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DST-Degreasers for industrial parts cleaning solutions.

Sustainable solution for industrial cleaning challenges

Written by Vivi Yde Laursen on .

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Manufacturing

Sustainable solution
for industrial
cleaning challenges

The secret behind a 40% lower energy consumption

BUFAB Lann is the leading producer of turned parts in Sweden, known for their exceptional machining capabilities and expertise in CNC Single Spindle, CNC Multi Spindle, Multiplex machines, milling machines, and Rotary Transfer Machines.
As a subsidiary of BUFAB, a major supplier of fasteners and related products in Europe, BUFAB Lann has built a reputation for excellence in the industry.

A SUSTAINABLE AND EFFICIENT SOLUTION

BUFAB Lann faced several challenges with its industrial cleaning processes. Specifically, the company was struggling with spots on the parts after washing, the need to wash at high temperatures, and the use of multiple chemicals in the process. To address these issues, BUFAB Lann sought a more sustainable and efficient industrial cleaning solution that would not compromise the quality of its products. After extensive research and evaluation, BUFAB Lann partnered with DST-CHEMICALS.

Emil Aggefors, warehouse manager at BUFAB Lann says: “When we select our supplier we want a partner. For us, DST could provide the help we needed to optimize the use of our chemicals and support our cleaning process.”

TCO CALCULATIONS AND EXTENSIVE
AFTER-SALES SERVICE & MAINTENANCE

When evaluating potential partners for a surface treatment solution, it’s important to consider the total cost of ownership (TCO) of each option. This includes not only the upfront cost of the actual cleaning products but also the cost of implementing and maintaining the solution over time. Together BUFAB Lann and DST-CHEMICALS calculated the TCO based on the cost of energy, water, and other resources needed to operate the solution.

The maintenance costs involved were also examined; from man hours to bath and machine maintenance. The water-based products from DST-CHEMICALS are formulated to cause minimum damage on the equipment used for degreasing and cleaning and Emil Aggefors is happy with the cooperation: “We have a very close cooperation where DST help us monitor our baths in order for them to stay in good condition. DST is also a great partner for advice and support.”

A SPOTLESS SURFACE WITH
A WATER-BASED CLEANER

Through the adoption of DST-CHEMICALS’ products, BUFAB Lann was able to achieve remarkable improvements on the surface cleaning.

The new solution offered superior cleaning performance, reduced energy consumption, and eliminated the need for multiple chemicals. Moreover, the use of DST-CHEMICALS’ products resulted in significant cost savings for BUFAB Lann, which amounted to a 40% reduction in energy costs alone.

BENEFITS

  • Cleaner parts
  • 40% reduction in energy consumption
  • Just one cleaning product in use
  • Improved work environment
  • Reduced environmental impact
  • Optimized production flow
  • Regular after-sales service
    & maintenance visits

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Perfect cleaning for the
wind turbine industry

Written by Tue Paulsen on .

Maintenance and cleaning

Optimising resources ensures
uniform quality

ZF Wind Power gets higher quality cleaning with less manual handling

ZF Wind Power puts wind turbines in motion. ZF Wind Power supplies gearboxes for the world’s leading wind turbine producers. But when the gears of the gearbox are not completely clean, it becomes a problem for the subsequent processes. Together, ZF Wind Power and DST-CHEMICALS have refined DST-PINK GEL as an efficient detergent for wind turbine gearboxes. But why the colour pink?

DST-CHEMICALS and ZF Wind Power developed, tested and optimised the DST-PINK GEL product in collaboration in 2018. Jens Lorentzen, Technical Process Specialist, and Pernille Simonsen, Chemical Engineer, describe the challenges, development efforts and collaboration involved the solution – and the result.

Jean-Pierre Huyberechts (ZF Wind Power): “ZF is dedicated to standardising ALL of our fluids – to a uniform high level of quality. This will allow us to guarantee the same and the best results to our customers, every time. Whether the gearbox is produced in the US, China, India or Belgium. That’s why DST-CHEMICALS is a key partner.”

OPTIMIZING POOR WASH QUALITY

ZF Wind Power had daily problems with poor wash quality and results after using a different detergent. The gearboxes were not absolutely clean. Moreover, the subsequent manual cleaning took an unnecessarily long time. ZF Wind Power and DST-CHEMICALS have worked together as partners for many years and have developed several products which is why ZF Wind Power contacted DST-CHEMICALS in Denmark: would DST-CHEMICALS be able to help develop and optimise DST-PINK GEL?

DST-PINK GEL is a manual detergent sprayed on the part to be cleaned. Afterwards it is rinsed out. The parts still pink are the nooks and crannies to be finished with manual cleaning, Jens Lorentzen says. When ZF Wind Power produces gearboxes, lots of parts have to be spotless before proceeding in the processing.

READY FOR USE AND EASY TO REMOVE

ZF Wind Power had very specific requirements for the abilities and appearance of the detergent. Pernille Simonsen has developed and optimised DST-PINK GEL together with ZF Wind Power.

Through a wide range of testing in both Lommel (Belgium) and Kolding (DST HQ, Denmark), we found an optimum solution. Adding the colour pink to the detergent makes it easier for the staff to see which areas require cleaning and where cleaning is insufficient. At the same time, the product also had to be ready for use and to be able to be applied and removed quickly. Studying the product’s composition, we have managed to find a good solution.

DST-PINK GEL has been developed and tested in various processes and then applied – at first in Lommel, Belgium and now globally at ZF Wind Power.

MORE GEARBOXES WITH LESS MANUAL HANDLING

DST-PINK GEL is applied using a hand sprayer, and after 10-15 min., one man can easily remove DST-PINK GEL and apply a water based corrosion inhibitor (DST-PAS/1).

Rather than using three hours to process one gearbox – and take up space – ZF Wind Power is now able to handle six gearboxes at a time. Just one man – without using any solvents.

BENEFITS

  • Total cleaning and degreasing of metal parts on wind turbine gearboxes
  • Preparation for additional processing – lacquer or paint
  • Water based solution – no solvents used
  • Saves resources – both manpower and time
  • Standardising fluids – and quality – globally

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A sustainable solution and
higher quality at Danfoss

Written by Tue Paulsen on .

Copyright ©Danfoss (12/2019)

Manufacturing

From identification
to quick implementation

A sustainable solution
and higher quality

Danfoss Easley in South Carolina (US) is a supplier of mobile hydraulics for agricultural machines and construction equipment (OHV’s). As a supplier, it is extremely important to be able to supply hydraulic components of a high quality, enabling the customers to operate optimally – and without breakdowns. 

Danfoss Easley experienced daily problems with their oxide removal baths after TEM (thermal deburring) and were not satisfied with the quality of the cleansed hydraulic manifolds. DST-CHEMICALS has visited Danfoss Easley in South Carolina, US.

Nick Bjerregaard, Technical Process Manager at DST-CHEMICALS, elaborates on the challenge, the solution – and the result.

OPTIMISE THE WASHING PROCESS 
– AND INCREASE THE QUALITY

For cleansing and washing hydraulic components, Danfoss Easley uses oxide removal baths. They experienced many daily problems causing baths to last only a week – and the results were poor. There were too many oxides on the surface after washing.

Danfoss Easley used many resources, water as well as time, on washing. And this at a temperature of 70°C. In order for the employees to be able to handle the washed components further along in the process, the components had to be placed in a cooling tunnel.

A long process, which had to be repeated every week. This resulted in waste of time, energy – as well as high water consumption and the use of many chemicals.

REDUCED USE OF CHEMICALS AND WATER
– AT A LOWER TEMPERATURE

We wanted to reduce the water consumption and the use of chemicals and increase the quality of the washing of hydraulic manifolds at Danfoss Easley. And to that end, we introduced various measures, explains Nick Bjerregaard.

Using DST-DEBURR, Danfoss Easley could lower the water temperature to 45°C. And instead of replacing the baths each week – Danfoss Easley was able to just replace once a month. By lowering the water temperature – from 70°C to 45°C – Danfoss Easley was also able to turn off the cooling tunnel after the washing process. 

The hydraulic manifolds could be handled right away. This also gave the employees a much better – and quicker – flow in the work process.

SUSTAINABLE SOLUTION 
– WITHOUT COMPROMISING ON QUALITY

Lowering the temperature of the baths – and using smaller amounts of chemicals – is also of great  significance to the environment. The solution is more sustainable – and has also optimised the handling of hydraulic manifolds at Danfoss Easley. At the same time, they have saved time and money and increased quality. And thus, they can deliver a better end product to their customers.

DST-CHEMICALS is currently working with several Danfoss divisions, training new employees and doing follow-up service.

BENEFITS

  • The temperature has been lowered from 70°C-45°C
  • Approx. 50% saved energy and carbon
  • Higher quality after TEM
  • Biodegradable and sustainable solution
  • A smaller carbon footprint
  • A more stable process – better flow

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