High-pressure deburring systems are equipped with comprehensive safety precautions, as a water jet with a pressure of several hundred bar can be dangerous to humans. The processes take place in closed pressure chambers that are locked during processing. The doors can only be opened once the pressure has been released. Operators must wear PPE during maintenance work to prevent injuries.

From an environmental perspective, the aqueous high-pressure process is considered relatively clean, as no aggressive chemicals are required. However, contaminated process water is produced, which must be treated. Modern systems filter oil, chips and fine particles out of the water and return the medium to the system in a closed circuit. This significantly reduces water consumption and disposal costs. In addition, system manufacturers pay attention to energy-efficient technology so that resource-saving operation is possible despite high pressures.

In high-pressure paint stripping, paint, powder and coating layers are mechanically removed from the surface using a very powerful water jet (typically approx. 800–3,000 bar). Depending on the system, this is done with pure water or with a small amount of abrasive additive. The method works without solvents and without significant heat exposure, so that the base materials (e.g. steel) are protected.

The advantages include the absence of solvents with correspondingly low emissions, material protection, very good results even on complex geometries (edges, drill holes, hooks/racks) and a uniform, clean surface as a bonding base for the new coating. In addition, the removal can be controlled selectively to remove only the coating and preserve the base material.

On the other hand, there are higher investment and operating costs (energy, water), the expense of wastewater and sludge treatment, noise and splash protection, and high occupational safety requirements. The area output depends heavily on the coating system and the plant technology.

High-pressure paint stripping is mainly used in the automotive industry and by suppliers (e.g. body and chassis parts, paint hooks/racks), in metal processing and surface technology, in the rail and commercial vehicle sector, in mechanical and plant engineering, including construction and agricultural machinery, and in shipbuilding/offshore and the energy sector (e.g. steel structures, turbine housings, etc.).

A rough distinction is made between batch systems and continuous systems in parts cleaning. Single-chamber or multi-chamber systems, multi-stage series immersion systems and similar concepts are available for batch processes. Continuous systems, on the other hand, automatically transport the workpieces on conveyor belts or chain conveyors through the individual cleaning and rinsing stages.

Cyclic systems are suitable for flexible batches and changing parts, while continuous systems offer advantages for high volumes and line-integrated processes.

Within the chamber systems, a further distinction is made depending on the chamber. Traditionally, a distinction is made between turntable systems and basket cleaning systems.

In turntable systems, the part to be cleaned is placed on a turntable in the cleaning chamber. While the part is sprayed by nozzle systems, it rotates on the turntable. These types of chamber systems are used for smaller batches and medium residual dirt requirements. Such turntable systems are often found in maintenance or workshops.

Vacuum-tight flood chambers are used for high to very high residual dirt requirements. Here, there is a Rhönrad in the chamber. The parts are placed in this using a basket or a special workpiece carrier. The chamber can be completely flooded and subjected to vacuum, e.g. for pressure change washing VIT © or vacuum drying. Ultrasound, pressure flooding and spray applications can also be implemented here. The part placed in the Rhönrad can rotate around its own axis.

Carryover refers to the transfer of liquid (cleaning or rinsing bath) by the workpiece to the next process stage, which leads to contamination and undesirable dilution there. To minimise carryover, the parts should be able to drain well when removed from the bath – e.g. by means of draining stations or a longer drainage time. Additional measures include air cleaning (blow-off nozzles), which allows adhering liquid to flow off before the next bath, and cascade rinsing systems, which dilute any remaining carryover in a controlled manner, thus keeping the media clean. A consistent reduction in bath carryover is important in order to extend the service life of the baths and maintain a stable cleaning quality.

Cleaning systems require regular maintenance and servicing to function reliably and avoid downtime. Typical maintenance tasks include replacing filters and used cleaning media and cleaning the tanks and chambers of residues and deposits. The operator can often carry out this routine work themselves at specified intervals. In addition, it is recommended that thorough maintenance be carried out by qualified personnel at longer intervals (e.g. annually), during which wear parts – such as seals, pumps or valves – are also checked and replaced if necessary. A well-documented maintenance routine ensures that the system continues to operate at optimum performance.

Modern parts cleaning systems can be operated largely automatically to ensure continuous throughput and reproducible results. Transport systems such as roller conveyors, conveyor belts or circular conveyor systems are often used for this purpose, automatically feeding workpiece carriers with parts into the system and moving them through the cleaning stages. Gantry systems or industrial robots are also used for loading and unloading cleaning chambers, gripping and positioning baskets or parts. Such automation solutions reduce personnel costs and minimise errors in parts handling. Overall, automation increases process reliability and enables seamless integration of cleaning into the production process.

High energy and resource efficiency is becoming increasingly important in parts cleaning. First of all, the system should be dimensioned to suit the task at hand in order to avoid unnecessarily large baths or overcapacity; this ensures that the system runs as little as possible at idle speed. During operation, intelligent controls help to automatically switch off pumps, heaters and dryers, for example, when no parts are being cleaned. Good thermal insulation of baths and pipes is equally important to ensure that little heat is lost to the environment. Many systems today also use internal energy recovery, for example with heat exchangers. The use of energy-efficient motors or speed-controlled pumps and the reduction of process parameters (temperature, time) to the necessary level also help to reduce the consumption of energy, water and chemicals without compromising the cleaning quality.

Stainless steel 1.4301 / AISI 304 / V2A is regularly used in the construction of cleaning systems because it offers good value for money and is easy to weld. Depending on the process and choice of cleaner, 11.4404 / AISI 316L / V4A stainless steel is also used. Stainless steels are pickled/passivated and, in cases where high residual dirt requirements apply (e.g. in the high-purity industry, medical technology, semiconductors), they are also electropolished. If UPW is used extensively in the cleaning systems, plastic tanks and pipes (e.g. PP) are also used.

An industrial cleaning system is operated on a daily basis via a control panel (HMI) with stored programmes. The operator uses the panel to select the programme appropriate for the material, contamination and purity requirements. These typically include pre-washing, main washing (e.g. spray cleaning/pressure flooding/VIT ©), rinsing stages (up to UPW water), drying (e.g. hot air, infrared, vacuum, compressed air blowing) and parameters such as temperature, time, nozzle power, basket movement or ultrasonic power.

During the cycle, the operator monitors status displays, alarm messages and limit values.

Quality assurance (QA) is carried out to ensure that products and processes meet the required quality standards. QA is designed to detect and prevent errors at an early stage before they reach the customer. This reduces waste and rework, increases product reliability and ultimately creates customer satisfaction and trust. In short, QA ensures that a consistently high level of quality is achieved and that functional, safe parts are delivered.

Cleanliness analyses are special quality tests in which parts are examined for residual contamination. These are also referred to as residual dirt analyses. The aim is to determine which and how many particles or residues are still present on a part after manufacturing and cleaning. These analyses often follow standardised procedures and are designed to ensure that part cleanliness is within the specified limits and that function is not compromised by dirt.

Even the smallest contaminants can have a major impact in modern technical systems. In the automotive industry, for example, tiny dirt particles in sensitive systems (such as ABS brakes or fuel injection systems) have led to malfunctions, increased wear and tear and even total failure. In general, a lack of cleanliness can significantly reduce the reliability of products. A high level of part cleanliness is important in order to avoid malfunctions, premature wear or failures and to ensure the quality and service life of products.

Technical cleanliness means that a part is so free of harmful particles that its function is not impaired. Particles and films (also known as residual dirt) are inevitably produced in every manufacturing process. As long as this amount of residual dirt is so small that no malfunctions or damage occur either immediately or in the long term, the parts is considered technically clean. In other words, the contamination is at a sufficiently low level that the parts work reliably during operation.

In industry – especially in the automotive sector – there are recognised standards for technical cleanliness. The most important of these are VDA 19 (a guideline published by the German Association of the Automotive Industry) and the international standard ISO 16232. Both essentially cover the same subject matter and describe methods for testing the technical cleanliness of parts. They provide detailed specifications on how to detect, measure and document particle contamination on parts. These standards standardise cleanliness tests, ensuring comparable and reliable results. VDA 19 and ISO 16232 thus help to maintain a high standard of quality and reduce the risk of functional failures caused by dirt.

How clean a part needs to be depends on its function and area of application. There are no blanket limits for all cases. Instead, cleanliness requirements are usually determined on an individual basis. During the development phase of a product, the maximum amount and type of residual contamination a component may have without compromising its function is defined. This takes into account the sensitivity of the system, as well as the manufacturing possibilities. This is often determined in consultation between the customer and supplier in order to set realistic and reasonable limits. It is important that the requirements are chosen in such a way that no malfunctions occur and, at the same time, no unnecessarily high cleaning effort is required.

A basic distinction is made between particulate and film-like contaminants. Particulate contaminants are solid particles, such as metal chips or abrasion, plastic or paint particles, dust grains or fibres. Such particles often arise directly in the process (e.g. chip residues during drilling or grinding, abrasion during machining) or get onto the part from the environment (dust from the air, fibres from clothing or cleaning cloths). Film contaminants, on the other hand, are thin layers on the surface – typically residues of oils, greases or other manufacturing aids. These arise when, for example, cooling lubricants, anti-corrosion oils or cleaning agents remain on the part and form a film. Both types of contamination (particles and films) must be minimised so that the part achieves the desired technical cleanliness.

Typically, a part is first cleaned in the laboratory in order to collect the contaminants on it (known as extraction). To do this, the part is rinsed with a specific liquid, sprayed or treated in an ultrasonic bath. The dirt particles that are removed in this process are collected on a special filter. The filter is then dried and evaluated under a microscope. The particles on the filter are counted and measured to determine the number and size of the remaining dirt particles. This data can then be used to conclude whether the part complies with the required cleanliness values.

Another common method is sampling. A sample is pressed onto a defined surface of the part using an adhesive and a stamp. The particles on the surface stick to the adhesive. This sample is then used to evaluate how many particles of what size are present. The result can then be extrapolated for the entire part.

Various measuring devices are used in cleanliness laboratories. The central tool is a light microscope with image analysis: this makes the particles collected on the analysis filter visible and automatically classifies them according to size and, if necessary, particle type (metallic, non-metallic, fibre). Precision scales are also frequently used – by weighing the filter before and after sampling, the total mass of contamination can be determined (known as gravimetry). For more in-depth analyses, high-resolution microscopes such as scanning electron microscopes are used to find very small particles and determine their material composition.

The significance of film contamination (e.g. grease or cooling lubricants) has increased in recent years. However, the existing measurement methods and limit values are not yet as sophisticated as those for particulate contamination.

The key parameter for determining film cleanliness is the surface energy in millinewtons per metre (mN/m). The surface energy of a part indicates whether the surface is wetted by a liquid or causes it to bead up. Common measurement methods are test inks, contact angle measurement and fluorescence measurement.

Test inks can be used to check surface energy quickly and easily. If the ink is applied to the surface as a thin film using a pen or cotton swab, it is immediately apparent whether the wetting is sufficient. If the ink remains evenly distributed, the surface has at least the corresponding surface energy of the ink and is considered sufficiently clean or activated. However, if the film contracts within a few seconds or forms droplets, this indicates that the surface energy is too low, which is usually due to residues of grease, oil or release agents. The method allows limit values to be determined by working with test inks of different values until the point is reached where the wetting is no longer stable.

When checking film cleanliness using contact angle measurement, the wettability of a surface is determined by the angle that a drop of liquid applied to the surface forms with the surface. Clean, grease-free and activated surfaces have high surface energy and cause liquid drops to spread out widely, resulting in a small contact angle. Contaminated surfaces or surfaces covered with residues, on the other hand, have a lower surface energy, causing the drop to remain spherical and creating a larger contact angle. For the measurement, a defined drop of water or another test liquid is usually applied to the surface and recorded optically with a camera. The evaluation is carried out using software that calculates the contact angle precisely.

When checking film cleanliness with fluorescence measurement, the fact that many organic contaminants – such as oils, fats or certain cleaning residues – fluoresce under UV light is exploited. In practice, the surface to be tested is irradiated with a defined light source. If there are film residues on the surface, their molecules absorb the radiation and emit visible light, which is recognisable as a fluorescent glow. This can either be assessed visually by the inspector or, in an instrumental variant, quantitatively recorded with a detector or camera. This also allows the intensity of the fluorescence signal to be measured and assigned to a specific level of contamination.

Answer: Inadequate cleanliness can lead to various problems, for example:

Mechanical impairments: Larger particles can accumulate in narrow gaps or block valves, nozzles and bearings. This leads to malfunctions or increased wear on moving parts. Abrasive particles (such as grinding dust) act like sandpaper and cause additional material abrasion and premature damage.

Electrical problems: Conductive metal particles (e.g. small chips) can cause short circuits in electronic assemblies or reduce insulation distances. This poses the risk of electronic defects or even complete device failure.

Loss of quality and function: Contamination on sensitive surfaces can reduce the performance of the product. For example, particles on optical parts (camera sensors, lenses) lead to blurred images or incorrect measurements. Similarly, thin layers of oil or grease can prevent paints, coatings or adhesives from adhering properly.

There are a number of measures to ensure a high level of cleanliness in the production process.

Clean manufacturing environment: Establishment of clean or clean zones in production to reduce particle ingress from the environment. For example, separate areas can be defined for dirty and clean processes, and air filters (e.g. HEPA filters) can be used to filter dust from the air.

Integrated cleaning procedures: Parts should be cleaned at appropriate points during production (e.g. washing or rinsing after machining) so that no old contamination remains at the subsequent assembly or testing stations.

Training and discipline: Employees are trained in the correct handling of sensitive parts. Wearing clean work clothes or special gloves and avoiding unnecessary contact with parts helps to prevent contamination. 

Clean storage and packaging: Cleaned parts should be stored in a dust-protected manner or immediately sealed in clean containers/packaging to prevent them from becoming dirty again. Special clean packaging and a short storage period until installation are ideal.

Maintenance of equipment: The production equipment and machines themselves must be kept clean. Regular maintenance (changing filters, cleaning tanks, emptying oil separators, etc.) prevents the equipment itself from becoming a source of contamination. In addition, suitable tools and auxiliary materials (lint-free cloths, cleaned containers) should be used.

Cleanliness tests are carried out at several points in the product life cycle. Typically, they are already carried out during the initial sampling of new parts. This means that before a part goes into series production, it is checked to see whether it meets the cleanliness requirements. During ongoing production, analyses are carried out regularly as part of quality assurance, for example on a random basis to monitor production or after certain production batch sizes. Incoming goods inspections are also common: when a company purchases parts from suppliers, random checks are carried out to ensure that the delivered parts meet the cleanliness requirements. In addition, a cleanliness analysis can always be initiated if there are any abnormalities – for example, after process changes, in the event of technical problems in the field or if contamination is suspected.

A number of things can go wrong when performing cleanliness analyses. Common sources of error include, for example:

Contamination during sampling: If the test environment or tools are not clean, foreign particles will get onto the filter. This leads to increased particle counts that do not actually originate from the part. For this reason, analyses must often be carried out in a clean room environment or under a clean air workbench, and all equipment (tweezers, containers) must be absolutely clean.

Improper handling of the filter: The filter membrane on which the particles are collected is sensitive. If you touch it with your bare fingers or use unclean tools, fibres, skin particles or grease can be transferred to it. Such external contamination falsifies the result.

Sample mix-ups or incorrect labelling: When testing multiple parts, filters or samples may be mixed up or incorrectly labelled if care is not taken. This leads to incorrect assignment of results to parts. Strict labelling and documentation are therefore important.

Unsuitable test parameters: If the wrong extraction method is chosen or rinsing is too short/excessive, particles may either not be completely removed or unnecessary particles may be generated. Choosing an unsuitable solvent can also be problematic (e.g. if it leaves residues). Such errors mean that the measured values do not correspond to reality.

Misinterpretation of results: Evaluating the filters requires some experience. Automatic particle counting systems distinguish between light (metallic) and dark particles based on reflection, for example – in this case, fibres could be classified incorrectly under certain circumstances. The operator must also be able to evaluate the results (particle counts/sizes) in context. Errors in interpretation can trigger false alarms or cause real problems to be overlooked.

High purity requirements go beyond normal technical cleanliness in several respects.

In high purity areas, extremely small particles often have to be removed, sometimes down to the submicrometre range. In contrast, normal technical cleanliness usually focuses on particles in the double-digit and triple-digit micrometre range (µm). In addition, high purity processes require that virtually no film residues such as oils, greases or other chemicals remain on the parts. In normal production, on the other hand, the focus is usually on particles; minimal oil films are tolerated to a certain extent as long as they do not interfere with function. Another important difference is the environment. High-purity manufacturing almost always takes place in clean rooms or clean environments. The air there is filtered (HEPA filters) and pressure conditions are controlled to prevent particle ingress. In conventional manufacturing, cleanliness zones are set up, but not necessarily complete clean rooms with strict particle classification.

The testing effort is also much more comprehensive. Additional analysis methods are often used to detect remaining traces – such as chemical analyses for organic residues or particle measurements far below the usual size ranges. The limit values are also much stricter, i.e. almost "zero" tolerated contamination is often permitted.

In high-purity production areas, extremely strict controls apply throughout the entire process. In addition to normal particle analysis, additional tests are carried out in high-purity areas. Organic residue on parts is often monitored, e.g. by measuring the total carbon content (TOC analysis) in the cleaning medium. Particles are also detected using even more sensitive counting systems (laser particle counters) in order to be able to detect even nanoparticles. These tests are of course also carried out under clean room conditions.

Each process step is designed to avoid contamination. Parts pass through airlocks between the grey room and the clean room so that they only enter the clean room in a clean state. Intermediate processing is carried out in closed systems, and the parts remain in clean containers until final assembly/packaging. In addition, regular audits and monitoring (e.g. air particle measurements in the clean room) are carried out to constantly check the cleanliness of the environment.

Careful handling of parts and workpiece carriers is crucial to prevent damage and contamination. If parts are moved improperly or not securely fixed, they can collide with each other and suffer scratches or other damage. Good handling also ensures that the cleaning medium reaches all surfaces and that dirt is thoroughly removed. In addition, well-thought-out handling allows several parts to be cleaned efficiently at the same time, which saves time and increases productivity.

A workpiece carrier is a holding device (often a rack or basket) in which parts are securely stored during cleaning. Workpieces can be fixed, transported, cleaned and even stored in it. The carrier ensures that the parts do not fall loose or slip during the cleaning process. Workpiece carriers are often designed so that the parts do not have to be repacked after cleaning. This means that they serve as "containers" for the parts from transport to storage, saving time and effort.

Yes, suitable workpiece carriers can generally be used for all common cleaning processes. An open-design, well-thought-out workpiece carrier ensures that cleaning fluids and mechanisms (e.g. jet nozzles or ultrasound) can reach every part of the components. It is important that the carrier material is suitable for the respective process: a standard stainless steel carrier can be used in both aqueous cleaning solutions and solvent baths and can also withstand the vibrations of ultrasound. After the washing step, the parts remain in the same carrier, for example for rinsing processes and drying. Therefore, the workpiece carrier must also withstand subsequent steps such as vacuum drying in terms of temperature and pressure. Workpiece carriers are even used in high-purity cleaning processes (for the highest purity requirements) – however, particularly pure and low-outgassing materials are often used here to rule out contamination.

When selecting materials, the focus is on durability and protection of the parts. Workpiece carriers are very often made of stainless, sometimes electropolished stainless steel, as this material is mechanically robust and can withstand the chemical stresses of all common cleaning media. Plastic workpiece carriers are an alternative. High-quality plastics are lighter than metal and prevent scratches on sensitive parts. It is crucial that the selected plastic can withstand the temperatures and chemicals used in the cleaning process. In general, the material should be corrosion-resistant, durable and free of substances that could contaminate the parts (e.g. no silicone or fibrous deposits). Weight also plays a role: a lighter carrier is advantageous in terms of handling, but must still be stable enough for the parts and the process.

Good workpiece carriers are designed to support cleaning and hold the workpieces securely. It is important to have as open a design as possible without hidden corners: the cleaning medium should be able to reach the parts unhindered from all sides. Therefore, surfaces or cavities where liquid could collect or dirt could accumulate should be avoided. The contact points for the parts are reduced to a minimum in order to minimise contact points and "shadow areas" during cleaning. At the same time, the workpieces must be firmly fixed in place so that they do not come loose or collide with each other during the washing process. In addition, the dimensions and shape of the carrier are adapted to the cleaning system so that it is easy to use and can be optimally placed in the cleaning room ( ).

Workpiece carriers are usually given a permanent marking so that they can be clearly identified. Numbers, codes or company logos are often applied directly to the carrier. For metal carriers, this is done, for example, by laser engraving or impact stamping, and for plastic carriers by embossing or durable labels. Alternatively, barcode or RFID labels designed specifically for industrial use (waterproof, chemical-resistant) can also be used. It is important that the marking remains legible and lasts for the entire service life of the carrier to avoid confusion.

In modern production environments, workpiece carriers are often transported and handled automatically. Cleaning systems are often equipped with conveyor systems or robots that move loaded carriers through the various cleaning and drying stations. To enable robots or handling devices to grip a carrier securely, it is designed accordingly, for example with standardised grip edges, pick-up points or a shape that fits into automation systems. The dimensions of workpiece carriers are often based on standard sizes (e.g. common shopping basket or pallet dimensions) so that they can be easily handled by automatic systems. If barcode or RFID labels are used, the cleaning system can also automatically select different cleaning programmes.

Traceability means being able to assign each cleaning process to a specific part or batch. This is achieved by uniquely identifying workpiece carriers and cleaning batches and documenting the process data. In practice, each workpiece carrier or batch is given an ID – for example, in the form of a number, barcode or RFID chip – which is recorded by the system. During and after the cleaning process, the system stores relevant information: which parts (or batches) were in which carrier, when and in which programme they were cleaned, and the most important process parameters. These parameters (such as temperatures, times, cleaning media) are logged and stored in a database together with the part ID. This allows you to trace exactly which part received which treatment. If quality problems arise later, the ID can be used to determine when and how the part in question was cleaned. All these measures ensure that the cleaned parts are traceable.

Not necessarily; there are both universal and part-specific workpiece carriers. For relatively simple or robust parts, standard cleaning baskets (e.g. Schäfer baskets) or modular carriers that can be adapted to different workpieces can often be used. Some systems work with adjustable inserts: variable retaining pins and dividers can be positioned on a base plate so that different part geometries can be fixed in place. This allows one carrier to be used for several types of parts, which is particularly economical for changing products or small quantities. For very sensitive, high-precision or complex-shaped parts, however, an individually developed workpiece carrier is often advisable.

High purity cleaning refers to part cleaning with extremely high purity requirements. There is no universal definition; the exact specifications vary depending on the industry and company. Essentially, the aim is to achieve a very high level of part cleanliness. Typical high purity industries include semiconductor production technology, the ultra-high vacuum industry and the optical industry. This involves not only the actual cleaning process, but also the entire process chain and environment, which are designed to minimise contamination. High purity cleaning is often used synonymously with terms such as ultra-fine or precision cleaning, but aims to achieve even higher levels of cleanliness.

In high-tech industries such as semiconductor manufacturing, optics, aerospace, and medical and pharmaceutical technology, the demands on the cleanliness of parts are constantly increasing. Tiny contaminants can have serious consequences here. High purity cleaning ensures that parts are as clean as the critical application requires. In the semiconductor industry, for example, components for EUV lithography must be absolutely free of particles and residues so that chip production can run smoothly. In medical technology, on the other hand, high purity prevents any foreign substances from entering sensitive devices or the patient.

digit and triple-digit micrometre range so as not to compromise the function of assemblies. High-purity cleaning goes far beyond this. Here, much smaller particle sizes of up to 0.5 µm are taken into account, and chemical films or molecular residues must also be virtually non-existent. In addition, additional requirements come into play in high-purity areas: for example, in semiconductor and vacuum technology, certain outgassing substances (HIO substances, hydrogen-induced outgassing) must be completely avoided, as even the smallest amounts could cause problems in a vacuum. Such outgassing issues or extremely low limits for organic residues do not normally play a role in conventional part cleaning. In summary, high-purity cleaning differs from conventional technical cleanliness in that it has much stricter limits, smaller tolerated particles and a focus on absolute freedom from residues.

High purity often requires multi-stage cleaning processes. Wet processes such as chamber cleaning systems or multi-bath ultrasonic systems, in which the parts are cleaned and rinsed in several stages, are common. Different process technologies can be combined. Dry technologies, such as CO₂ snow blasting, are used for special cases. Vacuum bake-out is also commonly used to remove any remaining volatile contaminants. The technique chosen depends on the required level of cleanliness, the type of contamination, and the material and geometry of the part. Often, the optimal solution is a combination of several processes to meet all requirements.

The cleaning chemicals are just as important as the process itself. Either high-purity aqueous cleaners or solvents are used. Aqueous cleaners in the high-purity range have a special formula. They are designed to remove the last remaining contaminants without leaving any new residues on the surface. This means that such cleaners must be particularly easy to rinse off. In general, rinsing is therefore much more important than in normal cleaning processes. Systems have several rinsing stages, and strict care is taken to ensure that no dirt is transferred from one bath to the next. In addition, only cleaning media without undesirable additives are used: for example, the cleaner must not contain any HIO elements in order to rule out cross-contamination. Alternatively, the HIO elements in the cleaner must be rinsable without leaving any residue. Overall, cleaning processes and chemicals in the high-purity sector are optimally coordinated to achieve maximum cleanliness without leaving any residue.

The plant technology for high-purity cleaning must be specially designed to exclude even the smallest contaminants. All materials used in the plant, such as the steel in tanks, pipes or brackets, sealing materials, etc., must be selected so that they do not release particles or contaminants themselves. High-quality stainless steel alloys and smooth surfaces are often used, as they do not release particles and are easy to clean. Design details are also important: weld seams, sharp corners or dead spaces where dirt could accumulate are avoided as far as possible or specially treated. The interior of a high-purity system is designed so that all wetted surfaces are easy to clean and no hidden deposits can form.

In addition, the systems must be very flexible and powerful, as different materials and complex part geometries often have to be cleaned. From sensitive plastics to metals, ceramics or glass. The system and the cleaning process must be adaptable to the respective part. Modern multi-bath ultrasonic systems or multi-tank chamber systems, for example, allow adaptation to a wide variety of materials and different cleanliness specifications thanks to modular cleaning and rinsing stations.

Rinsing is very important in high-purity processes. Once the cleaning agent and dissolved contaminants have been removed, several rinsing stages usually follow in succession to ensure that all residues are rinsed off. Pure water is often used for this purpose, e.g. deionised water or ultrapure water (UPW). The water quality is crucial, as normal municipal water would contain too many ions or particles. In complex systems, the rinsing baths are arranged in cascades: the part passes through a series of rinsing steps, starting with a coarse rinse and becoming increasingly purer, without water being carried over from the dirtier to the purer area. Between the stages, ultrasound can also be used in ultrapure water to remove any remaining particles. Some processes also use an overflow rinsing step or spray rinsing with ultrapure water at the end to ensure that all foreign substances are removed.

The parts are dried as gently and particle-free as possible. Contactless drying methods such as vacuum drying or drying with hot, HEPA-filtered clean air are common. In vacuum drying, the parts are placed in a chamber under negative pressure so that any remaining water evaporates at a lower temperature. This dries the part without leaving any residue or water spots. Alternatively or in addition, purified hot air is used, often via HEPA-filtered recirculated air, to prevent particle contamination. In some cases, infrared drying is used, which quickly heats the surfaces and allows the water to evaporate. It is important that no new contaminants get onto the part during drying. For this reason, drying chambers are often integrated into the cleaning systems or directly connected to the cleanroom . After drying, the parts are immediately ready for cleanroom packaging without ever being exposed to unclean ambient air again.

After cleaning, parts must be packaged in such a way that they retain their purity until use. In practice, this means that packaging takes place in a clean environment (clean room or clean room airlock) immediately after drying. Typically, specially cleaned, airtight bags or films are used that do not release particles and do not outgas. Parts are often double or triple bagged to create a contamination barrier. For example, the part is first sealed in an antistatic cleanroom bag,

Various testing methods are used to verify that a part has achieved the required level of cleanliness, depending on the type of contamination relevant:

Particle measurement (PMC): This tests how many particles of what size are still present on the part. This is often done by rinsing the part with a defined liquid or immersing it in an ultrasonic bath. The liquid is then filtered and the filter is evaluated under a microscope or with automatic particle counters. Another variant, which is mainly used in semiconductor production technology, is PMC (Particle Measurement Card). PMC functions like a tape-lift sampler: it picks up particles from the surface, even on uneven or curved parts, without leaving any residue or damaging the surface. The sampler provided is inserted into the sample scanner. There, high-resolution image analysis takes place in seconds. The scanner detects particles from 0.5 µm, classifies them according to size, position and number, and delivers the data quantitatively. Visual inspection under UV light is also used. Organic residues often fluoresce and can thus be detected.

TOC measurement (total organic carbon): This method measures the total content of organic carbon, i.e. organic residues, in the medium used. A low TOC value means that there are hardly any organic contaminants present. In strict cases, the TOC limits are in the ppb range (parts per billion). For example, it may be required that the TOC be below 100 ppb, but in fact, with the right water treatment in high-purity processes, values below 1 ppb can be achieved.

Residual gas analysis (RGA): This test is particularly important for vacuum applications. The cleaned part is placed in a vacuum chamber and heated gradually. A mass spectrometer monitors which gases escape from the part. This allows the detection of outgassing substances such as solvent residues, moisture or other volatile compounds. RGA provides a value for the outgassing rate, for example, and shows whether critical substances (such as silicones or halogens) are still being released. Some manufacturers require proof that the outgassing rate does not exceed a certain value.

XPS (X-ray Photoelectron Spectroscopy): XPS is a high-resolution surface analysis method. It involves examining the top atomic layer of the part surface with X-rays to determine which elements and chemical bonds are present. XPS can be used to quantitatively check whether, for example, there are still silicone oil residues, salt deposits or metal traces on the surface. This method is often used to validate the effectiveness of a cleaning process. XPS analyses are complex and require laboratory equipment, but they provide very accurate information about whether the chemical cleanliness of a part has been achieved.

In practice, a combination of these tests is often used. In addition, many customers require a cleaning certificate or report from the supplier documenting the results (e.g. particle count, TOC value, etc.). Such test methods provide objective evidence of compliance with high purity requirements.

Avoiding recontamination is a top priority. That is why it is addressed even before the actual cleaning process. All upstream production steps must be as clean as possible. For example, during machining, care should be taken to ensure that no hard-to-remove residues are incorporated into the material. The entire production chain must support the cleanliness objective. During and after cleaning, a strict separation is made between "dirty" and "clean" areas. Physical separation of the work areas prevents cross-contamination. Cleaned parts must not come into contact with the raw part environment again.

Part handling is also strictly regulated: employees wear gloves, hair nets and, if necessary, cleanroom suits to prevent the introduction of particles or skin oils. After cleaning, parts are only moved with clean tools and under clean conditions. They are often transferred directly to a clean room – for example, through an airlock from the cleaning system to the clean room. There, they are inspected and packaged without being exposed in between. Air filter systems ensure that there are hardly any particles in the ambient air, and positive pressure is maintained so that no dust can enter from outside.

Employees in high-purity areas must work with particular care and receive specific training for this. They wear suitable cleanroom clothing: depending on the degree of cleanliness, this includes full-body suits, overshoes, hoods, mouth and nose protection and, of course, particle-free gloves. It is important that the clothing itself releases hardly any fibres (special fabric) and is cleaned regularly. Employees learn rules of conduct, e.g. not to take lint-producing materials into the clean room and to clean tools before use. There are often checklists for specifications.

The working environment is usually a controlled cleanroom or at least a clean room. Cleanrooms are classified according to ISO 14644 (classes 1 to 9) or similar standards. In high-purity cases, very clean cleanrooms are often used, e.g. ISO class 5 or 6, depending on requirements. The cleanroom class is determined based on the required surface cleanliness class, i.e. it is linked to the permitted particle concentration on the parts. In the cleanroom, HEPA/ULPA filters ensure low-particle air, there is a slight overpressure and the temperature and humidity are often kept constant to guarantee stable conditions.

Regular cleaning of the cleanroom (wiping surfaces with suitable cloths, adhesive floor mats at entrances, etc.) and monitoring (particle counters, germ samples) are also part of the requirements. In summary, both people and the environment must "play their part": discipline, training and cleanroom technology form the framework for successful high-purity cleaning.

The logistics – i.e. transport and storage – of cleaned parts must be designed in such a way that no new contamination (recontamination) occurs. Internally, this means that once parts have been cleaned and packaged, they may only be moved in defined clean containers. Special transport boxes or trolleys are often used for this purpose. These containers are labelled " " and are reserved exclusively for cleaned parts in order to prevent mix-ups.

Labelling and documentation along the supply chain is also important. Each high-purity part is usually given a label with information such as the purity class, the date of cleaning, the batch number and instructions ("Do not open outside the clean room", etc.). The shipping documents or technical product documentation refer to the special cleanliness requirements so that everyone, from logistics personnel to the end user, is informed. Finally, the storage period should not be unnecessarily long: even with sealed packaging, minimal diffusion or ageing can occur over a very long period of time, so the time between cleaning and final assembly is kept as short as possible. Overall, the logistics of high-purity parts require meticulous care to ensure that the cleanliness achieved at great expense is not lost.

Cleanliness requirements are usually specified in the technical documentation for a part. Drawings or specifications then contain a reference to the required cleanliness, often with a reference to a specific cleanliness specification. The technical product documentation (TPD) for a part contains such information so that every supplier knows what level must be achieved. Many companies have internal factory standards or cleanliness classes that they impose on their suppliers. These are often based on ISO standards or industry standards, but are defined specifically for each company.

Terms such as GSA can mean different things depending on the context – they are often abbreviations for agreements or standards. For example, GSA could stand for "GENERIC STANDARD OF ASML", in which general cleanliness criteria are defined between the customer and the supplier. In any case, it is important that there is a specific cleanliness specification that states: What is the maximum permitted particle size/number? What residues are prohibited? How is testing carried out and according to which standard? This information is passed on throughout the supply chain – from the end customer to the Tier 1 supplier down to the cleaning service provider. Customers often request proof (measurement report, certificate) for each batch to ensure that the supplier is complying with the specifications.

Purity classes are categorisations of cleanliness that are often defined specifically for a company or industry. For example, some manufacturers such as ASML refer to Grade 4 to Grade 1 cleaning. Here, Grade 1 is the highest level of cleanliness and Grade 4 is a lower level. Purity classes are often related to the environments in which the parts will later be used. For example, parts that are cleaned to ASML Grade 1 are installed in the main/vacuum chamber of an EUV machine.

ORK stands for "surface cleanliness class". This is a classification that primarily describes the particulate cleanliness on a surface. A low ORK number means very clean. For example, ORK 1 corresponds to extremely high surface cleanliness, while higher numbers (e.g. ORK 5) would be correspondingly less strict. In practice, ORK classes are often based on standards, such as ISO standards or company-specific standards.

This depends on several factors, in particular the scope of requirements, the available expertise and the investment opportunities. High purity cleaning requires high initial investments (equipment, clean rooms, measurement technology) and specialist knowledge. For companies that only occasionally need such purity levels, it often makes sense to commission a specialised service provider. These companies already have the necessary infrastructure and experience to implement the demanding processes in a stable manner. This saves the expense of setting up clean rooms, training staff in detail and ongoing measurement technology calibration. When starting out with high purity requirements, it is therefore advisable to work with service providers, at least until the volume is large enough to operate your own equipment economically.

On the other hand, it may make sense for large companies with continuous demand to bring high-purity cleaning in-house. Advantages: You have full control over the process, can react more quickly to changes and avoid transport routes (which can themselves be a risk). Some companies build their own high-purity cleaning centres or invest in machines that they integrate into existing clean rooms.

High-purity cleaning is significantly more complex than standard cleaning, which is reflected in both costs and production times. The processes consist of several stages (cleaning, multiple rinsing, drying, testing, cleanroom packaging) and can therefore take more time per part. For example, a cleaning cycle with all the fine rinses and vacuum drying can take much longer than simple degreasing in a standard system. Due to the complexity, fewer parts can often be processed at the same time (batch sizes are smaller), which increases the throughput time per part.

On the cost side, there are several factors to consider: high-purity systems and clean rooms have high investment and operating costs (air conditioning, filter replacement, ultrapure water treatment, etc.). In addition, high-purity chemicals and materials are required, which are more expensive than standard agents. Staff must be trained more intensively and work more slowly and carefully, which increases personnel costs per part. All in all, high-purity cleaning can be significantly more expensive per unit than conventional parts cleaning.

However, it is important not to view the process costs in isolation. Part cleaning is a production step that is relevant to both quality and cost. If cleanliness is not up to standard, there is a risk of rejects, rework or failures in the field, which could incur far higher costs. For this reason, high purity cleaning is usually accepted as a more expensive process because it makes an indispensable contribution to product quality and reliability. Many companies try to improve efficiency through optimisation: e.g. automation of handling to shorten process time, or parallelisation (multiple cleaning lines for different assemblies). New technologies, such as flexible chamber system concepts, can also help to reduce time and costs. Nevertheless, high-purity cleaning remains an area where quality takes precedence over speed. When planning a project, sufficient time and budget should therefore be allocated for this step in order to meet the high requirements without compromise.

Yes, definitely. Although the core idea of extreme cleanliness is common to all, each industry has its own focus. In the semiconductor industry and in electronics/optics in general, the main focus is on particles and outgassing substances. Here, for example, no metallic particles or dust-like residues are allowed to get onto chips or optics, and materials must be free of certain elements that could outgas in a vacuum. This means that a semiconductor part must not only be particle-free, but often also ultra-high vacuum clean.

In medical technology and pharmaceuticals, biological cleanliness plays a particularly important role alongside particles. Here, attention is paid to endotoxin-free, sterility (where necessary) and biocompatibility of residues. A medical part must not have any cytotoxic residues so that it does not cause inflammation or other reactions in the body. This means that, in addition to particle and film purity, limits are defined for bacterial contamination and endotoxic contamination (which are not relevant in other industries). The cleaning media must often be pharmaceutically approved, and sometimes high-purity cleaning is followed by sterilisation if a sterile product is being manufactured.

In aerospace, the requirements are similar to those in semiconductor technology: particle and film purity plus low outgassing. In addition, molecular cleanliness is often a consideration here, because even the smallest amounts of organic films can condense in a vacuum.

High-purity cleaning systems must themselves be kept clean so that they do not become a source of contamination. This means, on the one hand, that cleaning baths and chemicals must be regularly monitored and replaced. The baths (whether aqueous or solvent-based) are replaced or reconditioned after a certain number of batches or when measured values (e.g. conductivity of the ultrapure water, TOC value in the bath) are exceeded. Filter systems, e.g. HEPA filters in the drying process, must be replaced at intervals before they become saturated. Many systems have automatic bath monitoring systems that indicate to the operator when, for example, the quality of the rinse water is no longer sufficient.

On the other hand, the systems require regular scheduled cleaning of their parts. Tanks, pipes and nozzles are rinsed in a loop (clean-in-place) with ultrapure water or special cleaning chemicals, for example, in order to remove deposited residues. Sometimes system parts are dismantled and cleaned manually in a clean room, especially if minimal dirt may have accumulated in corners. Seals and moving parts must not only be made of suitable material, but also inspected and replaced more frequently.

A high-purity cleaning process usually consists of several consecutive steps to gradually move from "coarse" dirt to absolute fine cleanliness:

Pre-cleaning: First, the parts are cleaned of coarse contamination after mechanical processing. For example, chips, dust, coarse particles and oil residues are removed in a pre-cleaning step. This can be an ultrasonic bath with a mild cleaner, spray cleaning or even manual rinsing under clean room conditions. The aim is to ensure that the main cleaning system is not burdened with heavy contamination.

Main cleaning (fine cleaning): The parts are now placed in the actual cleaning system. This is often an automatic multi-bath system in a clean room or clean area. There, the parts pass through several stations one after the other with cleaning and rinsing steps.

Final rinsing: often using an overflow process with UPW (ultra-pure water) under clean room conditions.

This sequence can be extended depending on the complexity of the part – e.g. additional pressure flooding, spray cleaning.

Drying: After the wet processes, the parts must be dried without anything settling again. Drying usually takes place in the same system to avoid environmental transfer. Common methods are vacuum drying (evacuating the chamber and heating it slightly if necessary) or hot air circulation with filtration, often combined with infrared radiators for efficiency. Important: Drying continues until there is no liquid residue left in gaps and holes to prevent water stains or corrosion.

Inspection (cleanliness check): Once the parts are dry, a quality check is often carried out in the clean room. Fluorescent residues, for example, are made visible under UV light or very bright light. Depending on the criticality, a random inspection with particle measurement or wipe test is also carried out. If a part clearly does not meet the requirements (e.g. visible stain), it would be cleaned again.

Packaging: Parts that have been cleaned in accordance with the requirements are immediately packaged in clean packaging. This usually takes place in the clean room zone. Each part is placed in its prepared, clean packaging and sealed. Labelling is applied without contaminating the part (the labels are usually placed on the outside of the bag).

Documentation/release: Finally, a cleaning report is often created. This may include the batch number, date, responsible person, cleaning baths used and, if applicable, test results. A quality engineer or cleanroom manager checks the documents and releases the batch for delivery.

In practice, the steps may vary depending on the product. For example, pre-cleaning may not be necessary if the production facility is already clean enough, or additional steps may be added. But basically, a high purity process follows this flow: Preparation → Cleaning in stages → Rinsing → Drying → Testing → Packaging, all under strict cleanliness precautions. This regulated sequence ensures that the desired purity is achieved and maintained for each part at the end.

BvL Oberflächentechnik GmbH is a German manufacturer of industrial cleaning systems (parts cleaning systems) and is one of the world's leading suppliers in this field. The company is family-run and belongs to the BvL Group, a group of companies with a long tradition in mechanical engineering dating back to 1860. BvL develops cleaning technology that impresses with its high quality, practical innovations and ease of use.

The company's headquarters are in Emsbüren in Lower Saxony, Germany. This is where the entire value chain is located, consisting of engineering, sales, production, after-sales and administration of BvL Oberflächentechnik GmbH. BvL also coordinates its international sales and service network from Emsbüren.

BvL Oberflächentechnik was founded in 1989. The company can therefore look back on over 30 years of experience in the field of industrial parts cleaning. Since its foundation in 1989, the name BvL has stood for reliable and innovative cleaning systems in the industrial sector.

BvL Oberflächentechnik employs around 170 people in Emsbüren. BvL has a sales and service network in 19 countries to support its customers worldwide. This international network ensures that BvL customers receive smooth support and fast service even for projects abroad.

BvL offers a comprehensive portfolio of products and services for industrial parts cleaning. The spectrum ranges from compact washing systems for small parts to individual, complex, automated large-scale systems for extensive cleaning tasks. The range includes not only the cleaning systems themselves, but also automation solutions (e.g. material transport systems), system components such as external vacuum dryers and cooling tunnels, and the integration of process monitoring to ensure the cleanliness of the parts. The service package is complemented by reliable service, from commissioning and maintenance to retrofitting, to ensure that the systems operate efficiently in the long term.

BvL manufactures various types of cleaning systems to meet different requirements. These include, among others:

Turntable systems: Systems with a rotating table (turntable), suitable for very heavy or heavily soiled parts, as the part is rotated during cleaning (BvL Ocean product series).

Basket washing systems: Systems for cleaning individual parts, bulk goods or baskets in a washing basket (BvL Niagara product series)

Continuous cleaning systems: Continuously operating conveyor belt systems for series processes with high quantities (BvL Yukon product series for short cycle times and high throughput).

Immersion cleaning systems: Multi-stage immersion bath systems for the highest cleanliness requirements, often with several tanks (BvL Atlantic product series)

Large-part cleaning systems: Special systems for particularly large or bulky parts that require high cleaning performance (BvL Pacific product series).

Rotary cycle systems: Cleaning systems with a rotating workpiece carrier on which the parts pass through various cleaning stations one after the other (BvL Twister product series).

High-pressure cleaning systems: Systems that clean with high-pressure water jets and remove burrs, for example, to eliminate even stubborn dirt (BvL Geyser product series).

In addition to these standard system types, BvL also develops customised special solutions.

BvL cleaning systems are used successfully in many industries. One of the main markets is the automotive and vehicle industry, where BvL systems are used, for example, to clean engine and transmission parts. Special BvL solutions are also used in the field of electromobility (electric cars) for new parts such as battery housings.

In addition, BvL technology is used in rail transport (cleaning of train and railway parts) and in the household appliance industry (e.g. cleaning of washing machine parts or bathroom fittings). Other important areas of application are hardening shops (heat treatment plants) and foundries, where cleaned cast and forged parts are required for subsequent processes.

The high-purity industry is a strategically important sector. It encompasses all industries with the highest cleaning standards, such as semiconductor production technology, the optical industry, (ultra-high) vacuum technology, aerospace and medical technology.

In general, BvL is used wherever technically clean parts are required in industry, from general mechanical engineering to high-purity applications in sensitive areas.

BvL refers to its smart cleaning concept as "intelligent cleaning". These are cleaning systems that think for themselves: sensors and intelligent controls enable the system to constantly monitor its status. All relevant parameters (e.g. degree of contamination of the washing water, cleaning agent concentration, filter status) are recorded. The system regulates sub-processes independently, reducing the need for manual intervention. This smart system increases process reliability and ensures that a consistently clean result is achieved at the end of each cycle. In short, the BvL system monitors and optimises itself independently to ensure optimum cleaning at all times.

BvL cleaning systems offer a number of advantages:

High cleaning quality and process reliability: BvL systems ensure consistently high cleanliness of parts and continuously monitor the process.

High system availability: The systems are robust and reliable, resulting in low downtime and high operating time. This means that the systems are characterised by a low total cost of ownership over their lifetime.

Time- and cost-efficient operation: Optimised processes (e.g. short cleaning cycles in continuous systems) save time and reduce operating costs.

Innovation: BvL holds patents and regularly registers new intellectual property rights. BvL cooperates with universities and other educational institutions in several research projects.

Predictive maintenance: Thanks to intelligent monitoring (smart cleaning), the system detects maintenance requirements at an early stage. This predictive maintenance minimises unforeseen downtime.

Energy and resource saving: Thanks to technical optimisations, the systems consume less energy and water, which reduces operating costs and benefits the environment.

Easy to operate: Despite their technical complexity, BvL cleaning systems are designed to be user-friendly, with clear controls and automation, so that operating personnel can work with them easily.

These advantages make the systems efficient, reliable and economical in industrial use.

BvL provides its customers with intensive support in automation and Industry 4.0 integration. The cleaning systems can be seamlessly integrated into production lines. BvL offers suitable transport systems (e.g. conveyor belts, workpiece carriers) and automation solutions for this purpose. For example, robots can take over loading and unloading, or systems can be integrated into fully automated production processes. At the same time, BvL is driving forward digitalisation: the Smart Cleaning System records all process data, which can then be evaluated centrally. This enables remote monitoring of the cleaning systems in real time. In combination with the system's sensor technology, this offers advantages such as predictive maintenance (the system reports maintenance requirements at an early stage) and complete documentation of all cleaning processes. Overall, these automation and digitalisation functions help to make processes more efficient, safer and more transparent.

Yes. In addition to standard systems, BvL also develops customised special solutions that are precisely tailored to the customer's requirements. Customers can work with BvL to configure tailor-made systems, from special dimensions and customised cleaning processes to customer-specific automation concepts. BvL offers systems in all variants, whether small or large, stand-alone or integrated into production and automated. This provides customers with tailor-made cleaning systems that are perfectly suited to the task at hand.

Yes, sustainability plays an important role at BvL. All BvL cleaning systems are water-based, meaning they use water and specialised cleaners instead of potentially environmentally harmful solvents. In addition, the systems are designed to conserve resources: the smart cleaning concept optimises energy and water consumption, which significantly improves the ecological balance of the cleaning process. For example, a BvL continuous cleaning system features efficient exhaust air management that minimises heat loss and intelligent drying control that uses only as much energy as necessary. These measures reduce the ecological footprint of cleaning. In addition, effective filtration systems extend the service life of the cleaning baths, so that liquids need to be changed and disposed of less frequently. Overall, BvL ensures environmentally friendly processes through technology that saves energy and reduces waste.

BvL provides customers with intensive support in advance when selecting a system. For example, there is a requirements analysis tool on the website: in just a few steps, interested parties can enter their requirements and receive suggestions for suitable systems as well as a free information package ( ). In addition, BvL operates its own technology centre where customers can have cleaning tests carried out on their original parts. Experienced BvL experts work with the customer to determine the optimal cleaning system and the appropriate cleaning process for their specific task. Through this combination of consultation, test cleaning and analysis, BvL finds the best possible solution and ensures that the selected system fully meets the requirements.

BvL Oberflächentechnik GmbH offers comprehensive after-sales services to ensure the long-term operation of the systems. These include, above all, regular maintenance and inspections to ensure that the cleaning systems always function perfectly. Required spare parts and consumables are delivered quickly and reliably. Older systems can be upgraded and modernised to the latest standards on request. In the event of a malfunction, BvL ensures rapid repair: many problems can be diagnosed via remote maintenance, and on-site service is available if required. The service also includes support during commissioning: BvL takes care of the system installation and provides comprehensive training for the operating personnel so that the system can be used optimally. In short: BvL does not leave its customers alone after the purchase and ensures smooth operation through maintenance, spare parts supply, upgrades, repair service and training.

Yes, BvL also offers comprehensive packages, in particular maintenance, inspections, spare parts, modernisation and repairs for cleaning systems from other manufacturers.

Yes, BvL offers used cleaning systems in addition to new systems. These used systems are often available at short notice, as they have already been produced, and can be a more cost-effective alternative. Despite previous use, they meet BvL's high quality standards. They are characterised by their robustness and reliability. A used BvL system can therefore be an attractive option for interested parties who want a quick solution that has already proven itself in practice.

Such a procurement project goes through several phases from the initial idea to commissioning. It usually begins with the determination of requirements, followed by planning (creation of a specification sheet) and the selection of a supplier. This is followed by the ordering and manufacture/installation of the system. Finally, the cleaning system is accepted and commissioned, including handover to the company. Overall, the procurement process can be divided into steps ranging from determining requirements to selecting a supplier and placing an order to acceptance.

The first step is a thorough clarification of requirements. This involves determining exactly what is needed and why. It is important to define which parts or products need to be cleaned, in what quantity and to what standard (cleanliness requirements). In addition, the general conditions are considered: e.g. the process (which cleaning technology is suitable), the space required and the installation location, connections for electricity, water or chemicals, environmental conditions (temperature, ventilation) as well as maintenance and safety requirements. It makes sense to involve all relevant departments, such as production, maintenance and occupational safety, so that all requirements and restrictions are collected and documented at an early stage. A clear assessment of requirements forms the basis for all further project steps.

BvL Oberflächentechnik supports you in all phases of the procurement of a cleaning system. Even before the first quotation is prepared, you can carry out test washes in our technology centre. In this way, we can work together to find the right system and the optimal cleaning process for your task. Our technical sales department develops various concepts for this purpose, which you can discuss with us directly. Special requests can be made at any time or, if necessary, removed from the project. Once the contract has been awarded, our project management experts take over responsibility. Your project is assigned to a dedicated project manager who is your contact person for all technical and commercial questions. They will coordinate internal communication and, if desired, keep you regularly informed about the current status. Once the system has been completed, we will invite you to our factory for a preliminary acceptance test under realistic conditions. There you can examine the cleaning process with original parts; the level of cleanliness achieved can then be confirmed by external laboratories, for example. After a successful preliminary acceptance test, our experienced team will install the system in your factory and commission it. In addition, we train your staff in the use of the cleaning system and, if desired, also accompany the start of production. Even after official acceptance, we remain your reliable partner: if defects occur during the warranty period, our service technicians will remedy them quickly and reliably. In addition, our after-sales department is available to you at any time for inspections, maintenance, modernisations or retrofits.

Acceptance is a crucial milestone at the end of the project. Together with you, we check whether the cleaning system delivered meets all the agreed requirements. As a rule, after installation, the system is assembled at your premises following a preliminary acceptance at our factory and commissioned on site. Defined tests and functional checks are then carried out: Does the system clean the workpieces as required? Are the cycle times, throughput and cleanliness values being achieved? Are all technical and safety-related equipment functioning properly with ? All results are recorded in an acceptance report. If any defects or deviations are found, these are documented and then rectified. Only when everything is running satisfactorily do the parties sign the acceptance report.

Answer: Training is essential to ensure that employees can operate the new cleaning system safely and efficiently. Even the best system is of little use if no one knows exactly how to operate it or what to do in the event of a malfunction. Therefore, part of the project involves providing timely instruction to the operating personnel and, if necessary, the maintenance personnel. In practice, we offer on-site operator training. During this training, we explain how the system works, the operating steps, which cleaning media are used, how to make settings and how to clean or replace parts that require regular maintenance. Maintenance personnel should also be trained so that they can carry out inspections, maintenance and minor repairs themselves. In addition, we naturally provide clear operating instructions in the respective language. These clearly describe handling, maintenance and, for example, troubleshooting.