the force of nature dry ice cleaning & production PLASTICS EDITION

Transcription

1 dry ice cleaning & production PLASTICS EDITION

2 What is Dry Ice Cleaning? 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 contaminates from substrates. 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 Microparticles 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. Variable Fragmenting MERN Nozzle Cold Jet nozzles feature MERN Technology used by NASA Patented technology for superior results: The patented MERN nozzles make it possible to define the size of the pellets during blast cleaning. Whether pellets or finest particles - you select the correct settings during the cleaning process without any time delay PELLET Maximum aggression for removing the toughest contaminants. MEDIUM FRAGMENTING Aggression with control. FINE FRAGMENTING Power and precision. EXTRA FINE FRAGMENTING Gentle cleaning on delicate substrates. Images shown are for representative purposes only. Products may vary from the images displayed. Cold Jet is not liable for typographical errors or changes to specifications presented.

3 Dry Ice MicroParticles 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 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 1.4 m³/min, using 1/3 of the compressed air and reducing noise levels and air usage Increase blast pressure up to 17.2 bar to clean the most stubborn contaminants 3

4 Industry Overview: Plastics A Faster, Better Clean. Clean mold cavities 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 that parting line, or 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 Molds Injection Molds Thermoform Molds Plastic Injection Screw Barrels Urethane Molds and Overspill Plate out Off gassing PRODUCT FINISHING Deflashing and surface/parting line vents Gloss leveling 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. 4

5 Automotive Mold Cleaning Solution A clean mold produces higher quality products Aero 40FP Plastics Edition 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 45,000 Euro. 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 The Cold Jet Aero 40FP Plastics Edition 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 Benefits Hopper Agitation & Ramrod System Coated Aluminum Rotor Onboard Pressure & Flow Regulator XP Performance Applicator 3/4 Rubber Blast Hose Sureflow Quick Disconnect Fittings Variable Fragmenting Mern Nozzle Nozzle Bag Custom Care PM Mold Cleaning Air Intake Mold Cleaning Textured Instrument Panels Sealing Paint Preparations Mold Cleaning ABS Front Grills Mold Cleaning & Deflashing Lights Car Seats Mold Cleaning & Deflashing ABS Mold Cleaning Covers, Carpet, Damping Cast Parts Motor Mold Cleaning Wheel Production Mold Cleaning & Deflashing Bumper Mold Cleaning Gears Mold Cleaning ABS Wheel Covers Mold & Part Cleaning Break Production 5

6 Automated Surface Preparation Solution Cold Jet s Automated Environmental Cleaning and Surface Preparation (ECaSP) systems were developed to improve quality and lower operating costs for manufacturers with paint lines. Our automated systems eliminate the need for power-washing or chemical cleaning prior to painting, thus saving companies up to 50% on their cleaning operating costs. Our systems can safely remove a variety of contaminants from the parts, including oil, dust, release agents, finger prints, etc. without causing part surface damage. Integrated System The System Cold Jet s Aero 80FP and E160 Pelletizer are integrated into an automated, non-abrasive cleaning system that prepares the surface of molded parts prior to painting. The fully automated E160 Pelletizer will produce on demand up to 160kg per hour of consistent, high density dry ice using liquid CO 2 and electric power. Dry ice from the E160 is produced directly into a Cold Jet Aero 80FP unit; equipped with our patented SureFlow System that is designed to ensure worry-free operation and uninterrupted pellet delivery. Dry ice cleaning is more effective than traditional methods. Cold Jet s fragmenting nozzles enable molders to clean a variety of part surface finishes without causing damage. For more details about how our systems can help with your specific application, contact your local Cold Jet representative or visit E160 Pelletizer / Aero 80FP Plastic Edition System Benefits Ability to integrate with robotic controls Reduce consumable costs through just-in-time manufacturing with no storage waste Superior cleaning performance Reduce labor and associated costs System Features Compact footprint Fully automated start up and shut down Operational in less than three minutes Up to 2.6 kg min dry ice feed rate Automated, inline surface cleaning of car bumper before painting Blast hose(s) with aerodynamic fittings up to 18 m Patented SureFlow Pellet Dosing System Production of 1-3 mm pellets for delicate cleaning Automated, inline surface preparation / cleaning of automotive mirror housing prior to painting Tilt out hopper feature for unseen production stops 6

7 EDITION Deflashing & Deburring Solution Surface Preparation Solution 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 Plastics Edition PLASTICS i 3 MicroClean Benefits Designed for precision applications MicroParticle Technology 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 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 Deflashing Application - Thermoplastic & Thermoset 7

8 Aero 40FP Setting a new standard in dry ice blast cleaning. HOPPER AGITATION & RAMROD SYSTEM Our SureFlow system prevents clogging and pellet sublimation, ensuring uninterrupted cleaning performance. COATED ALUMINUM ROTOR Enhanced coated aluminum material for improved durability. ONBOARD PRESSURE & FLOW REGULATOR Internal, resulting in a smaller, lighter weight machine with superior performance. XP PERFORMANCE APPLICATOR Dual triggers for drop protection, sealed electrical switches, tough outer shell, two industrial-grade lights and ergonomic design. Clean mold cavities and vents are a major concern for plastic part manufacturers in maintaining today s high industry standards. Cold Jet has developed an all new Plastics Edition a comprehensive application solution that provides accessories to best clean mold cavities and vents in the press at operating temperatures, thus reducing production costs, minimizing downtime and improving quality. Aero 40FP - Plastics Edition The new Aero 40FP Plastics Edition is a full pressure dry ice cleaning system packaged with accessories that will provide the best clean for your environment. The Aero 40FP is a Performance Class machine utilizing our advanced SureFlow pellet technology, featuring an isolated, insulated hopper with advanced agitation, internal pressure regulator, full pressure dosing system, coated aluminum rotor and is equipped with plastics-friendly accessories. The Aero 40FP Plastics Edition improves quality, increases productivity and reduces cost for the end user. ERGONOMIC HANDLES HOSE HANGER 3/4 RUBBER BLAST HOSE Designed to eliminate constrictions and freezing. SUREFLOW QUICK DISCONNECT FITTINGS Ultra-light and aerodynamic to ensure full particle flow and maximum performance. Removable for use on replacement hoses. VARIABLE FRAGMENTING MERN NOZZLES Allows for ability to control aggression at the dial for full range of performance with maximum effectiveness. 110V.6 and 312V.1 are recommended for the plastics industry. NOZZLE BAG Soft-sided nozzle bag designed for safe and convenient storage and transport of five Aero nozzles. CUSTOM CARE PM Extend the life of your equipment with a custom care preventative maintenance plan. 360 TURNING RADIUS WELDED STEEL FRAME DRY ICE CAPACITY 18.2 kg FEED RATE 0-2 kg/min DIMENSIONS 91 x 51 x 102 cm WEIGHT 112 kg AIR CONSUMPTION m 3 /min at 5.5 bar for standard nozzles BLAST PRESSURE RANGE bar POWER 1/4 HP, AC Motor, 1,750 RPM

9 Aero 80FP Setting a new standard in dry ice blast cleaning. Clean mold cavities and vents are a major concern for plastic part manufacturers in maintaining today s high industry standards. Cold Jet has developed an all new Plastics Edition a comprehensive application solution that provides accessories to best clean mold cavities and vents in the press at operating temperatures and prepare plastic part surfaces prior to painting and coating, thus reducing production costs, minimizing downtime and improving quality. HOPPER AGITATION & RAMROD SYSTEM Our SureFlow system prevents clogging and pellet sublimation, ensuring uninterrupted cleaning performance. STAINLESS STEEL ROTOR Upgraded stainless steel material for improved durability. ONBOARD PRESSURE & FLOW REGULATOR Internal, resulting in a smaller, lighter weight machine with superior performance. XP PERFORMANCE APPLICATOR Dual triggers for drop protection, sealed electrical switches, tough outer shell, two industrial-grade lights and ergonomic design. 1 RUBBER BLAST HOSE Designed to eliminate constrictions and freezing. SUREFLOW QUICK DISCONNECT FITTINGS Ultra-light and aerodynamic to ensure full particle flow and maximum performance. Removable for use on replacement hoses. Aero 80FP - Plastics Edition The new Aero 80FP Plastics Edition is a full pressure dry ice cleaning system packaged with accessories that will provide the best clean for your environment. The Aero 80FP is a Performance Class machine utilizing our advanced SureFlow pellet technology, featuring an isolated, insulated tilt-out hopper with advanced agitation, internal pressure regulator, full pressure dosing system, stainless steel rotor and is equipped with plastics-friendly accessories. It can also be integrated into an automated dry ice production system. The Aero 80FP Plastics Edition improves quality, increases productivity and reduces cost for the end user. WELDED STEEL FRAME STORAGE COMPARTMENT HOSE HANGER DRY ICE CAPACITY 36.4 kg FEED RATE kg/min TILT-OUT HOPPER WITH STORAGE BAG Allows you to empty unused ice easily, for future use. VARIABLE FRAGMENTING MERN NOZZLES Allows for ability to control aggression at the dial for full range of performance with maximum effectiveness. 110V.6 and 312V.1 are recommended for the plastics industry. NOZZLE BAG Soft-sided nozzle bag designed for safe and convenient storage and transport of five Aero nozzles. CUSTOM CARE PM Extend the life of your equipment with a custom care preventative maintenance plan. TILT-OUT HOPPER 360 TURNING RADIUS DIMENSIONS 109 x 52 x 118 cm WEIGHT 172 kg AIR CONSUMPTION m 3 /min at 5.5 bar for standard nozzles BLAST PRESSURE RANGE bar POWER 1/2 HP, AC Motor, 1,750 RPM

10 EDITION PLASTICS EDITION Precision cleaning and product finishing system. Clean mold cavities and vents are a major concern for plastic part manufacturers in maintaining today s high industry standards. Cold Jet has developed an all new Plastics Edition a comprehensive application solution that provides accessories to best clean mold cavities and vents in the press at operating temperatures and also deflashes/deburs parts, thus reducing production costs, minimizing downtime and improving quality. PATENTED MICROPARTICLE TECHNOLOGY 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. STAINLESS STEEL ROTOR Stainless steel material for improved durability. ERGONOMIC APPLICATOR Ergonomic head, extremely durable, high intensity LED lights and light weight. i 3 MicroClean - Plastics Edition 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. ICE LEVEL INDICATOR INTERNAL AIR FILTER 1/2 RUBBER BLAST HOSE Designed to eliminate constrictions and freezing. PLASTICS PRECISION AND FAN NOZZLES There are a variety of nozzles available. The 5E0478 (MC19) precision nozzle and 5E0241 (MC88) fan nozzle are recommended for the plastics industry. NOZZLE ACCESSORIES The 3N0067 (90 degree) angle adapter allows for tight access cleaning and is machined to offer free particle flow. The 3E extension tube is recommended to extend to 10 in (25.4 cm) length. NOZZLE CASE Hard-sided nozzle case designed for safe, convenient storage and transport of MicroClean nozzles. CART AND COOLER Includes cart for mobility and cooler for conveniently storing dry ice. CUSTOM CARE PM Extend the life of your equipment with a custom care preventative maintenance plan. STAINLESS STEEL CONSTRUCTION DRY ICE CAPACITY 9.1 kg FEED RATE kg/min DIMENSIONS 56 x 41 x 53 cm WEIGHT 59 kg AIR CONSUMPTION m 3 /min at 5.5 bar for standard nozzles BLAST PRESSURE RANGE up to 9.7 bar POWER 1/4 HP, AC Motor, 1,750 RPM

11 SDI Select TM 60 Any Ice. Any Application. Anywhere. Clean mold cavities and vents are a major concern for plastic part manufacturers in maintaining today s high industry standards. Cold Jet has developed an all new Plastics Edition a comprehensive application solution that provides accessories to best clean mold cavities and vents in the press at operating temperatures and prepare plastic part surfaces prior to painting and coating, thus reducing production costs, minimizing downtime and improving quality. PATENTED MICROPARTICLE TECHNOLOGY 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. BYPASS FOR FULL 3MM PELLETS With heavier contaminants, simply bypass the shaving media, turn up the aggression and clean using full 3mm pellets. XP PERFORMANCE APPLICATOR Dual triggers for drop protection, sealed electrical switches, tough outer shell, two industrial-grade lights and ergonomic design. SDI Select 60 - Plastics Edition The SDI Select 60 Plastics Edition uses any form of dry ice - standard block, 3mm pellets, nuggets, slices, even leftover scrap - to 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. End users can tap into the ultimate precision technology required to clean small molds in larger volumes and also quickly and effectively clean large molds, including fenders and dashboards. The SDI Select 60 Plastics Edition can reduce cleaning times by as much as 75%, providing a cost-effective cleaning solution for molders.as 75%, providing a cost-effective cleaning solution for molders. 1 SILICONE BLAST HOSE The lightest and most flexible blast hose, starting at less than 10 lbs (4.5 kg). Includes outer wrap that repels moisture and easily wipes down after use. WELDED STEEL FRAME ERGONOMIC HANDLES HOSE HANGER SUREFLOW QUICK DISCONNECT FITTINGS Ultra-light and aerodynamic to ensure full particle flow and maximum performance. Removable for use on replacement hoses. VARIABLE FRAGMENTING MERN NOZZLES Allows for ability to control aggression at the dial for full range of performance with maximum effectiveness. 110V.6 and 312V.1 are recommended for the plastics industry. NOZZLE BAG Soft-sided nozzle bag designed for safe and convenient storage and transport of five Aero nozzles. CUSTOM CARE PM Extend the life of your equipment with a custom care preventative maintenance plan. 360 TURNING RADIUS DRY ICE CAPACITY 27.2 kg FEED RATE kg/min DIMENSIONS 61 x 71 x 109 cm WEIGHT 155 kg AIR CONSUMPTION m 3 /min at 5.5 bar for standard nozzles BLAST PRESSURE RANGE bar POWER 1 HP, AC Motor, 1,750 RPM

12 Industry leaders look to Cold Jet Case Study: Injection Mold Cleaning and Deposit Removal Dry ice cleaning provides a reliable, gentle solution that increases production and quality COMPANY HG Hans Geiger Formenbau GmbH HG Hans Geiger Spritzgießtechnik GmbH APPLICATION Reinigung von Spritzgießwerkzeugen - Entfernung von Belägen COLD JET SYSTEM i 3 MicroClean KEY BENEFITS - Coating removal - Reduce maintenance cycles by 50% - Improve productivity, reduce risks and support environmental initiatives - Minimal mold disassembly The Situation The Geiger group is made up of Hans Geiger Spritzgießtechnik GmbH located in Franken -, Hans Geiger Formenbau GmbH - located in Franconian Nürnberg and HG Geiger Kunststofftechnik GmbH located in Hilpoltstein. The company was founded in 1961 as a mold designing company by Hans Geiger and in 1968, injection molding was added. Today, the company specializes in producing complex components. Kolb, Process Engineer at Hans Geiger. The quality and added value of a product is always a result of several, perfectly interlocking, individual steps - just one of the reasons why Geiger puts so much emphasis on the product development process. The cleaning of our tools is really important for our end product. The formation of coatings, due to the additives and flame retardants in plastics, has a direct influence on the quality of the products and the lifespan of tools. Therefore, fixed cycles have been established to ensure that the molds are well maintained and in flawless condition. Traditionally, molds have been cleaned by hand in the machine or alternatively, the mold could be removed from the machine and then cleaned with chemicals, ultrasonic baths or by hand. If you need to clean 96 cavities by hand, it is not only time consuming but also hard to reach each crevice and angle, said Kolb. Cleaning by hand in the machine was not very effective. Depending on the mold, 20 man-hours and up to 2 employees were needed. In addition, there was always the risk of damaging the mold, thereby reducing the lifespan of the equipment and tools needed to be replaced. Additional concerns were caused by beginning a new process, employee retention in the injection molding business and machine downtime. In addition to the cleaning process, an additional four hours (assembly and disassembly of the mold) needed to be added. It was not surprising that the Geiger Group was looking for a new cleaning process. The Solution 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 Clean mold cavities and vents are a major concern for plastic part manufacturers in maintaining today s high quality standards and is a main priority for the Geiger group, whose customers are electronics and automotive manufacturers. The Problem Each product is only as good as its developing process, said Hans CUSTOMER COMMENTS: The cost factor was an essential part in their purchasing decision. The company calculated that the investment will pay for itself in less than one year due to time savings and increased machine utilization. 12

13 CUSTOMER COMMENTS: This cleaning method is very effective to remove the contaminant from the tool and even helps when burning occurs. From certain coatings, we could reduce maintenance cycles up to 50%. BEFORE AFTER 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. Kolb was familiar with dry ice blasting and it was clear that a block dry ice system was the right solution. A material supplier recommended Cold Jet s i 3 MicroClean dry ice cleaning system and patented shaved MicroParticle technology. 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 mold surface or changing dimensions guaranteeing a consistent product quality. After a demonstration of the i 3 MicroClean, a rental system was offered and tested by the mold designing team. After a 4 week trial period, the results of the quality control were presented to the Geiger management team. The experience was so positive that they decided to purchase the rental system. This cleaning method is very effective to remove the contaminant from the tools and even helps when burnings occur, said Kolb. From certain coatings, we could reduce maintenance cycles up to 50%, therefore, the costs and downtime reduced considerably. Additional benefits for the Geiger group include productivity improvement, risk reduction and environmental initiative support. The cost factor was an essential part in their purchasing decision as well. Calculations for certain product groups were carried out to estimate the reduced effort. The company calculated that the investment will pay for itself in less than one year due to time savings and increased machine utilization. A specific staff was assigned to review the usability. The mobile i 3 MicroClean allowed the staff to go quickly through the production line and clean whenever and wherever it was necessary. The applicator s ergonomic design and LED light provided optimal illumination of the surface being cleaned, increasing cleaning speed. Because of the 45, 90 and 360 rotating nozzles available for the i 3 MicroClean, it is now easy and effortless to clean hard to reach areas. Another benefit is the dry ice and the compressed air, which can be regulated individually and the settings can be exactly matched to the requirements. An average of one dry ice block is required for two tools. The maintenance staff is now better equipped to do preventative maintenance as less unplanned actions can occur. In addition, the mold does not often need disassembly for cleaning, reducing the risk of damaging the mold. Kolb is a member of the Plastic Network in Franconia. Together with a Cold Jet employee, he carried out a presentation which resulted in great interest with the audience. Due to several advantages (quality, environment and cost) of Cold Jet dry ice blasting, we are holding a test phase at our sister plant Fa. Reiter, which manufactures mainly products for the medical industry. 13

14 Comparison to Manual Cleaning Example: Cleaning of Injection Molds Mold Cleaning 48 Cavity IMM 96 Cavity IMM 144 Cavity IMM Production maximum (Hours/Year) 8,400 8,400 8,400 Time saving per week with Cold Jet Jet Time saving with Cold Jet per year Efficiency Improvement with Cold Jet Jet 0.9% 1.2% 1.2% 1.5% Extra hours production Mold cycles per hour Extra preforms made per year 1,347,840 3,594,240 6,739,200 Profit per preform Profit per year from extra production 4,044 4,044 10,783 10,783 20,218 20,218 Payback-time per IMM in months Payback-time per 5 IMM in in months *IMM: Injection Molding Machine Variables: Production Maximum, Mold Cycle time, Profit per preform, Not taken into consideration: Savings by labor cost, Reduced repair costs, Extended equipment life time. Benefits of Dry Ice Cleaning Faster than traditional methods -Clean on line, in place, while hot -Less down-time = more run-time Produces a cleaner clean -Cleans in tight spaces with precision -Does not leave residue Dry cleaning process -Non-Corrosive, Non-Conductive Environmentally Friendly -Eliminates or reduces chemicals -Non-Toxic and Food-safe -Dry ice CO2 is recycled Increased safety High reduction in waste Decreased Downtime Dry Ice Blasting Benefits Reduction or elimination of solvents Faster & thorough cleaning No equipment damage 14

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16 Americas. Asia. Europe.