INTERNATIONAL NEWS

MAXIMUM CLEANLINESS: FAR MORE THAN A PARTS WASHING PROCESS

To secure a future-proof and competitive position in the market, numerous companies are restructuring their product ranges. The trend is towards sophisticated solutions for high-tech industries. This not only means higher demands on the precision of components, but also extremely strict specifications regarding particulate and film cleanliness, which must be achieved in a process-reliable, economical and sustainable manner. The trend demands a different approach to cleaning: a critical look at the entire production chain and manufacturing environment, and an experienced partner.

In the course of industrial transformation, more companies are focusing on the manufacture of high-quality products and components with good margins. The focus is on high-tech industries that promise stable demand through growth in the future. The extremely high demands on manufacturing precision in these sectors – such as e-mobility, optical, sensor technology, photonics, thin-film technology, vacuum, laser and aerospace – include the cleanliness of components. This factor applies regardless of whether the components are millimetre-small connecting elements, precision optics or metre-sized structural components, and regardless of the materials from which they are manufactured.

The trend poses challenging tasks for parts cleaning. Unlike conventional component cleaning, which usually involves removing large quantities of manufacturing residues such as chips and processing media, ultra-fine and high-purity cleaning is all about removing minimal residual contamination. The specifications for particulate cleanliness extend into the sub-micrometre range.

Depending on the industry, component and its application, film-like residual contamination, such as organic and inorganic residues, ionic residues and microorganism residues, must be removed in a process-reliable and reproducible manner down to nanometre levels. In high-purity applications, such as the manufacture of components for EUV lithography, so-called hydrogen-induced outgassing (HIO) substances must also be considered.

The requirements for particulate cleanliness to be met during cleaning are specified by the corresponding surface cleanliness class (ORK) according to EN ISO 14644-9 (SCP – surface cleanliness by particle concentration) or the corresponding VDI guideline 2083, sheet 9.1. Film-chemical, organic and inorganic surface cleanliness is usually defined by individual specifications or factory standards. In addition, outgassing rates may be evaluated using mass spectrometers.

These demanding tasks require a technology partner which not only has comprehensive technological expertise and knowledge of the applications and physical relationships, but also experience in the field of cleaning and appropriate test facilities for cleaning trials under production-related conditions. As an experienced full-service provider of future-oriented and globally available solutions for ultra-fine and high-purity cleaning, Ecoclean says it meets these requirements.

To meet these very strict cleanliness specifications in a process-reliable, reproducible and sustainable manner, several cleaning steps are usually required along the manufacturing chain. The following questions play a role in selecting the optimal solution for the respective cleaning process: What is the workpiece material? What are the geometry, dimensions and weight of the component? What contaminants require removal? What cleanliness requirements must be met? Which cleaning process and chemicals are suitable for the task?

On this basis, it becomes possible to determine which and how many cleaning steps are necessary, using which medium and which process technologies. Other aspects that need consideration include the required quality of the rinsing medium and the appropriate drying technology, as well as clean part handling and the operating conditions (such as a cleanroom).

The basis for ultra-fine or high-purity cleaning is “oil- and grease-free” parts. To achieve and maintain this level of cleanliness, a cleaning process is carried out after the various processing steps, such as machining, forming, grinding or polishing. The effect of the cleaning medium deployed is enhanced by various process technologies that can be combined in almost any combination, such as steam degreasing, spray, high-pressure, immersion, ultrasonic and megasonic cleaning, as well as plasma cleaning, injection flood washing, pulsed pressure cleaning (PPC) and ultrasonic plus. These process options ensure that the required cleanliness is consistently achievable, even for geometrically complex workpieces.

For intermediate cleaning processes or parts with less stringent cleanliness specifications, modular single- or multi-chamber systems operating under full vacuum, such as EcoCstretch or EcoCvela, are typically used. Depending on the processing medium, these systems can be operated with an environmentally friendly solvent, such as hydrocarbons or modified alcohol, or a specially selected water-based cleaner. The design, system engineering, media flow and treatment of the systems are specially tailored to ultra-fine cleaning and high-purity applications. Thanks to the process mechanics concentrated in the working chamber – like injection flood washing, ultrasound and PPC – this type of system also offers advantages when cleaning large and complex workpieces.

Ultrasonic multi-bath immersion systems are the optimal solution for parts with a wide variety of materials, high throughput requirements and/or strict cleanliness specifications. In addition to individually designed cleaning systems for high-end applications, Ecoclean offers an efficient solution with its UCMSmartLine and UCMPerformanceLine series of systems consisting of standardised modules. The electrical and control technology is integrated into the respective modules for the process steps of cleaning, rinsing, drying, loading and unloading, as well as for the transport system. This, together with the provision of process mechanics tailored to requirements, such as PPC, allows the systems to be optimally adapted to the respective task. The option of upgrading the cleaning system at a later date ensures future-proofing in the event of increased requirements.

Ecoclean determines the right system concept for the application and the optimal cleaning process in its own High Purity Test Centre. It has a Class 7 clean room with Class 6 zones and various measurement and analysis methods (microscopy, residual gas analysis, UV light and fluorescence measurement). In addition to the product-specific development of cleaning processes and parameters, Ecoclean also uses its test centre to carry out contract cleaning orders. A packaging station for cleaned parts ensures that the high level of cleanliness achieved is also delivered to the customer.

More information www.ecoclean-group.net

Cosen fills the gap with new SH-520DM bandsaw

Any new fabrication equipment worth mentioning is often the result of a company listening to the needs of its customer. As just one example, fabricators working in structural steel, heavy manufacturing and job shop environments sometimes find themselves forced to compromise by investing in a small saw that cannot keep pace with production needs because the large-format saw would be overkill in more ways than one. The engineers at Cosen Saws, however, listened to customers and developed a solution with a product that it says “fills the gap” – the SH-520DM bandsaw.

Peng Huang, president of Cosen Saws North America, says at the heart of the SH-520DM double-mitre bandsaw is its ability to make a mitre cut up to 60° in either direction. For a variety of shops, that range is critical as it allows aggressive angles and precise cuts on I-beam, channel, tubing and other structural material without the need for multiple set ups or added equipment.

Huang says manufacturers in the utility and fabrication space need a saw that can handle straight cuts and severe angles, and the SH-520DM gives them that flexibility while keeping the material flow straightforward and well-supported.

“There was a need for the shops that started out with a smaller machine and wanted to grow their production into the next machine, but the next machine was too big to fit their floor space,” he explains. “The introduction of this model not only saved them on floor space, it also produces at the capacity that they can comfortably grow into.”

Cosen made a deliberate decision to go semi-automatic with the SH-520DM. Huang notes that not everyone needs a fully computerised machine. There is a strong market for saws that are intuitive, practical and versatile without heavy programming. The SH-520DM is designed to meet that need.

More information www.cosensaws.com

Kaltenbach introduces saw-drill line of machines

Kaltenbach has unveiled its latest innovation: the KKS 463 NA | KD 140 saw-drill line. This versatile all-round machine has been developed to meet a wide range of requirements in metal construction, steel stockholding and steel fabrication. It combines all essential processing steps in one compact system – capable of handling various steel shapes, especially in the smaller dimension range. While large systems are often uneconomical for small-format profiles, Kaltenbach says this machine offers the solution the market has long been seeking.

With the new saw-drill line, steel processing companies can handle nearly all materials and profile shapes: from round material with a diameter as small as 15 mm to special profiles up to 140 x 140 mm or flat material up to 240 mm wide. Mitre cuts of up to ±20° make the machine highly versatile.

The technology enables fully automated and precise drilling, milling, thread cutting, flow drilling and marking on all four sides of the profile. High automation and speed are the hallmarks of this machine, which only requires personnel for loading. Remnant lengths of less than 15 mm ensure maximum material utilisation, making the entire production process more efficient and resource-friendly.

The automatic tool changer, intelligent material preloading with feed magazines and fully automated part sorting boost productivity. Automatic adjustment during material changes – without any manual set up – reduces staffing needs to a minimum.

“Our new saw-drill line was specifically developed to meet the needs of our customers,” explains René Eger, managing director of Kaltenbach Cutting Systems GmbH. “Market demand was high, and we’re proud to offer a solution that combines high automation with fast processing times. This enables our customers to work more efficiently and significantly increase their productivity.”

More information www.kaltenbach.com

Compact storage and sawing from a single source

To meet growing demand, stockholder, processor and distributor Brütsch/Rüegger Metals AG, located in Regensdorf near Zurich, has upgraded its operations by replacing a semi-automatic honeycomb storage system for housing long stock with fully-automatic Unitop and Unitower storage systems from Kasto.

Brütsch/Rüegger is witnessing significant growth, today stocking 5500 tonnes of metals of 8000 different types and sizes. However, with this higher level of business came challenges. The honeycomb storage system from the 1980s was reaching the limit of its capability.

“Expanding the existing warehouse was not feasible due to infrastructure constraints, leaving only one option – consolidation,” explains Patrick Epp, managing director of Brütsch/Rüegger. “This led to the initiation of a new project to increase storage capacity, modernise the warehouse and enhance process efficiency.”

The metals specialist had complex requirements for the new installation, which needed to offer twice the storage capacity and fit within the 26 m wide hall. Additionally, the system had to be reliable, easy to operate and able to employ seven different storage and retrieval stations, allowing simultaneous processing of materials with multiple saws.

Says Epp: “We’ve been using a KASTOwin A 3.3 bandsaw from Kasto since 2018 and we’re very satisfied with its performance. This was one of the primary reasons we chose to meet with Kasto at a trade fair to talk about our requirements.”

Kasto recommended its Unitop 3.0 overhead, horizontally-moving gantry crane system with 521 storage positions for storing material up to 6.5 m long, and its Unitower 3.0 cassette storage system, with vertically-moving stacker crane, able to accommodate 12 m long material. Both systems are computer controlled by the KASTOlogic warehouse management system. The installation also includes two new bandsawing centres from the KASTOwin series, models F 3.3 and A 3.6.

More information www.kasto.com

Behringer introduces high-performance bandsaw

A highlight of the Behringer stand at the EMO 2025 exhibition in Germany towards the end of last year was the company’s new HBM500SC high-performance bandsaw. The HBM500SC saws solid material from case-hardened steel with a diameter of 300 mm in under 2 minutes.

But speed is not everything: the HBM500SC is also highly flexible, offering suitability for a wide range of materials and applications. In addition, the machine impresses with its high energy efficiency and AFC Pro technology, which automatically determines the optimum sawing parameters. This capability simplifies operation. After a short briefing, any employee can start the sawing process.

Other exhibits on show at EMO included the HBE320-523G mitre bandsaw and the LPS-TA automatic table bandsaw, which is suitable for sawing small panels and blocks.

Behringer Eisele  displayed innovations in the field of circular saws. The HCS 150E, for example, is a powerful multifunctional device for the steel trade and predestined for large batch sizes and mass cutting. The VMS 400H and PSU 450H mitre circular saws, and the VMS 370PV vertical circular saw, on the other hand, are designed for manual and semi-automatic applications – suitable for smaller metal construction companies and metalworking shops.

Behringer says now is a particularly attractive time to invest in modern sawing technology: the subsidy programmes of governments around the globe are opening new financial scope for small and medium-sized manufacturers and stockholders – especially for replacement investments. The energy-efficient sawing systems from the Behringer Group typically fulfil the requirements for a subsidy and therefore offer not only technological progress, but also economic advantages.

More information www.behringer.net