Is it time to Replace Your Old Vapor Degreaser?
A vapor degreaser can operate for many years. In fact, many manufacturers continue using equipment that has been in service for decades.
But there is an important question to ask:
Is your old vapor degreaser still giving you the performance, efficiency, safety, reliability, and production capability you need today?
Older vapor degreasers were built around the technology, solvents, production requirements, and environmental expectations of their time. Today's cleaning requirements can be very different. In this blog, we look at 8 key reasons modernizing your parts cleaning equipment will provide significant benefits.
why replace an old vapor degreaser / parts washer
There is no single age at which a vapor degreaser needs to be replaced. A better approach is to look at the condition and performance of the equipment. Here we will explore some of the reasons that replacing your older system will upgrade your over-all cleaning operation.
1. Maintenance Is Becoming More Frequent
As equipment ages, components eventually require more attention. Pumps, refrigeration systems, heaters, controls, seals, switches, valves, piping, condensers, and other components can become increasingly difficult or expensive to maintain and service. A machine that once required occasional maintenance may begin requiring regular repairs.
So the question becomes: How much are we spending to keep the old machine running compared with the productivity and capabilities of a new system?
The evaluation would include considerations about: price of each repair, downtime, spare parts, technician time, production interruptions, and the potential impact of an unexpected equipment failure.
Modernized Vapor Degreasing Equipment helps reduce maintenance costs and time, lost production and downtime.
2. Cleaning Consistency Has Become a Problem
Quality issues in downstream functions, such as plating and painting, become more acute as the cleaning systems are loosing effectiveness. If parts require extra immersion time, additional agitation, manual wiping, or repeated cycles to achieve acceptable cleanliness, the cleaning process may be the reason.
QUESTION: Can the machine consistently produce the required result from batch to batch? Are we having to do rework? Do we have quality issues?
Modern vapor degreasing systems like the ULTRA systems have basket automation to ensure consistent cleaning each basket.
3. Cannot get parts or support for my old unit.
Many of the original vapor degreaser manufacturers are out of business. Original manufactures like Greco Brothers, Finishing Equipment, Ultra-Kool, Phillips, Detrex, Tally, Delta and Vapor Engineering are no longer in business…so you cannot get support or parts.
QUESTION: Are we not able to get support or parts for our unit?
Modern systems use currently available parts mitigating the frustration of non-availability.
4. Your Old Machine Was Designed Around an Older Process
Cleaning requirements change. Parts become more complex. Production volumes increase. Cleanliness specifications become more demanding. New materials are introduced. Different soils need to be removed. An older vapor degreaser may have been perfectly suited to the old needs it was originally purchased for, but that does not mean it is a match with your current needs.
QUESTION: Have our cleaning needs changed? In what ways?
Considering a replacement is an opportunity to design the equipment around the current process instead of continuing to adapt the process around an old machine.
Modern vapor degreasing systems can incorporate updated process controls, filtration, refrigeration, distillation, automation, ultrasonic cleaning, and automated material-handling options.
5. Your Solvent has Changed
AeroTron-AV: Modern Vapor Degreasing Solvent
With excellent H&S profile
Solvent selection is one of the biggest reasons companies reevaluate older vapor degreasing equipment. Many companies have moved away from historically common vapor degreasing solvents (like TCE, Methylene Chloride, nPB & Perc) However, most older units are not NESHAP compliant and thus cannot be used with these solvents. More and more cleaning operations are routinely shifting to modern solvents like AeroTron-AV because of the improved health and safety profile.
QUESTION: Can your existing vapor degreaser operate effectively with the solvent you want/need to use?
Modern vapor degreasing systems, like the ULTRA systems have the solvent containment and controls to utilize the newer approved solvents. Newer units will be NESHAP compliant - which means they are engineered to NESHAP specifications.
Bottleneck
Bottleneck
6. The cleaning equipment has become a bottleneck
A vapor degreaser that worked well when production was lower may become a bottleneck as production increases.
QUESTION: Are operators waiting for the unit? Are parts piling up waiting for the cleaning process?
A replacement system can be sized around the actual production requirement rather than simply replacing the existing tank with another tank of approximately the same size.
Modern systems can be sized and engineered for your current production. They also have automation and other features to help reduce cycle time.
7. The Machine Takes Up Too Much Floor Space
Older equipment can have a large footprint compared with what is available from modern system designs.
QUESTION: Can we benefit from a modern, more compact system, that will give us better cleaning in less footprint?
Modern systems use best current practices and updated component design to minimize foot print.
8. Inefficient Process Controls
Older machines may rely heavily on manual operation and intervention. Modern equipment can incorporate updated controls and process monitoring that make it easier to establish repeatable operating conditions, including basket automation.
QUESTION: Do we have to dedicate people to monitoring and operating the vapor degreaser?
Modern vapor degreasers can automate cleaning cycles including immersion time, ultrasonic operation, and drying time. Modern systems, like the ULTRA systems, also have safety monitoring indicators including, vapor up, solvent levels, and operator safety interlocks.
SUMMARY: QUESTIONS TO ASK
Equipment age: How long has the machine been operating?
Cleaning Consistency: Do parts come out clean every time?
Maintenance: How frequently does it require repairs?
Parts availability: Are replacement components readily available?
Downtime: How much production is lost during repairs?
Solvent: Is the current solvent still appropriate?
Cleaning: Does the machine consistently meet requirements?
Capacity: Has production outgrown the equipment?
Controls: Can the machine provide the process control you need?
Floor space: Could a modern system reduce the footprint?
Safety: Does the system provide the desired modern safeguards?
Future needs: Will the equipment support your next several years of production?
THE BOTTOM LINE
Modernized Vapor Degreasing Equipment will enhance your cleaning operation via:
Increased production reliability and capacity
Reduced maintenance time and costs
Automation for consistent part cleaning
Enhanced safety features
NESHAP Compliance for solvent changes
Upgraded features
How Reliance Specialty Products Helps Modernize your Cleaning Operation
Reliance Specialty Products works with companies to replace their old systems. Whether your have antiquated systems from Branson or Baron Blakeslee to obsolete systems from defunct companies like Greco Brothers, Finishing Equipment, Ultra-Kool, Phillips, Detrex, Tally, Delta and Vapor Engineering.
Our Comprehensive Vapor Degreasing Package you will get a every thing you need to modernize your cleaning operation:
Equipment - ultrasonic, low-emission, vapor degreasing systems
Solvent - powerful cleaning with excellent health and safety profile
Automation - for consistent part cleaning every time
Training - start-up and system maintenance
Accessories - parts basket
Consultation - part processing optimization and validation
On-Going Technical Support
contact us at Reliance Specialty Products today to discuss your cleaning needs and issues. We understand many of the old systems, as we have worked with them all as we help companies modernize their cleaning operation.
At Reliance, we take a comprehensive, systemic approach to supporting our customers to finding solution to their cleaning needs. Reliance Technical Support Department at 847-640-8923. We are glad to be of assistance.