Background:
A recent Fortech customer was experiencing significant challenges with the sump life of their existing cleaning solution used in their spray booth cabinet for cleaning cast iron exhaust rockers. Their previous cleaner, supplied by a competitor and run at a 5% concentration, provided a sump life of only 1.5 weeks. This short lifespan was primarily due to the rapid onset of rust on the cast iron rockers, which caused frequent and disruptive sump change-outs to prevent quality issues. This resulted in increased downtime, chemical consumption, and maintenance costs.
Problem:
The primary problem was the extremely limited sump life of 1.5 weeks. Extending the sump life without compromising part cleanliness and corrosion protection was crucial for improving operational efficiency and reducing costs.
Solution:
The customer began implementing TechKleen FT163RP, a newly formulated industrial-strength cleaner from Fortech. TechKleen FT163RP was introduced at a concentration of 5%, matching the previous cleaner’s usage for initial comparison. The cleaning process continued to operate within the existing spray booth cabinet at a temperature of 120°F, with a sump capacity of 120 gallons.
Results:
The implementation of TechKleen FT163RP yielded significant and positive results:
- Extended Sump Life: The sump life dramatically increased from 1.5 weeks to 6 weeks. This represents a 300% improvement in the lifespan of the cleaning solution and establishes a more predictable preventative maintenance schedule, ensuring consistent cleaning performance.
- Reduced Cleaner Usage: Despite a slight price increase of $0.10 per gallon for TechKleen FT163RP, the overall cleaner usage was reduced by 70%. This reduction leads to fewer complete sump recharges and a lower makeup rate required to maintain optimal cleaning performance.
- Improved Operational Efficiency: Reduced downtime increased the production uptime, and improved overall operational efficiency.
- Enhanced Working Environment and Part Quality: Operators reported noticeable improvements, including a more pleasant smell within the work environment.Additionally, the parts were observed to be visually cleaner after processing with TechKleen FT163RP, and the interior of the spray booth cabinet itself remained cleaner, reducing maintenance efforts on the equipment.
Conclusion:
The successful implementation of TechKleen FT163RP for this customer demonstrates its superior performance in extending sump life, reducing chemical usage, and improving overall cleaning efficiency for critical cast iron components. Despite a minor price increase per gallon, the substantial reduction in consumption and the associated operational benefits have made TechKleen FT163RP a cost-effective and highly valuable solution for their metal cleaning needs.
For more information on how TechKleen FT163RP can enhance your projects, please contact us today.