Squeaky Clean Components

The CastAlum machining centre utilises several operations that support our high-capacity Heller Machine Tools Ltd (UK) machines in preparing high-spec machined components to be supplied to our customers. One of those operations is our washing systems. This essential step in our manufacturing process enables us to work to specifications and meet the specific cleanliness standards as set out by our customers.?

The process of die casting and machining aluminium parts will always produce contaminants that are unwanted. These may be lubricants such as oil or grease used on die cast tooling, or flakes of metal created during machining. Removing these before our parts are shipped to our customers is essential in order to ensure they are ready for subsequent operations. Any contaminants could also result in the failure of products either upon inspection or even after assembly. Producing clean parts is important not just for aesthetic purposes, but also in order for us to meet the highest standards of quality possible.

To that end, we have a total of four wash systems in use in our machine shop. Three of these are Technowash Ltd (Safetykleen Group Company) tunnel wash systems. One is a manual load, single-station used for a specific product line, with the other two being integrated in-line with our conveyor system from The EWAB Group . On this system, once machined, parts are loaded onto pallets on the conveyor and then moved through various process stations, including being conveyed through the wash.

The TechnoWash system consists of a three-stage process:

1. Wash Process: this initial stage removes the majority of contaminants from the component part.
2. Rinse Process: this stage further removes any residual contaminants and prepares the parts for drying.
3. Drying Process: this final stage ensures the parts are completely dry and ready for the next phase of production.

Our inline conveyor wash systems are suitable for processing large volumes of component parts where batch washing is not suitable. This ensures high levels of component cleanliness and fast process times. We are able to effectively remove typical soils such as oil, coolant, grease, ink, metal swarf, and cutting fluid.

The TechnoWash system is not just efficient but also adaptable. This means we are able to repurpose our existing systems for different product ranges as we win new contracts. It provides repeatable cleaning results through a pre-set (and variable) conveyor belt speed, fixed position spray jets, and particle filtration. Additionally, it offers energy savings through thermostatically controlled fluid heating combined with fast, efficient washing.

We also employ a MecWash Systems Ltd Duo rotary wash system on site, which is used for a specific product range. This is a front-loading wash system where parts are loaded into a basket and subjected to another 3-stage wash process.

1. Wash Process: the wash chamber contains over 100 high volume jets that thoroughly penetrate and saturate the workload. This means that components are cleaned whether they are placed in metal baskets or plastic containers.
2. Rinse Process: the powerful spray rinsing stage achieves very high standards of surface finish and cleanliness. It can also be used to apply a longer-term corrosion inhibitor for ferrous components.
3. Drying Process: a high velocity ambient or heated drying cycle completely dries the parts in total cycle times of only 5-10 minutes.

The MechWash Duo is highly versatile, suitable for both large components and dense baskets of small parts.

The wash systems employed in our machine shop are meticulously designed to ensure the highest standards of cleanliness, adaptability, accuracy, and energy efficiency. We are committed to delivering components to our customers with the highest levels of quality, whilst minimizing our environmental impact.

To learn more about our machining capabilities, visit castalum.com/machining.

Employee Spotlight

This month we have an interview with our Machining Manager: Richard Jones.?Go to our website?to read more!

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