Skip to main content

Kategori: Sustainable Solution

Perfect cleaning for the
wind turbine industry

Manufacturing

Optimised cleaning processes ensures
high quality

How ZF Wind Power optimised their cleaning process and boosted productivity

ZF Wind Power puts wind turbines in motion and their advanced technology and service solutions contribute to the transformation of the global energy system, in which reliable, robust and efficient products and systems conserve precious resources.

In the world of wind turbine production, gearboxes are the heart of the operation. ZF Wind Power, a leading name in the industry, knows this all too well. But even the best gearboxes can’t perform their magic if they’re not spotless. That’s where DST-CHEMICALS comes into play, with their innovative cleaning solution – DST-PINK GEL. But you may ask, why pink?

Back in 2018, DST-CHEMICALS and ZF Wind Power put their heads together to develop, test, and optimise DST-PINK GEL. The journey wasn’t without its challenges, but the result was worth every effort.

Jean-Pierre Huyberechts (ZF Wind Power): “ZF is dedicated to standardising all our fluids to a consistently high level of quality. This ensures we deliver the same top-notch results to our customers, every time, no matter whether the gearbox is produced in the US, China, India, or Belgium. That’s precisely why DST-CHEMICALS is such a crucial partner for us.”

TACKLING THE ISSUE OF POOR WASH QUALITY

ZF Wind Power faced daily problems with poor wash quality and poor wash results using a different detergent. The gearboxes weren’t as clean as they needed to be, which led to excessive manual cleaning. Given their long-standing partnership and successful product development history, ZF Wind Power reached out to DST-CHEMICALS. Could they help develop a new cleaner?

DST-PINK GEL is a ready-to-use product that’s sprayed onto the part needing cleaning, then rinsed off. Any part of the gearbox still showing the pink colour are the tricky spots that need a bit of extra elbow grease. When ZF Wind Power produces gearboxes, every part must be immaculate before moving forward to the next step in the production process.

So, next time you see a wind turbine spinning gracefully in the breeze, remember – it’s not just about the wind. It’s also about the perfect cleanliness of each gearbox, thanks to DST-PINK GEL. And yes, it’s pink for a reason!

READY-TO-USE AND EASY TO REMOVE

ZF Wind Power had a very particular set of requirements for the new detergent. It had to be effective and versatile and yet extremely user-friendly. Enter DST-CHEMICALS, with their can-do attitude and cleaning expertise.
Through a series of rigorous tests in both Lommel (Belgium) and Kolding (the headquarters of DST-CHEMICALS in Denmark), they hit upon the perfect solution. They added a dash of pink to the detergent. Not just for aesthetics, mind you, but to help the staff identify which areas needed a bit more elbow grease. The product also had to be ready-to-use and easily applied and removed.
After studying the product’s composition, our scientists at the lab at DST-CHEMICALS found just the right solution. DST-PINK GEL was then developed, tested in various processes, and put to work – first in Lommel, Belgium, and now globally at ZF Wind Power.

MORE GEARBOXES, FEWER HASSLES

Here’s where things get really interesting. DST-PINK GEL is applied using a hand sprayer, and after a quick 10-15 minutes, it can be effortlessly removed by one person. They then apply a water-based corrosion inhibitor DST-PAS/1.
Now, instead of spending three hours on one gearbox and taking up valuable space, ZF Wind Power can handle six gearboxes at once. And all this with just one person and without using any solvents.

KEY OUTCOME

  • Co-creation and innovative solutions
  • 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

Continue reading

A sustainable solution and
higher quality at Danfoss

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

More about DST-DEBURR

Continue reading

Contact us