Case study
From Oil-Based to Water-Based Lubrication in Embossing Processes
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Nachalu Cleaner
Case studyComplete removal of lubricants at lower temperatures for perfect coating adhesion
Download case studyCHALLENGE
A manufacturer of aluminum tubes for use in the cosmetics, food packaging, and industrial markets used a lubricant during the tube forming and punching process.
Before the tubes could proceed to the coating stage, all traces of the lubricant had to be completely removed. Even the smallest traces of contamination can lead to problems with coating adhesion, quality defects, and product rejection.
The challenges:
- Complete removal of lubricant residues was essential to ensure perfect coating adhesion.
- The cleaning process consisted of a multi-stage washing system with strict quality requirements.
- Conventional cleaning products required operating temperatures of up to 70–80°C.
- The high energy consumption resulted in significant operating costs.
- Cleaning performance had to be maintained despite lower process temperatures.
- The solution had to be fully compatible with the existing washing system and integrate into the existing multi-stage washing process.
- Excessive etching of the aluminum surface when using conventional cleaning products.
- High maintenance requirements for the washing system due to hard deposits caused by the use of conventional cleaning products.
Complete removal of lubricant residues
Minimal etching of the aluminum surface
Perfect surface preparation for coating applications
Reduced use of cleaning products
Lower water temperature
which results in lower energy consumption
Consistent product quality
SOLUTION
Product
Nachalu Cleaner
Nachalu Cleaner is a powerful alkaline cleaner specifically developed for industrial cleaning applications.
Thanks to its high cleaning efficiency, Nachalu Cleaner effectively removed lubricant residues within the existing multi-stage washing process, while maintaining the surface quality required for high-quality coating applications.
The process parameters were optimized to achieve excellent cleaning performance at temperatures significantly lower than those traditionally used in the industry.
Nachalu Cleaner is also NSF-approved for applications with high-quality requirements.
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Reduction of the operating temperature from approximately 70–80°C to 55°C.
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Improved sustainability and cost efficiency of the production process
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Integration into the existing multi-stage washing process
Results
- Lower energy costs. The reduced operating temperature significantly lowers energy consumption.
- Perfect preparation for coatings. A completely clean and grease-free surface ensures optimal adhesion of the coating.
- High cleaning performance. Lubricant residues are effectively removed, even at lower temperatures.
- More sustainable production. The lower energy consumption reduces the process's environmental impact.
- Less maintenance. Using Nachalu Cleaner results in soft deposits, which makes maintaining the washing system easier.
Contact
If you are looking for a customized chemical solution, our team of specialists is ready to test, design, develop, and manufacture it to ensure that you achieve your desired results.
Please feel free to contact us so we can explore together what we can do for you.
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