NEWSIssue 6

Leading global aerospace company, Goodrich,have installed the new MecWash AqueousDegreaser (AVD) specifically on an NDT (non-destructive testing) operation, which isundertaken to a recognised ASTM internationalaerospace industry standard using what is known as a TAM panel test piece for quality assurance.

The TAM panel incorporates five ‘starbursts’ used for testing the sensitivity of the dyepenetrant NDT process. This is a daily processquality test carried out by most aerospacemanufacturing companies.

The panels have previously been cleaned usingtrike (trichloroethylene) before NDT, whichexposes three or four of the starbursts. Cleaningin the new MecWash AVD not only matches thisbut has exposed all five starbursts, therebyachieving a more effective result. The smalleststarburst exposed using the AVD – the fifth – ishighlighted on the lower left section of thepictured TAM panel.

Senior Materials Engineer at Goodrich, TonyRoots, reports “The new AVD system isperforming this important quality task to a higherlevel than trike, but in this case uses a moreenvironmentally acceptable aqueous solution.”

Eliminating the use of solvents is a major priority for the company, not only to comply with the SED, but also in line with its progressive corporate health, safety andenvironmental policy.

The company has also tested the AVD for general component cleaning and degreasing –on pump and valve bodies, for example – againachieving results comparable with or better thansolvent degreasing.

NEW AQUEOUS DEGREASER FROM MECWASHBy harnessing the high thermal energy ofboiling water, the new Aqueous Degreaser from MecWash Systems effectively cleans and degreases the parts that normal aqueous systems, and in some cases solvent systems, cannot.

The system is the result of a two-yeardevelopment project backed by a SMART GrantAward from the South West RegionalDevelopment Agency, and is the subject of apatent application. The new MecWash AqueousDegreaser has already proven effective atremoving some of the most difficult andtenacious contaminants – including resins,greases, NDT inks, zinc stereate, lapping pastesand polishing compounds.

OUTPERFORMS ‘TRIKE’ DEGREASINGULTRASONICSROTATIONAL AQUEOUS CLEANING WITH

Successful cleaning trials pre and post non-destructive testing for Goodrich Aerospace Components

Operating at over 100°C in a fully sealed system, and using new cleaning chemistrydeveloped by MecWash for the high operatingtemperature, heavy contamination is brokendown and removed in just minutes. Subsequentvacuum drying is also rapid, giving a total cycletime of around 5 minutes for most applications.The high operating temperature also reducesthe viscosity and surface tension of the solutionallowing it to penetrate into smaller holes than is achievable with normal aqueouscleaning methods.

Apart from addressing the difficult cleaningapplications noted above – which can often leavesolvent systems struggling – MecWash alsobelieves there is a significant opportunity for itsnew system in the re-manufacturing industry.Here, heavy grease and oil residues build up on

NDT TAM Panel

components during several years in service andneed to be removed before assemblies aredismantled for inspection and re-work.

The new Aqueous Degreaser is based on theproven MecWash single chamber systemdesign. Components are securely placed into abasket and pushed from a conveyor into a front-loading chamber, which can be supplied indifferent sizes to suit the size and quantity ofparts that require cleaning. The complete wash,rinse and dry process is carried out

automatically within a sealed and fully insulatedsystem. There is only minimal loss of watervapour and energy from the system which keepsthe operating costs low.

Both ferrous and non-ferrous parts can becleaned through the new process withoutdiscolouration, attack or corrosion. Only lowconcentrations of organic chemistry arerequired to assist the high temperature cleaningprocess and protect the parts. This compares totraditional cleaning processes using corrosivecleaners that can result in the etching and

corrosion of the parts, operational health &safety problems and effluent disposal issues. All of these problems are resolved by the new system.

In light of the Solvent Emissions Directive and the search for safer alternatives totrichloroethylene, the new aqueous degreasingsystem from MecWash provides a solution forthe most demanding cleaning applications for which solvents have previously beenconsidered the only option.

MEASURES UP AT RENISHAWMECWASH COMPONENT CLEANING TECHNOLOGY

Aqueous-based component cleaningtechnology from MecWash is meeting theextremely high performance standards laiddown by one of the world’s leadingmanufacturers of measurement equipment.Four MecWash Midi cleaning systems havebeen installed at Renishaw and are achievingresults that even satisfy Tof SIMS analysis(Time-of-flight secondary ion massspectrometry) – a highly demanding surfaceanalysis process undertaken at BristolUniversity. As a result, the 330,000components per month produced atRenishaw’s Stonehouse and Wotton-under-Edge facilities are achieving the high levels ofcleanliness required for a range of applicationsin industries as diverse as medical, forensics,calibration, aerospace and automotive, whereRenishaw is seen as a major producer ofprobing systems and calibration equipment.

Each of the four MecWash Midi installationsare comprehensively specified and benefitfrom a built-in Aqua-Save wash watertreatment system which cleans and recyclesthe wash and rinse solutions. Consequently,the wash installations do not need aconnection to drain allowing them to be sitedwhere required within the production lines.

Based on the acclaimed MecWash rotationalwashing technology, the Midis’ choice ofprogrammes provides rotational floodimmersion washing, rinsing, final rinsing, highperformance filtration, oil separation and hotair and vacuum drying. This ensures thatmaterial such as metal swarf, coolant andauto de-burring residue is removed from eachcomponent ahead of further assemblyoperations that take place at Renishaw’splants both in the UK and Ireland. The systems also provide a clean, bright,

residue free surface finish without spots andstains which is paramount to the highlyaesthetic appearance of the final product.

The consistent results and the self-containeddesign of the MecWash equipment are keyfactors in the installation and offer distinctadvantages compared with the previousmethods used by the company.John Fielder,Senior Production Engineer, explains –

“Previously, we used a series of ultrasonicdip tanks and solvent cleaning so there areclear performance and environmentalbenefits associated with thedecision to move to theMecWash installations,” hesays. “Alongside this, the in-built Aqua-Save unitswhich require onlysmall amounts ofwaste oil to betransportedoccasionally for safe disposal off site, enhance ourenvironmentalperformance whichwe believe is a key

“Previously, we used a series of ultrasonic dip tanksand solvent cleaning so there are clear performanceand environmental benefits associated with thedecision to move to theMecWash installations”

element in responsible, modernmanufacturing processes.

“Because of the highly accurate performanceour customers require from our products, andthe types of industry within which they operate,the quality of each stage of the manufacturingprocess is critical,” he continues. “we aredelighted with the contribution made by theMecWash equipment.”

The aqueous-based installation in the CleanPneumatronic Systems Division of KVAutomation in Milton Keynes has replaced theprevious cleaning system that saw very complexparts cleaned and dried through potentiallyharmful solvents. Significantly, allowing thecleaning process to play the optimum roleduring manufacturing.

The full range of pneumatic components – themajority of which are bespoke systems destinedfor microelectronic, precision measurement andinstrumentation applications – are machinedoff-site before undergoing sub-assembly workwithin the main factory.

Roger Day, Senior Production Engineer for theAdvanced Product Division at the companydetails the procedure that is used –

“Depending upon their size, products arelocated in baskets or trays often as kits and thenloaded from the clean side into the rotational

Roger Day notes significant performance gains– in terms of reduced failure rate – comparedwith the previous ultrasonic, solvent-basedinstallation. The MecWash cleaning processincludes spray/flood immersion wash and rinsestages with very high standards of filtration to 1micron level. The targets set by the CPSDivision – some 1 to 1.5 microns on final rinse –are thus readily achieved.

“The range of components sees aluminium,plastic, stainless steel and nickel-plated brassall pass through our installation with some 400parts per day commonplace,” commentsMecWash Director Paul Young, who points outthat the company also supplies the cleaningchemicals. Importantly, we believe thedevelopment is providing KV Automation with a‘future proof’, high performance, aqueouscleaning method which helps to overcome boththe current and potential future regulatorycontrols relating to solvent cleaning systems.”

drum which is at the heart of the MecWashsystem,” he says. “The cleaning process thenproduces components which can be transferreddirectly into the adjacent Class 1000 clean roomfor final assembly. This loading area is itselfheld in positive pressure of 10 Pascals above thefactory environment to create the optimumbuffer zone between manufacturing and finalclean room operations.

With blind holes and deep, small bore drillingstypical of the increasingly complex components,cleaning performance is clearly critical and

PNEUMATIC COMPONENTCLEANLINESS

MECWASH COMPONENT WASHING SYSTEMGOES THROUGH THE WALL TO MAXIMISE

‘The MecWash cleaning processincludes spray/flood immersionwash and rinse stages with veryhigh standards of filtration to 1micron level’

High levels of component cleaning performance and location in a partition wall that separates the

manufacturing area from a large scale clean room have combined to maximise the benefit of a MecWash

Midi component cleaning system for one of the UK’s leading manufacturers of pneumatic components.

High quality, aqueous-based componentcleaning installations from MecWash Systemsare now being implemented by Perkins Enginesin Peterborough with, significantly, the two ‘Midi’units interfacing directly with the robotichandling systems. The units are key elementsin a self-contained, highly focused operationwhich, says Perkins, effectively enables themanufacturing cell to operate as its own profit centre.

Cylinder heads for the Perkins Type 400Dengines – in both turbo and naturally-aspiratedformats – are processed in the new facility. Rawcastings proceed in pairs through four Hellermachining centres with the MecWash Midi unitsused for both intermediate and final washprocesses. The results accordingly to RogerLee, NPI Project Manager at Perkins Engines,are excellent –

“The MecWash Midi’s remove coolant and swarf which are inevitably produced by themachining operations and need to meet ourspecification figures of no more than 145milligrams per cylinder head. The actual figurebeing achieved is between 10 and 20 milligramswhich dramatically exceeds the target andmakes a major contribution to maintaining thehigh quality levels that our customers requireand expect.”

The environmental gains arising from theaqueous operation of the MecWash installationsare enhanced by their ability to interface directlywith the Fanuc robotic system. The handlingsystems control the full movement of thefinished components from receipt throughmachining and washing processes and alsoaccommodate the purpose-designed fixturesthat MecWash have developed to enable thecylinder heads to be washed in the mosteffective way.

The Midi specification at Perkins includes adedicated jetting facility which sees the washsolution fed directly through the fixture to be

“We are delighted that each installation has metPerkins’ precise requirements in terms of thecleaning and drying of complex componentsquickly and accurately – all within the totallyautomated processing operation.”

Operating 24 hours a day, five days a weekacross three shifts and producing some 80,000cylinder heads per year, this is a highlyimportant part of Perkins Engines’Peterborough operation. Structured aroundindividual processing teams which includeproduction, maintenance and training – whichthe organisation points out effectively gives theemployees ‘ownership’ of the process – thefacility demonstrates not just highly efficientmanufacturing procedures but also aninnovative approach to operational procedures.

“We believe the decision to specify the MecWashMidi’s within this context reflects favourably onboth our equipment performance and designand also our willingness and ability to workclosely with other key suppliers – of bothrobotics and machine tool centres – at the site,”concludes Paul Young.

directed at key areas of each component. Not only does this allow the wash process tooperate most effectively, but the pipe-workarrangement also delivers pressurised air to thesame locations to optimise the subsequentdrying process. This combines with theMecWash flood and spray wash procedures – allcontained in the company’s rotational drumdesign – to produce the excellent results thatPerkins are now experiencing.

“We have also designed drag conveyors into thewash tanks to allow the machine swarf to beremoved automatically, reducing operatorinvolvement and machine downtime forcleaning,” adds MecWash Director Paul Young.

‘Operating 24 hours a day, fivedays a week and producingsome 80,000 cylinder heads peryear, this is a highly importantpart of Perkins EnginesPeterborough operation’

FULLY AUTOMATIC ROBOT OPERATED

CLEANINGSYSTEMSPRODUCE MAXIMUM BENEFITS FOR PERKINS ENGINES

MECWASH AND AQUA-SAVEWORK TOGETHERFOR LEADING TURNEDPART MANUFACTURER

shipment to the end user, as Managing Director,Nick Groom explains.

“Each of our customers needs to be able to slotthe component straight into his productionprocess without the need for further cleaningoperations,” he says, “which is why all of ourproducts now pass through the two MecWashunits. The decision to use either the AqueousDegreaser (AVD) or the Solo primarily dependsupon the component type. The more complexdesigns gain from the benefits offered by thenew AVD unit which includes in-built ultrasonic capability.”

“The AVD is our latest development and isideally suited to many of the operations atQualiturn,” comments MecWash Director, PaulYoung. “Because it combines the safety ofaqueous cleaning with ultrasonics, flood andspray washing and rinsing, followed by hot airand optional vacuum drying in a single compactunit, its performance capability is extremelyhigh.” he explains.

“Working in conjunction with the Solo, Qualiturnis gaining from maximum washing versatilitywhilst being able to maintain the highest level ofcleaning quality irrespective of the componentconfiguration.” Paul Young points out that the

installations have replaced an existing MecWash‘Mini’ system which Qualiturn operated forsome eight years.

The Aqua-Save Junior, located between the two machines, recycles the wash waters,removing the waste soils and returning cleanwater for re-use with only some 5% of theoriginal volume then requiring off-site disposal.Nick Groom reports that water consumption hasbeen reduced by some 75% for the cleaningprocesses whilst, at the same time, minimisingwaste disposal requirements has enhanced hiscompany’s environmental credentials. “A simple flick of a lever allows the Aqua-Save unit to link to either unit,” he explains, “whichwe can then set to run overnight to ensure that the wash processes are optimised for the following morning.”

With high profile customers in highly demanding industries – in areas as diverse asthe military and the music industry as well aselectronics, automotive and aerospace –Qualiturn has developed an internationalreputation of which it is extremely proud. Boththe MecWash machines and the Aqua-SaveJunior are now making significant contributions to this objective.

The coming together of componentcleaning systems from MecWashSystems and environmental waterrecycling capability from Aqua-SaveTechnologies, is providing tangiblebenefits to one of the country’sleading CNC precision turningcomponent companies.

Qualiturn, which can point to a growinginternational market for its products, hasinstalled a MecWash Solo alongside an AVD 300aqueous degreaser from the company, both ofwhich are linked directly to an Aqua-Save waterrecycling facility. The result is enhancedproduction efficiency, greater throughputflexibility and environmental improvement – ofequal benefit to Qualiturn and its customers.

The company’s 18 machining centres produce avast range of turned parts, mostly in steel, brassand aluminium, of varying dimensions andconfigurations, using neat mineral oils. Witheach component passing through CNC turningand milling operations, it is vital that theresultant oil and swarf is removed ahead of

MECWASH SYSTEMS LIMITED64 Hundred, Severn DriveTewkesbury Business Park

Tewkesbury, GloucestershireGL20 8SF, UK

Tel +44 (0) 1684 271600Fax +44 (0) 1684 271601

E-mail enquire@mecwash.co.ukWeb site www.mecwash.co.uk

In addition to the supply of component cleaningequipment, MecWash have also developed acomprehensive range of cleaning chemicals thatmaximise the equipment performance. With in-house fully qualified chemists and laboratory,all cleaning applications are evaluated beforemachine trials, ensuring that the contaminantsare completely removed to the requiredcleanliness standards whilst at the same timeprotecting and in some cases enhancing thematerial substrate. Whether the componentsare manufactured in cast iron or sensitivealuminium and copper alloys, the MecWash AC

cleaner range will provide the high standards ofcleanliness and finish required.

Through a new dedicated Customer ServicesDivision, MecWash provides a comprehensiveand dedicated support service to all itscustomers worldwide. Qualified mechanical andelectrical engineering support is provided overthe telephone, through field visits and via directon-line modem connections to provide fast and effective response times, backed up by on-going parts supply, timed service contractsto suit machine operating conditions andmachine refurbishments.

MecWash Systems Limited is a British companywith its fully equipped design, development andmanufacturing facilities for cleaning equipment,Aqua-Save water recycling systems and processchemicals located in Tewkesbury,Gloucestershire. This local and specialisedfacility enables MecWashto provide its customerswith unrivalled support inall aspects of the machineand process operation.

TAKING PRIDE IN BRITISH ENGINEERING

COMPLETE SUPPLY & SUPPORTFROM A SINGLE SOURCE

Solo 300Spray Wash; Mist Rinse; Hot Air Dry.

Wash Chamber300 x 300 x 450Machine Dimensions 1125(W) x 1230(D) x 1900(H)

Solo 400Spray Wash; Mist Rinse; Hot Air Dry.

Wash Chamber400 x 450 x 650 - 1000Machine Dimensions 1275(W) x 1445(D) x 2100(H)

Solo 600Spray Wash; Mist Rinse; Hot Air Dry.

Wash Chamber 600 x 600 x 800Machine Dimensions 1575(W) x 1845(D) x 2700(H)

AVD 300Flood/Spray Wash; Flood/Spray Rinse; Ultrasonics; Hot Air & Vacuum Dry.

Wash Chamber 320 x 320 x 450Machine Dimensions 1175(W) x 2300(D) x 2355(H)

Midi 400Flood/Spray Wash; Flood/Spray Rinse; Ultrasonics; Hot Air & Vacuum Dry.

Wash Chamber 400 x 450 x 650 - 2000Machine Dimensions 2980(W) x 1845(D) x 2250(H)

Maxi 600Flood/Spray Wash; Flood/Spray Rinse; Ultrasonics; Hot Air & Vacuum Dry.

Wash Chamber 600 x 600 x 800 - 1000Machine Dimensions 3830(W) x 2015(D) x 2400(H)

Duo 400Spray Wash; Spray Rinse; Hot Air Dry.

Wash Chamber400 x 450 x 650Machine Dimensions 1530(W) x 1635(D) x 2235(H)

FLOOD/SPRAY WASH SYSTEMS

SPRAY WASH SYSTEMS

PRODUCT RANGE