Automotive Overview. the force of nature

Transcription

1 Automotive Overview the force of nature

2 What is Dry Ice Cleaning? Environmentally responsible cleaning and surface preparation. How does it clean? Dry ice cleaning uses solid CO2, a non-abrasive media that won t damage surfaces or equipment. The super cooled dry ice pellets or particles are accelerated at supersonic speeds and sublimate on impact, resulting in the surface being cleaned, lifting dirt and contaminants off the underlying substrate. How it works... Instead of abrasive media to grind surfaces (and damage them), Cold Jet uses dry ice (Solid CO 2 ) accelerated at supersonic speeds that sublimate upon impact and lift contaminants from substrates. Cold Jet nozzles feature MERN Technology used by NASA While pellets are most suitable when removing heavy, thick contaminants, shaved ice is ideal for cleaning delicate substrates, intricate geometries or tiny openings. The versatile i 3 Series features our patented dry ice block shaving and feeder technology, providing a powerfully gentle and precise clean. The revolutionary Aero Series features our SureFlow System, ensuring a reliable flow of dry ice pellets for a superior and efficient clean. MERN: Multiple Expansion Reflection Nozzle MERN: A technology used in similar form in the aviation industry to achieve optimum energy efficiency with maximum performance enhancement. MERN BENEFITS 1 Nozzle for different applications Quality design Easy handling Environmentally responsible Improved quality of products

3 Dry Ice: The Green Clean A safe alternative for you and the environment Dry ice cleaning is effective and safe Dry ice is an approved medium by the EPA, FDA and USDA as an acceptable material in cleaning methods. For food processors, dry ice cleaning has been documented by the Food Standards Agency to effectively decontaminate surfaces of Salmonella, E. coli and Listeria. Dry ice cleaning does not release harmful gases into the atmosphere. Dry ice does not produce CO 2 or add CO 2 to the atmosphere and therefore does not contribute to the greenhouse effect. Dry ice cleaning does not generate secondary waste. Dry ice cleaning is safe and nontoxic (once pellets impact the surface, they dissipate). Dry ice cleaning reduces or eliminates employee exposure to (and corporate liability from) the use of dangerous chemical cleaning agents. Environmentally Responsible In addition to being clean and safe, it is also important to remember that dry ice is obtained as a byproduct of other industrial processes - i.e. it is made from reclaimed CO 2. It does not produce CO 2 or add CO 2 to the atmosphere and therefore does not contribute to the greenhouse effect. Dry ice cleaning is truly and completely environmentally responsible. Other cleaning methods can be toxic When using solid grit media or water for cleaning hazardous materials, the cleaning media also becomes hazardous, requiring special handling, disposal and regulatory reporting. Dry ice creates none of these waste stream additions. Sand, soda or water blasting can create downstream contamination that affects surrounding installations. Soda blasting can kill surrounding vegetation. Chemical and solvent cleaning methods are toxic, which creates toxic waste and requires disposal. Workers are exposed to potentially harmful substances through the use of chemicals and solvents. We ve been able to cut back on our use of chemical solvents. We use about 25% of what we used to, which makes us a much more environmentally responsible company. Matt Schrift, Engineer Robotworx It s better for the people and for the environment. This technology has shaved time and allowed us to reduce our use of chemicals. Bob Hawkey Versa-Trim Using dry ice cleaning reduces harmful air emissions and generally creates no addition to the volume of the cleaning process waste stream in-process machinery can be cleaned on-line, resulting in decreased labor costs and less down-time. EPA technical fact sheet for TCA hazards and alternatives. EPA 905-F

4 Dry Ice MicroParticles Less Air. Less Ice. More Coverage. Cold Jet s patented, shaved dry ice MicroParticle technology provides the most thorough clean for many applications. By shaving dry ice media into the finest MicroParticles, more particles enter the air stream and strike the surface per second than traditional methods, quickly removing the contaminant and providing the fastest clean. The sugar-sized, shaved MicroParticles will enter the hardest-to-reach places and are small and delicate enough to pass through sensitive materials (like vents) for a thorough clean without worry of damaging the surface. Managing consumables is important when incorporating dry ice cleaning and shaved MicroParticles will save you time and money. Due to the particle size, less compressed air is needed to propel the shaved MicroParticles to peak velocities, resulting in a much quieter clean. In addition, the improved particle coverage and particle strikes per square inch when shaving reduces the amount of dry ice required for cleaning. vs. MicroParticle Systems Shaved dry ice technology - MicroParticles Faster Because the surface is hit by more MicroParticles at a time, it is cleaned faster and more evenly Quieter When compared to pellets or fragmented pellets, MicroParticles produce less noise, resulting in a better working environment Safer MicroParticles minimize the risk of damage to surfaces, vents, ducts, bridges, high gloss polished forms or ejectors 3mm pellets Flexible Due to size, MicroParticles are able to reach areas where pellets and conventional methods can not Economical Less power and kinetic energy are needed to accelerate MicroParticles, significantly reducing dry ice and compressed air consumption i 3 MicroClean Accepts pellets, nuggets or block with patented shaved technology Designed for absolute precision Easy to maintain with removable panel design Table-top footprint, includes cart for mobility SDI Select TM 60 Uses any form of dry ice (standard block, 3mm pellet, nugget slice, leftover scrap) Bypass for full 3mm pellet performance Clean from as low as 50 CFM, using 1/3 of the compressed air and reducing noise levels and air usage Increase blast pressure up to 250 PSI to clean the most stubborn contaminants Americas. Europe. Asia.

5 Industry Overview: Automotive Reduce cleaning time by as much as 70% A Faster, Better Clean. Cold Jet dry ice cleaning has helped Automotive companies cut their mold-buildup cleaning costs by as much as $50,000 per year. Cold Jet s non-abrasive dry ice cleaning systems easily remove excess grease, sludge, sealant and weld slag from equipment. Dry ice blast cleaning is faster and more effective than traditional cleaning methods, in part, because it does not generate any secondary waste or leave any residual blasting media to clean up or dispose of. Discover Cold Jet. Contact Cold Jet today to speak with an industry expert and choose the best cleaning solution for your application. Call or visit us online at to learn more. APPLICATIONS Core Box Permanent Aluminum Mold Paint Hook Weld Line E-coat Blow Mold Compression Mold Injection Mold Urethane Mold Transmission Housing KEY BENEFITS Reduce labor cost Reduce scrap Increase productivity Increase operator safety Non-abrasive process No secondary waste stream Environmentally responsible REFERENCES Join industry leaders already benefiting from Cold Jet dry ice blast cleaning systems. RESULTS Before After Cold Jet vs traditional cleaning methods. * CLEANING METHOD NO SECONDARY WASTE NON- CONDUCTIVE NON-TOXIC* NON- ABRASIVE Dry Ice Blast Cleaning Sand Blasting * Soda Blasting * Water Blasting * Hand Tools Solvents/Chemicals Upon contact, traditional blasting materials become contaminated when used to clean hazardous substances and objects. These blasting materials are then classified as toxic waste and require appropriate safe disposal. Before After USA: Belgium: +32 (0) Germany: +49 (0) Asia: Canada: x501 Latin America: +52 (81)

6 Automotive Mold Cleaning Solution Cold Jet s Environmental Cleaning and Surface Preparation (ECaSP) systems have helped automotive molders meet stringent industry demands: 6-Sigma, Kaizen, 5S, TPM (Total Productive Maintenance) and annual cost downs. Our systems enable molders to optimize their manufacturing process by cleaning contaminants from cavities, vents and hard-to-reach places faster, better and more economically than traditional methods. This can reduce cleaning times by as much as 75% and decrease annual mold cleaning costs by as much as $50,000. i 3 MicroClean Dry ice cleaning definitely results in a superior clean. And with less downtime, we have been able to increase production. Our automotive customers have very stringent quality control procedures and demands, and dry ice cleaning has helped us meet those requirements. The detail of cleaning we get with Cold Jet s system allows us to clean areas that otherwise could not be cleaned. - Mike Wohlfarth, MPC The System Cold Jet s i 3 MicroClean is a non-abrasive dry ice cleaning system that extends the life of your molds by eliminating the need for harsh chemicals, wire brushes and abrasive pads. It also does not create any secondary waste. When reducing costs, improving quality and increasing productivity are vital, let Cold Jet s dry ice cleaning solutions help you clean molds, deflash molded parts and prepare surfaces prior to painting. For more details about how our systems can help with your specific application, contact your local Cold Jet representative or visit i 3 MicroClean Benefits Designed for precision applications Low noise operation Easy to maintain with removable panel design Increased blast pressure Pneumatic circuitry regulates pressure loss and reduces moisture buildup Minimal air/ice usage

7 Industry Overview: Plastics Increase productivity, improve product quality A Faster, Better Clean. Clean mold cavities and vents are a major concern for plastic part manufacturers in maintaining today s high quality standards. The build-up of unwanted surface residues from either the product mix itself, mold releases or the labeling process can create various problems, ranging from product release ( knock out ) to inferior product quality and possible damage to tools. Flash on the product also creates challenges for manufacturers. Mold halves leave a parting line in the final product, and sometimes flash, must be removed for product quality. Traditional cleaning and deflashing methods involve tedious and ineffective manual processes using chemicals and hand tools. Cold Jet s alternative cleaning process provides a non-abrasive and environmentally responsible method that allows molds and product to be cleaned in a fraction of the time, allowing increased cycles between preventive maintenance. In addition, molds can be cleaned hot and in-place, without water, chemicals or creation of secondary waste. APPLICATIONS GENERAL MOLD AND TOOL CLEANING Blow Molds Compression Molds Extrusion Dies Injection Molds Thermoform Molds Plastic Injection Screw Urethane Molds and Overspill Plate out and off gassing Rotation Molds Blown Film Lines PRODUCT FINISHING Deflashing and surface/parting line vents Surface Prep before painting Deburring machined parts KEY BENEFITS Improve product quality Reduce scrap Reduce production downtime Reduce cleaning time and labor costs Clean in-place, no disassembly required Non-abrasive, no damage to product or equipment No secondary waste Environmentally responsible REFERENCES Join industry leaders already benefiting from Cold Jet dry ice blast cleaning systems. Cold Jet vs traditional cleaning methods. CLEANING METHOD NO SECONDARY WASTE NON- CONDUCTIVE NON-TOXIC* NON- ABRASIVE Dry Ice Blast Cleaning Sand Blasting * Soda Blasting * Water Blasting * Hand Tools Solvents/Chemicals * Upon contact, traditional blasting materials become contaminated when used to clean hazardous substances and objects. These blasting materials are then classified as toxic waste and require appropriate safe disposal. Discover Cold Jet. Contact Cold Jet today to speak with an industry expert and choose the best cleaning solution for your application. Call or visit us online at to learn more.

8 Industry Overview: Rubber Keep the lines running with mold cleaning made easy A Faster, Better Clean. A major problem faced by rubber molders is mold fouling. Build-up of cured material and mold release agents causes sticking molds, blemishes and unwanted flash on final parts, making them unusable and requiring line shutdown for cleaning. Traditional cleaning methods such as manual scraping, glass bead blasting or ultrasonic cleaning can be time consuming, ineffective, damaging to molds and result in high labor and material costs. Dry ice blast cleaning offers an in-place, online, quick and effective way to clean without damaging expensive molds. Discover Cold Jet. Contact Cold Jet today to speak with an industry expert and choose the best cleaning solution for your application. Call or visit us online at to learn more. APPLICATIONS Injection Molding Blow Molding Compression Molding Tilt-back Press Lift Press Metal Bonded Mold Tire Industry KEY BENEFITS Eliminate production shutdown; clean online, no cool down required No disassembly of molds; eliminate reassembly damage and scrap Reduce product scrap; no more delayed cleaning resulting in product defects Non-abrasive; no impact damage or mold erosion Increase production time; 25-50%* Reduce cleaning time; labor cost reduction up to 75%* Environmentally responsible; no secondary waste * Individual results may vary. REFERENCES Join industry leaders already benefiting from Cold Jet dry ice blast cleaning systems. Cold Jet vs traditional cleaning methods. CLEANING METHOD NO SECONDARY WASTE NON- CONDUCTIVE NON-TOXIC* NON- ABRASIVE Dry Ice Blast Cleaning Sand Blasting * Soda Blasting * Water Blasting * Hand Tools Solvents/Chemicals * Upon contact, traditional blasting materials become contaminated when used to clean hazardous substances and objects. These blasting materials are then classified as toxic waste and require appropriate safe disposal. USA: Belgium: +32 (0) Germany: +49 (0) Asia Canada: x501 Latin America: +52 (81)

9 Composite Tool Cleaning Solution In-Place, Non-Abrasive and Environmentally Responsible Mold Cleaning. Cold Jet s Environmental Cleaning and Surface Preparation (ECaSP) systems have helped manufacturers meet stringent industry demands by providing a composite tool cleaning solution that is fast, delicate and does not use solvents. Dry ice cleaning uses recycled CO 2 in the form of solid dry ice particles that are accelerated through high-velocity nozzles onto the surface being cleaned. The combination of the kinetic and thermal gradient effects breaks the bond between the contaminant and the substrate. The dry ice particles sublimate on impact, transitioning from a solid to a gas, leaving no secondary waste behind. before Cold Jet dry ice cleaning extends the life of a mold by eliminating the need for harsh chemicals, wire brushes and coarse pads. It is a non-abrasive mold cleaning solution that protects the critical dimensions and geometric shapes of parting lines and sealing surfaces and preserves the mold surface finish. There are a variety of materials of construction within composite tooling and the substrates will vary from Urethane, aluminum and steel to Teflon-coated, vacuum molds and autoclave. Dry ice cleaning can safely remove a variety of contaminants from the molds, including epoxy, Teflon tapes, silicones, mold release agents, phenolic, carbon, graphite, PEEK, Kevlar and many more without damaging the mold. after Dry ice cleaning is faster and more effective than traditional methods and utilizes low air and ice consumption. You can also clean molds in the machine at processing temperatures without causing mold wear, thus unlocking hidden production capacity and improving product quality. before after For more details about how our systems can help with your specific application, contact your local Cold Jet representative or visit USA: Belgium: +32 (0) Germany: +49 (0) Asia Canada: x501 Latin America: +52 (81)

10 Deflashing & Deburring Solution Surface Preparation Solution i 3 MicroClean Cold Jet s Automated Environmental Cleaning and Surface Preparation (ECaSP) systems were developed to improve quality and lower operating costs for manufacturers with parts that have flash or burrs. Our automated systems eliminate the need for manual deflashing or deburring, thus improving part quality, increasing productivity and lowering cost. Our systems can safely remove flash and burrs from a variety of materials: PEEK, PBT, Acetal, Nylon, LCP, ABS, UHMWPE, Nitinol, etc. without causing part surface damage. i 3 MicroClean Benefits Designed for precision applications The System When it comes to product finishing, Cold Jet s i 3 MicroClean systems can be used to deburr or deflash products manually or robotically - or can be integrated into your manufacturing process. The i 3 MicroClean utilizes Cold Jet s patented MicroParticle technology to create a greater flux density of dry ice particles, resulting in a faster, more uniform burr or flash removal without causing part damage. Cold Jet s i 3 MicroClean systems are often integrated into fully automated production cells. For more details about how our systems can help with your specific application, contact your local Cold Jet representative or visit MicroParticle Technology Low noise operation Safe operation Increased blast pressure Continuous, consistent pellet flow No ice clogging Minimal air/ice usage Pulse-free cleaning Easy to maintain with removable panel design

11 Industry Overview: Foundry and Forging Reduced cleaning time = less downtime A Faster, More Productive Clean. A major issue for the foundry and forging industries is the downtime caused when cleaning permanent aluminum molds, core box vents, semi-solid castings and die casting machines. Typical manual cleaning methods require cooldown, disassembly, unproductive hours of messy hand cleaning or bead blast cleaning and then reassembly. In addition, most traditional cleaning methods are not fully effective and often result in damage to the part or equipment. Dry ice cleaning offers significant improvement in cleaning times (up to 60%) as well as reduction of damage to equipment and resulting scrap product. As dry ice blast cleaning allows a non-conductive, in-place method to clean parts, even touch-up cleanings are safe and easy. Discover Cold Jet. Contact Cold Jet today to speak with an industry expert and choose the best cleaning solution for your application. Call or visit us online at to learn more. Cold Jet vs traditional cleaning methods. CLEANING METHOD NO SECONDARY WASTE Permanent Aluminum Molds Refractory Coatings Core Boxes and Vents Die Cast Tooling Shell Core Molds Semi-solid Castings / Forging Remove Resins & Release Agents General Equipment & Facility Conveyors General part cleaning Reduce production downtime Eliminate disassembly of molds Clean better, hot and in-place Eliminate waste disposal cost Increase production time Non-abrasive, no damage to tooling Environmentally responsible Delivers superior as-cast finish NON- CONDUCTIVE APPLICATIONS KEY BENEFITS REFERENCES Join industry leaders already benefitting from Cold Jet dry ice blast cleaning systems. NON-TOXIC* NON- ABRASIVE Dry Ice Blast Cleaning Sand Blasting * Soda Blasting * Water Blasting * Hand Tools Solvents/Chemicals * Upon contact, traditional blasting materials become contaminated when used to clean hazardous substances and objects. These blasting materials are then classified as toxic waste and require appropriate safe disposal. Before After USA: Belgium: +32 (0) Germany: +49 (0) Asia Canada: x501 Latin America: +52 (81)

12 Industry Overview: Weld Line Cleaning Better Welds = Less Scrap and Downtime A Faster, Better Clean. Weld slag, spatter, resin, smoke, oil and dampering adhesive builds up on production equipment. This causes misalignment and can prevent the proximity switch from firing in the appropriate spot. The robot stops welding, or welds incorrectly creating scrap and causing equipment failure and production downtime. No contact dry ice blast cleaning provides an effective and economical removal solution for slag and spatter build up. Discover Cold Jet. Contact Cold Jet today to speak with an industry expert and choose the best cleaning solution for your application. Call or visit us online at to learn more. Robot Joints Transfer Cases Shuttle Jigs Diamond Plates APPLICATIONS KEY BENEFITS Reduce scrap rates Reduce fixture repair Reduce replacement costs Environmentally responsible Minimize downtime Maximize tooling life No secondary waste Non-abrasive, won t damage sensors Clean online, no cool down required Replaces ineffective and costly labor intensive cleaning methods REFERENCES Trunnions Weld Tables Fixtures Join industry leaders already benefiting from Cold Jet dry ice blast cleaning systems. Before After Cold Jet vs traditional cleaning methods. CLEANING METHOD NO SECONDARY WASTE NON- CONDUCTIVE NON-TOXIC* NON- ABRASIVE Dry Ice Blast Cleaning Sand Blasting * Soda Blasting * Water Blasting * Hand Tools Solvents/Chemicals * Upon contact, traditional blasting materials become contaminated when used to clean hazardous substances and objects. These blasting materials are then classified as toxic waste and require appropriate safe disposal. USA: Belgium: +32 (0) Germany: +49 (0) Asia Canada: x501 Latin America: +52 (81)

13 Industry Overview: Facility Maintenance Reduce cleaning time and production line disruptions A Faster, Better Clean. Dirt, soot, grease, and oil build up in production facilities causes machinery to function improperly and can create an unsafe working environment. Effective cleaning extends the life of electric motors, reducing or eliminating costly repair, replacement or rental programs. However, manual cleaning is often delayed to prevent shut down of production lines. Dry ice cleaning provides a quick, safe and economical solution that allows equipment to be cleaned in-place without disassembly or cool down. Discover Cold Jet. Contact Cold Jet today to speak with an industry expert and choose the best cleaning solution for your application. Call or visit us online at to learn more. APPLICATIONS Forklifts Pipes and Hoses Motors / Electrical Boxes Conveyors Cooling Fans General Equipment & Facility KEY BENEFITS Reduce cleaning downtime Environmentally responsible No secondary waste Eliminate wear and tear Non-abrasive process Clean in-place; no cool down required Enhances Total Productive Maintenance (TPM) programs REFERENCES Join industry leaders already benefiting from Cold Jet dry ice blast cleaning systems. Before After Cold Jet vs traditional cleaning methods. CLEANING METHOD NO SECONDARY WASTE NON- CONDUCTIVE NON-TOXIC* NON- ABRASIVE Dry Ice Blast Cleaning Sand Blasting * Soda Blasting * Water Blasting * Hand Tools Solvents/Chemicals Before After * Upon contact, traditional blasting materials become contaminated when used to clean hazardous substances and objects. These blasting materials are then classified as toxic waste and require appropriate safe disposal. USA: Belgium: +32 (0) Germany: +49 (0) Asia Canada: x501 Latin America: +52 (81)

14 Case Study: Cleaning High Performance Injection Molding Equipment Dry ice cleaning extends the running time of the mold, prevents damage. COMPANY Performance Plastics - Cincinnati, OH APPLICATION Cleaning of Plastic Injection Molds and Equipment COLD JET SYSTEM i 3 MicroClean BENEFITS Extends the running time of the mold from percent before the manufacturer has to perform a complete teardown. Safely cleans the mold hot in the press or cold on the bench, preventing damage to the mold. Part quality is improved, saving time and labor. CUSTOMER COMMENTS Cleaning with Cold Jet will not roll parting lines, change or destroy the metal, said Mendel. And best of all, it allows our running time to be extended. We use it every day, on every shift. The Situation Performance Plastics specializes in high performance injection molding. The company produces small, complex, high quality parts with material attributes that solve their customers toughest problems. For 30 years, they ve focused on the application of these highly engineered plastics for the performance advantages that they provide when producing intricate part geometries with extremely tight tolerances. They excel at helping companies in the medical device, energy, aerospace/defense, industrial, electronics and food and beverage industries solve current product problems or to create competitive next generation advantages. From designs through production, we do what others have dreamed of, failed at or said can t be done, said Tom Mendel, president and CEO. We are defined not by the industry, but by the material we run, the sophisticated tooling we use and the tight tolerances we hold. The company has aggressively lowered their per part cost with a proprietary, high volume direct gating hot runner injection molding process that significantly reduces waste and costs. They have molded PEEK since the material was first introduced in the early 1980 s and they have deep experience as an approved processor of Torlon. They have also been involved in development work for liquid crystal polymer (LCP) resins. The company is one of the few able to mold fluorinated ethylene propylene (FEP) using eight-cavity, high volume molds with hot runner systems to produce critical fluoropolymer parts. They do not mold commodity plastics or bid in auctions. They concentrate on the high-end materials that give customers the properties they need for very specific applications. In other words, the really tough stuff. And they are growing. Almost 30 percent of the components produced are shipped to international customers providing Best in Class value. We are pushing the envelope here running 150 miles per hour in a 20 mph zone, said Mendel. We do lots of R&D, lots of engineering and lots of hard stuff. The Problem As any mold manufacturer knows, keeping the mold clean is a must in the mold making process. But there are two problems. First, the mold is heated (in Performance s case) to an extreme of 450 degrees Fahrenheit,

15 CUSTOMER COMMENTS I would say that using the Cold Jet cleaning process extends the running time of our molds by percent, It saves us from cooling the mold down, removing it, disassembling it, reassembling it, putting it back in and heating everything up. That is a lot of time and risk for damage. We are very sensitive to the extension of a production run and our startup costs. Once we get something running we don t want to stop. as a natural byproduct and, as it liquefies, the volatiles generated will stick to the mold. With the extreme materials Performance uses in their molds, this gas sticks tough Mendel said the contaminants can resemble tar. Another issue occurs when the plastic is poured from one end of the part and flows around to the endof-fill. At the end-of-fill the gas must be vented through a very accurate opening in the mold one that lets the gas out, but does not allow the plastic to escape. This vent at the end-of-fill gets clogged from the buildup of the particulate gases that condense when the mold is cooled. If the tool doesn t vent properly, problems will occur. The gas can destroy the metal of the mold, or a part may not meet standards for quality. This is why all molders aim to keep their vents clear in order to maintain a clean mold. As Mendel explains, good molders have a predictive preventative maintenance program where they address the phenomenon of gas buildup in the mold. Properly cleaning the mold is not only required, it is an acquired skill. No one wants to destroy the mold, because they can be a huge expense to replace in Performance s case, some molds can cost as much as $250,000. When a mold is cleaned it usually requires a complete teardown the assembly is stopped, the mold taken out, disassembled, and every nook and cranny is cleaned. Then it must be put back together. This is very time consuming, and because Performance Plastics is moving at high speeds they don t like to stop. Performance s traditional method of cleaning molds can include any type of grit blasting, or using solvents and wire brushes. The secondary waste from solvents and other media can be a big problem environmentally, in addition to sometimes eating into the metal. These types of cleaning methods can also be time consuming because the metal often needs to be soaked, or a wire brush must be later used to mechanically remove the debris. In any of these cases, they run the risk of damaging the mold. The Cold Jet Solution Mendel will be the first to tell you that mold makers are usually pretty suspicious, skeptical and critical when it comes to trying new things; they have seen many fads and gimmicks come and go. But because someone he trusted recommended trying Cold Jet to clean his equipment, and because Mendel is no stranger to taking risks afterall, it s brought him success he put down his guard and brought in the Cold Jet i 3 MicroClean for testing. Cold Jet s dry ice cleaning system uses non-abrasive media in the form of recycled CO 2 media (pellets or block) that won t damage surfaces or equipment. The combination of dry ice blast cleaning s kinetic energy and thermal effects break the connection between the dirt and surface, lifting away contaminants. Unlike blasting with other media, dry ice cleaning does not leave any secondary waste, as the dry ice pellets or particles sublimate convert from solid to gas upon impact. Dry ice cleaning is also safe and non-toxic, does not create downstream contamination, and reduces or eliminates employee exposure to dangerous chemical cleaning agents.

16 The Results After Mendel s team tried the Cold Jet MicroClean machine, everyone was on board with using the system. Since implementing the Cold Jet solution, Performance Plastics has been able to extend the running life of the mold by cleaning it in place in the press including the vent and ejector pins extending time between complete teardowns. Cleaning with Cold Jet will not roll parting lines, change or destroy the metal, said Mendel. And best of all, it allows our running time to be extended. We use it every day, on every shift. Mendel said the ability to clean the part in place with the Cold Jet solution really saves time. A complete teardown can vary with the part sometimes it takes two days or 16 man hours to complete, sometimes it takes less time. When running at extreme temperatures like Performance does, it s not just the teardown itself that is timeconsuming it takes four hours to heat up the machine and four hours to cool it down. Time is money in this business, and it s very expensive to shut down. The longer that a complete teardown can be delayed without damaging parts, the better. I would say that using the Cold Jet cleaning process extends the running time of our molds by percent, said Mendel. It saves us from cooling the mold down, removing it, disassembling it, reassembling it, putting it back in and heating everything up. That is a lot of time and risk for damage. We are very sensitive to the extension of a production run and our startup costs. Once we get something running we don t want to stop. When they do stop they use the Cold Jet solution, whether the mold is hot in the press or taken apart cold on the bench cold. The second major benefit Performance has experienced is that Cold Jet allows a lot of flexibility when cleaning the mold. They can apply just the right pressure to prevent damage, which is something they cannot always do when using solvents and wire brushes. To illustrate how exact the molds at Performance can be, the shutoffs on certain high pressure materials have to be because at it will flash, and at it can t be vented and will destroy the metal. These molds are very delicate; equals one-sixth of the diameter of a human hair. That s pretty tight, said Mendel. And when you go in with a wire brush and accidentally take a little bit of the metal off, the mold can be destroyed. Finally, because a cleaner mold equals a better part, and the molds at Performance can now be cleaned quickly while running, the part is vented more effectively. Scrap rates go down, and quality goes up. And Performance Plastics now needs only one person to clean the mold, versus two, so critical personnel can be directed elsewhere. I would tell others to try this out, said Mendel. Certainly everyone in this industry is skeptical and you need some skin in the game to take the risk, but the benefits are well worth it. << BEFORE AFTER >>

17 Case Study: Progress Casting Group Foundry cleans core boxes and molds with Cold Jet dry ice MicroParticles faster & quieter COMPANIES Progress Casting Group APPLICATION Cleaning core boxes and molds with Cold Jet s patented shaved dry ice technology SOLUTION i 3 MicroClean BENEFITS Core boxes: Cold Jet reduces cleaning time from 3.25 hrs. to 28 minutes or 85.6% No damage to the ventilation slots Approx. annual labor savings: $15,340 Approx. annual productivity gain: $92,115 Annual net profit (5 mold machines): $106,544 Rate of Return: 367% Pays for itself in 3.3 months Permanent Aluminum Molds: Cold Jet reduces cleaning from 4.5 hrs to 35 min (no need to cool, disassemble and reheat the machine) Annual net productivity gain: $250,500 Approx. annual labor savings: $31,313 Approx. annual net profit: $271,575 Rate of Return: 905% Pays for itself in 1.3 months The Situation The Progress Casting Group in Plymouth, Minnesota / USA, was founded out of Continental Castings in 1962 and the Progress Foundries in The foundry specializes in precision die casting and sand castings for the automotive, aerospace and defense industries. The refractory coating (releasing agent), the resin spray buildup, sand casting components and core residues on the core boxes and low-pressure casting molds are currently being removed by sand blasting and manual brushes. Both cleaning processes are slow and ineffective - causing damage to machines and putting workers safety at risk. Sand blasting destroys the urethane on the molds and both methods routinely destroy the vents on the core boxes. The Challenge The Progress Casting Group was looking for a cleaning method that removes the refractory coatings and other residual material without damaging mold vents. In addition, uneven refactory coating should be avoided as this can affect the quality of the final product and the speed of production. Release agents and residual materials should also be removed from the surface as smooth as a feather without rounding the corners, an important prerequisite for product quality. The area around the tool should be clean and safe for the employees. The tools need to be cleaned as after every use to minimize the downtime and the molds should still be hot to reapply the refractory coating. The problem with steel shot, glass bead and sandblasting is the possibility of mold vent damage and urethane damage on molds. Rounding of mold edges leads to flash on the parts, shortens the mold life, creates secondary waste and potential eye injuries from atmospheric contaminants. Manual cleaning with chemicals and brushes is extremely labor intensive and potentially harmful to the workers, causing long downtime and inefficient and ineffective clean in some places. CUSTOMER COMMENTS We estimated that it would pay for itself in six months; I know that it took only a month. Every foundry needs to own one

18 The Cold Jet Solution Cold Jet is the only supplier that offers the patented shaved dry ice technology for dry ice MicroParticles on the market. Many small dry ice MicroParticles clean the surface faster, smoother and much quieter than conventional 3 mm pellets. The dry ice blast cleaning process is similar in concept to sand or soda blasting, where the respective media is accelerated through a pressurized airstream. The main difference is that, rather than sand or soda, Cold Jet s system use recycled CO 2 in the form of dry ice MicroParticles to clean surfaces. The CO 2 MicroParticles are accelerated at supersonic speeds through a specialized hose and nozzle. Once the MicroParticles hit the mold surface, the combination of kinetic energy and thermal gradient effects of the dry ice blast breaks the bond between the surface and the residue. Upon impact with the tool surface, the CO 2 sublimates, returning to its natural gas form, leaving no secondary waste to clean up. BEFORE The Result The Progress Casting Group tested a Cold Jet MicroParticle dry ice cleaning system and used it to the clean their most delicate screen vents at full blast. Even at maximum blast aggression, there was no damage to the parts and the molds looked brand new. The system was shown to the president of the company and after the test, he turned around and said: Buy it immediately! Within two days, the Cold Jet dry ice blasting system was in our company and at work, said Daryl Hesch, Tooling Supervisor at Progress Casting. Today, it takes one worker 10 minutes to clean a mold while it remains hot and online, whereas it took two to three workers, 3-4 hrs to clean one or two molds previously. The tooling supervisor estimates that they are saving $400 - $500 per mold with a Cold Jet dry ice blasting system. We estimated that it would pay for itself in six months, but it took only a month. This machine is incredible, said Hesch. Every foundry needs to own a Cold Jet dry ice MicroParticle cleaning system. AFTER Benefits of MicroParticles - Faster - Quieter - Safer - Flexible - Economical Americas. Europe. Asia.

19 Case Study: Innovative Dry Ice Cleaning for Weld Lines Better Welds = Less Scrap and Downtime COMPANY Maclellan Integrated Services APPLICATION Robot & weld line cleaning COLD JET SYSTEM Aero 40 BENEFITS Savings of $2,956 per station per week Labor hours reduced from 7.2 to 0.5 per robot $ in annual savings over the traditional method of cleaning (for 38 robot cleanings per week) ROI is 344 robot cleanings or 2.3 months CUSTOMER COMMENTS We are able to do 2-3 times the number of jobs and the outcome is better... also we can meet the kaizen shared cost reduction now using Cold Jet and still make good margins on the job... lastly we keep finding more applications which created more business for us with the same customer Steve Foster - Maclellan Integrated Services The Situation Weld slag, spatter, resin, smoke, oil and dampering adhesive build up on production equipment. This causes misalignment and can prevent the proximity switch from firing in the appropriate spot. The robot stops welding or welds incorrectly creating scrap and causing equipment failure and production downtime. Traditional cleaning methods to remove weld spatter and slag from welding jigs, cells and robots such as using a hammer and chisel can damage the weld line equipment and ultimately lead to increased downtime. Cold Jet dry ice cleaning systems provide an effective, economical and delicate removal solution for slag and spatter build up. Cold Jet s dry ice cleaning systems use non-abrasive media in the form of recycled CO 2 pellets that won t damage surfaces. The combination of dry ice cleaning s kinetic energy and thermal effects break the connection between the dirt and surface, lifting away contaminants. Unlike blasting with other media, dry ice cleaning does not leave behind any secondary waste, because the dry ice particles sublimate on impact converting from a solid to a gas. Dry ice cleaning is safe and nontoxic, does not create downstream contamination and reduces exposure to dangerous chemical cleaning agents. We are able to do 2-3 times the number of jobs with dry ice cleaning and the outcome is better, said Steve Foster with Maclellan Integrated Services. We can also meet the kaizen shared cost reduction now using Cold Jet and still make good margins on the job. Lastly, we keep finding more applications for Cold Jet dry ice cleaning systems, ultimately creating additional business for us with the same customer. Americas. Europe. Asia.

20 CUSTOMER COMMENTS We often avoid cleaning until there s a problem or the robot fixture breaks... this will really save us time and labor costs... I plan to develop a preventive maintenance program based on Cold Jet Line Supervisor - Automotive Plant The Cold Jet Solution Using Cold Jet s Aero 40 singlehose dry ice cleaning system resulted in the following benefits when compared to hammering and chiseling: Reduced required labor from 4 workers to 1 Reduced labor time by up to 69% Reduced cleaning costs by up to 60% Drastically reduced equipment damage (though photoeyes and proximity sensors should not be deliberately or directly blasted) Dramatically decreased labor intensity because it is safer and more ergonomic for the worker, thus improving overall worker morale Eliminated the use of chemical solvents, thus improving worker safety from the non-use of caustic chemicals Eliminated secondary waste streams because dry ice is solid CO 2 gas, which quickly sublimates and disappears upon contact with the surface being cleaned ROI / Cost Justification: Savings of $2956 per station per week Labor hours reduced from 7.2 to 0.5 per robot $153,712 in annual savings over the traditional method of cleaning (for 38 robot cleanings per week) ROI is 344 robot cleanings or 2.3 months Americas. Europe. Asia.

21 Aero 40FP New technology. Proven design. the force of nature Our mid-level machine, the Aero 40FP is a full pressure dry ice cleaning system that includes brand new radial feeding system technology that is aerodynamic loading to reduce wear on pads and rotor; utilizes a compact motor that reduces weight and lowers power consumption; includes an enhanced rotor that provides pulse-free blasting and precision feed rate control; and has an onboard pressure regulator. Customized with accessories that will provide the best clean for your environment, the Aero 40FP provides new technology in a proven design. ADVANCED RADIAL FEEDING SYSTEM TECHNOLOGY Aerodynamic loading reduces wear on pads and rotor, increasing machine life Compact motor that reduces weight and lowers power consumption Enhanced rotor that provides pulse-free consistent pellet flow and precision feed rate control Full range of blast pressure Onboard pressure regulator INTUITIVE CONTROL PANEL SEALED LID EASY-OFF PANELS ERGONOMIC HANDLES WELDED STEEL FRAME NOZZLE HANGER XP PERFORMANCE APPLICATOR WHIP CHECK AERO 40FP FEATURES Performance Minimized sublimation SureFlow System Minimal air/ice usage Full range of pressure Easy to maintain Reliable pellet flow Safe operation 360 o TURNING RADIUS Rugged and mobile Most advanced nozzles ESD (static) control LARGE FLAT-FREE TIRES DRY ICE CAPACITY 40 lb (18.2 kg) FEED RATE lbs/min (0-2 kg/min) DIMENSIONS 36 x 20 x 40 in (91 x 51 x 102 cm) WEIGHT 257 lbs (117 kg) AIR CONSUMPTION CFM ( m 3 /min) at 80 PSI (5.5 bar) BLAST PRESSURE RANGE psi ( bar) POWER 1/4 HP, AC Motor, 1,750 RPM SPEC.A Americas. EMEA. Asia-Pacific (0)

22 Aero 80FP Premium technology. Proven design. the force of nature Our top-of-the-line machine, the Aero 80FP is a full pressure dry ice cleaning system that includes brand new radial feeding system technology that is aerodynamic loading to reduce wear on pads and rotor; utilizes a compact motor that reduces weight and lowers power consumption; includes an enhanced rotor that provides pulse-free blasting and precision feed rate control; and has an onboard pressure regulator. Customized with accessories that will provide the best clean for your environment, the Aero 80FP provides premium technology in a proven design. ADVANCED RADIAL FEEDING SYSTEM TECHNOLOGY Aerodynamic loading reduces wear on pads and rotor, increasing machine life Compact motor that reduces weight and lowers power consumption Enhanced rotor that provides pulse-free consistent pellet flow and precision feed rate control SEALED LID Full range of blast pressure Onboard pressure regulator ERGONOMIC HANDLES INTUITIVE CONTROL PANEL WELDED STEEL FRAME EASY-OFF PANELS NOZZLE HANGER XP HEAVY DUTY APPLICATOR TILT-OUT HOPPER LARGE FLAT-FREE TIRES DRY ICE CAPACITY 80 lb (36.4 kg) FEED RATE 0-7 lbs/min (0-3.2 kg/min) DIMENSIONS 43 x 20 x 46 in (109 x 52 x 118 cm) 360 o TURNING RADIUS WEIGHT 389 lbs (176 kg) AERO 80FP FEATURES Advanced SureFlow System Full range of pressure+ Reliable pellet flow Tilt-out hopper SPEC.A Deluxe Accessory Package Minimized sublimation Minimal air/ice usage Easy to maintain Safe operation Rugged and mobile Most advanced nozzles ESD (static) control AIR CONSUMPTION CFM ( m 3 /min) at 80 PSI (5.5 bar) BLAST PRESSURE RANGE psi ( bar) POWER 1/2 HP, AC Motor, 1,750 RPM Americas. EMEA. Asia-Pacific (0)

23 Precision cleaning and product finishing system. the force of nature When precision counts, the single hose electric i 3 MicroClean featuring Cold Jet s patented shaved MicroParticle technology is your best choice. This environmentally responsible system enables you to safely clean delicate surfaces and complex cavities and crevices that other machines can t reach without surface abrasion, disassembly or harmful secondary waste. SYSTEM FEATURES Designed for precision applications Stainless steel rotor Low noise operation Easy to maintain with removable panel design Increased blast pressure Uses 5x5 or 6x6 inch block (quick change trough inserts) Now uses pellets & nuggets with upgrade Pneumatic circuitry regulates pressure loss and reduces moisture build-up Integrated bonding cable virtually eliminates the risk of static shock ICE LEVEL INDICATOR Durable burst-proof blast hose w. hose cover Table-top footprint, includes cart for mobility ERGONOMIC APPLICATOR APPLICATOR HANGER WELDED STEEL FRAME ERGONOMIC HANDLES DRY ICE COOLER i 3 MICROCLEAN DX (OPTION) Experience Cold Jet s patented shaved MicroParticle technology with your i 3 MicroClean Deluxe (DX), an optional upgrade that shaves both pellets and nuggets. MicroParticles allow you to clean and prepare surfaces with more precision, more delicacy, less air and less noise than traditional dry ice pellet blasters. Understanding and operating the i 3 MicroClean with pellets or nuggets is simple. INTUITIVE CONTROL PANEL DRY ICE CAPACITY 20 lb (9.1 kg) FEED RATE lbs/min (0-0.6 kg/min) DIMENSIONS 22 x 16 x 21 in (56 x 41 x 53 cm) WEIGHT 130 lbs (59 kg) AIR CONSUMPTION CFM ( m 3 /min) at 80 PSI (5.5 bar) for standard nozzles BLAST PRESSURE RANGE up to 140 PSI (up to 9.7 bar) POWER Electric SPEC.A Americas. EMEA. Asia-Pacific (0)

24 SDI Select TM 60 The Power of Selection the force of nature Designed with application variability and ever-changing industry demands in mind, the SDI Select 60 can navigate the dry ice cleaning spectrum with ease. Showcasing Cold Jet s patented shaved dry ice technology, the SDI Select 60 can clean large surfaces of thin, hard contaminants without damaging the substrate. And when faced with heavier contaminants, simply bypass the shaving media, turn up the aggression and clean using full 3mm pellets. SYSTEM FEATURES Shave with any dry ice media (standard block, 3mm pellet, nugget, slice, even leftover scrap ice) INTUITIVE CONTROL PANEL Bypass for full 3mm pellet performance Increase blast pressure up to 250 PSI to clean the most stubborn contaminants WELDED STEEL FRAME SEALED LID Clean from as low as 50 CFM, using 1/3 of the compressed air, thus reducing noise levels and air usage vs. alternative dry ice cleaning systems EASY-OFF PANELS Choose from any Aero nozzle or accessory to maximize flexibility ERGONOMIC HANDLES NOZZLE HANGER ERGONOMIC APPLICATOR DRY ICE CAPACITY 60 lb (27.2 kg) THE POWER OF SELECTION 360 o TURNING RADIUS FEED RATE 0-6 lbs/min (0-2.7 kg/min) DIMENSIONS 24 x 28 x 43 in (61 x71 x109 cm) WEIGHT 343 lbs (155 kg) AIR CONSUMPTION CFM ( m 3 /min) at 80 PSI (5.5 bar) for standard nozzles Cold Jet s patented feeder technology creates shaved dry ice on demand, regardless of input. Simply switch to full pellet cleaning to penetrate the most difficult, thick contaminants. BLAST PRESSURE RANGE psi ( bar) POWER Electric SPEC.A Americas. EMEA. Asia-Pacific (0)

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26 Review Evolve the way you clean your equipment with the world s first multi-power dry ice blasting machine! The Elite 20 contains a 24 volts DC motor that utilizes a higher torque to eliminate freeze ups. From the complete control over ice and air consumption to the worry free troubleshooting, the Elite 20 provides a dry ice blasting experience that is divergent in the industry. Stainless steel body Air only blasting option Machine controlled gun light More powerful motor Insulated hopper Made with a pure stainless steel frame, the Elite 20 is a dynamic machine designed to give you the thorough clean you need by supplying a gentle way to decontaminate equipment. Perfect for lighter applications like those found in the pharmaceutical and food industries, the Elite 20 is the only tool for cleaning and maintaining equipment. The user friendly control panel gives you easy access to controls and maintains blasting parameters. IceTech Dry Ice Blasting: powered by Multifunctional Environmentally-friendly Non-abrasive Non-toxic Non-electrical conductive Completely dry Void of secondary waste Cleans equipment online Cleans equipment at operating temperature Offer low pressure and high pressure blasting capabilities Less power consumption Lowest cost of ownership on the market What makes the Evolution Line different? The Evolution Line provides the perfect universal dry ice blasting experience. New, quick change dosing disc allows for a faster replacement, which leads to shorter downtime and lower maintenance costs. The insulated lid and hopper helps eliminate clumping of the dry ice, and provides troublefree blasting time. The stainless steel frame provides a high strength, scratch-resistant machine designed to keep up with the toughest conditions, while still suitable for lighter applications. TECHNICAL DATA: Dimensions mm/inch: Length: Width: Height Incl. handle: Elite 20 3/ / / / 42.5 Weight: kg:/lbs: 104 / 230 Dry Ice Capacity: liter: / ft 3 : 20 / 0.71 Dry Ice Consumption: kg/hr: lbs/min: Supply Pressure: bar: psi: Blasting Pressure: bar: psi: Air Consumption: Nm3/min: cfm: (depending on nozzle combination Compressed Air Connection: min 5 - max 16 min 72 - max 232 min 2 - max 16 min 29 - max claw coupling Air Quality: According to ISO Class 3 for environment temperature below + 5 C / 41 F Power Consumption: 500 W. 100V - 240V AC 50/60 Hz + PE (GND) Blasting Hose: 3/4 Single Hose System Noise: Noise level up to 120 db(a) Depending on blasting pressure, nozzle combination and material surface Americas EMEA +32 (0) Germany +49 (0) Asia-Pacific +81 (0)

27 Advanced Nozzle Performance Patented technology for superior results. Dial in the perfect clean. Introducing the revolutionary line of variable Aero nozzles. With patented MERN technology and patent pending variable fragmenting technology you have the power to control aggression in supersonic flow region of nozzle for a full range of performance with maximum effectiveness. HIGH FLOW 523V2 STANDARD FLOW 323V2 The universal standard for flexibility in all applications. HIGH FLOW 508V.8 High aggression for tight areas. 0 1 PELLET Maximum aggression for removing the toughest contaminants. MEDIUM FRAGMENTING Aggression with control. Aero DESIGNED FOR THE AERO SERIES STANDARD FLOW 312V2 Medium aggression. HIGH FLOW 523V4 Gentle aggression for large areas. 2 3 FINE FRAGMENTING Power and precision. EXTRA FINE FRAGMENTING Gentle cleaning on delicate substrates. LOW FLOW 110V.6, 123V.7 High to low aggression with low noise. Dial selection 3 is not applicable to HIGH FLOW 508V.8 and LOW FLOW 110V.6, 123V.7 Precision technology. These nozzles are used with Cold Jet s patented shaved dry ice technology, the i 3 MicroClean, to provide an effective solution for product finishing or cleaning delicate surfaces and complex mold cavities and crevices that other methods can t reach. MC26M Patented MERN technology psi, blast swath 0.26 MC29MH Patented MERN technology psi, blast swath 0.29 MC88 Fan nozzle for fast gentle cleaning 30 80psi, blast swath 0.88 MC88F Fragmenting nozzle for even gentler cleaning psi, blast swath 0.88