Surface World October 2019 Surface World October 2019 | Page 80
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PRE-TREATMENT, SURFACE PREPARATION, DEGREASING & CLEANING
Layton Technologies development
of new quicker cleaning process
for ceramic components
A world-renowned
manufacturer of advanced
technical ceramics
components approached
Layton Technologies Limited
with a requirement to
rationalise the cleaning
and drying process used
on ceramic components
destined for the medical
device industry.
The client operated a time and chemistry
heavy cleaning process carried out in two
separate systems which were in excess of
20 years old and they had already identified
the substantial risks to their operation due
to increasing issues with the reliability of the
ageing systems.
They had a long list of requirements for the
project the main focus being that they
needed to be able to manage their
forecasted increased throughput, which was
in excess of 10 times the current throughput,
whilst at the same time ensuring that they
maintained a scrupulously clean process to
medical device standards and provide a high
degree of safety for both the environment
and operatives.
The list also included increasing yields,
removing the requirement for the multiple
operators of the current systems, reducing
energy usage, increasing throughput and
removing any need for the use of hazardous
chemistries.
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Layton were tasked with developing a
streamlined automated process which
would meet all of the above requirements.
In addition, Layton were required to ensure
that due to the extremely fragile nature
of the product no damage occurred to
them during the cleaning and drying process.
In addition to the client’s already lengthy
wish list was the ability of any new system
to provide a high level of functionality to
improve process control and data collection.
To achieve all the requirements placed
upon Layton, the following key uncertainties
needed to be resolved:
Would it be possible to introduce a more
reliable automated system with the ability to
increase yields with a more effective cleaning
and drying process whist reducing energy
consumed?
Could the manual intervention required
for the current process be removed by
automation?
Could the process be rationalised resulting in
a consistent end-product and shorter overall
process time?
How could the level of functionality be
improved to provide greater process control
and data collection?
Could the risk be removed to operators
and the environment due to exposure to the
chemicals employed.
Following the issue of the purchase order to
Layton their in-house design team produced a
comprehensive Design Documentation Package
which included a general arrangement diagram,
a piping and instrumentation diagram and a
functional design specification, a software design
specification together with a comprehensive
Project Plan.
At the same time as the main system design
and manufacture Layton undertook the
design, development and manufacture of a
specialist fixturing to hold the components and
to optimise the cleaning and drying process.
The final design resulted in a new, fully auto-
mated, multistage cleaning and drying system
complete with Layton’s unique 5-year warranty.
For more information contact
Layton Technologies
Telephone: +441782370400
Email: [email protected]
Visit: www.laytontechnologies.com
About the company:
Extensive, customer witnessed, trials were
conducted to rationalise the current process
and to ensure a clean and dry end product.
Due to the fragile nature of the components,
tests were developed with the client to ensure
that all contamination was removed, and the
parts sustained zero damage.
OCTOBER 2019
An extensive Technical Proposal was
produced which included for automated
processing, complete system enclosure,
automated chemical dosing and monitoring
and data logging this satisfied the concerns
that the client had expressed as to the overall
ability of the new system to meet the
requirements of the project.
Staffordshire-based Layton Technologies
Limited is a global leader in the design,
manufacture and installation of precision
cleaning equipment for the medical,
aerospace and specialist engineering
industries. The company is located in the
heart of England, with easy access to main
transport networks via road, rail and air.
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