Removing Contaminants from Industrial Part Washing Processes
Throughout the manufacturing process, components are washed to remove contaminants that could negatively impact any subsequent process, the quality of the component, or increase the potential for a warranty claim of the final product.
Manufacturers of cleaning technologies do a great job of removing the contaminants from the component. But they do a poor job of removing the contaminants from the cleaning process.
Typically, bag filters are utilized to remove the contaminants. The problems associated with bag filters include:
- Extremely labor intensive → Labor costs associated with changing bags increases operating and maintenance costs and consumes manpower that could be utilized for more value-added plant services.
- Inconsistent and unreliable → Bag filters are nominally rated so the effective filtration can vary by supplier, and even by batch.
- Premature “blind off” → When this occurs, the useful life of the bag is significantly reduced.
- Easily circumvented at the operator level → If bag filters require change out too frequently, then the micron rating is typically increased to reduce change out frequency; or the bags are permanently removed from the housings.
The changing of bag filters can be the single biggest source of contamination. The bags may remove the contaminant: but the contaminant gets re-introduced during the change out.
ZGF technology removes contaminants effectively and efficiently
Depending upon the component, cleanliness can be critical, and poor cleanliness can be costly. Dirty components can have long-term cost implications when they are part of a complex assembly that fails due to contamination that was not effectively removed.
In many cases, the problem is a poorly designed filtration system. Even if the cleaning technology (i.e. washer) effectively removes the contaminant from the component, if the contaminants are not effectively removed from the process (i.e. the wash solution), they will redeposit on the component and render the entire cleaning process ineffective.
Typically, it is not the big contaminants that cause problems in that they are easily removed. The particles that are 75 micron and smaller are of greatest concern. Some of these particles you can’t even see! The human eye can’t see particles smaller than 40 micron. Click on the Particle Size Chart to better understand the size of common things and how clean industrial components must be after the washing process.
ZGF technology is:
- fully automatic
- consistent & reliable
- energy efficient - only utilizes a minimal amount of electricity and air during purge/backwash cycle
- able to capture and remove ferrous particles down to 1 micron (Maggie) and non-ferrous particles down to 20 micron (Spring Filter)
- able to extend washer fluid life, improve part cleanliness, minimize labor, and minimize the environmental footprint of the cleaning process
ZGF technology provides value
To learn more about the advancements and advantages of ZGF technology as compared to bag filters, open Automatic Filtration in the Parts Washer Industry.
This white paper provides a comprehensive overview including:
- the case for filtration in the parts cleaning industry
- the various existing filtration technologies in use today
- the advantages of “Variable Geometry Filtration”
- the pros and cons of full flow versus side-stream filtration
- the economic case for non-disposable filter media
- a specific parts washer case history application.
ZGF technology has been adopted as the best available technology for part cleaning / washing operations within many well-known Fortune 500 manufacturing organizations. As they continue to implement our technology and realize the exceptional value, some organizations have shared their success stories.
Click on Success Stories to jump to the Success Stories / Case Studies page to learn how ZGF technology provides value. Click on the links below to learn how our customers were able to reduce operating costs, improve process reliability and quality, and reduce the environmental footprint of their part washing operations by implementing ZGF technology.
- Improve Process Reliability and Eliminate need for Bag Filters
- Prevent Nozzle Plugging & Provide Consistently Cleaner Parts
ZGF technology can be installed in a variety of places in your process.
ZGF Maggie and Spring Filter technologies are often implemented in Industrial Part Cleaning / Washing Operations.
ZGF technologies can be installed:
- in-line to the nozzles to prevent nozzle plugging / blockage ensuring consistent flow of the cleanest possible wash solution to the component that is being cleaned,
- as a side-stream filter providing continuous filtration of the wash solution.
To get a better understanding as to where ZGF Maggie and Spring Filter technology can provide value in your Part Cleaning / Washing Operations, download the Process Diagram, Industrial Part Cleaning / Washing.
If your part cleaning / washing operations are primarily ferrous (i.e. cast iron, steel, powdered metal, CGI, etc.) and you want to learn more about ZGF Maggie technology, then download the Maggie Product Data Sheet or view the Maggie in action by watching the Maggie video.
If your part cleaning / washing operations are primarily non-ferrous (i.e. Aluminum, Brass, Titanium, etc.) and you want to learn more about ZGF EZ Clean technology, then download the EZ Clean Phoenix Product Data Sheet or the EZ Clean EC700S Product Data Sheet or view the Spring Filter video and see how all the contaminants are removed during backwash when the filter element opens and shimmers.
Simplicity, consistency, reliability and the lowest cost of ownership make ZGF technology the best solution and value for your part washing operations!
ZGF is your preferred partner.
Filtration should not be a burden.
Filtration should be a tool that improves quality and reduces cost.
Let us help you meet your objectives and make your job easier!
We are always available by phone too. Give us a call!