Die cleaning is often a work that involves many health and safety risks. PCA Water has developed a method that guarantees the safety of the operator.
For a long time, these dies were mainly cleaned mechanically and manually, which had a number of disadvantages:
a slow and labour-intensive process,
risk of the operator coming into contact with NaOH, which could have very serious consequences,
the use of hazardous chemicals caused a lot of toxic fumes (H2),
since H2 gas was released, measures had to be taken with regard to ATEX,
the place where the dies were cleaned was often the dirtiest corner of the factory,
the chemical cleaning equipment often did not meet the requirements in terms of productivity, ergonomics and safety.
The PCA method
In order to drastically improve working conditions and increase the speed of the cleaning process, PCA has developed a better system at a reasonable price. The dies cleaning method is as follows: 1. The operator places the dies in empty process baths. He does not come into contact with NaOH. 2. The dies are immersed in closed process baths with heated NaOH solution. During this process, the aluminum residue will be dissolved. Because these baths are at negative pressure, there is almost no vapour released in the environment. In addition, a relatively high flow rate of fresh air ensures that the H2 concentration cannot get too high and give a risk of explosions. 3. In a third step, the dies are rinsed with water to rinse away as much dirt as possible. 4. Only when all steps have been completed (including the rinsing cycle) and the baths are empty again, the lid opens and the operator can remove the dies from the process bath. The operator therefore never comes into contact with hazardous substances or gases.
In addition to these relevant safety benefits, our solution also has a number of other advantages:
The cleaning process is much faster than in an ordinary heated tank.
We offer the option of adding an automatic crane to the system, which makes the process even more efficient.
Our installations are fully custom designed. After all, not all dies have the same shape and each production process has its own specific characteristics. However, this is not a problem for us; we make our process baths according to your needs.
The installation is built according to the ATEX safety measures.
PCA can help you with this technology in design and construction of the installation, as well as in follow-up and maintenance.
Are you also looking for a safe method to clean your dies? Please contact us so that we can work out the most suitable solution together.