Oteraccordi is an Italian leader in the field of thermo-hydraulics, sanitary fixing systems and industrial fixings.
The company offers products specific to the building sector, heating and plumbing. It also designs and produces customized parts for the automotive sector, agriculture and earth moving equipment.
“Our commitment to technological innovations is fundamental to our success,” says Cristiano Ballan, Head of Production at Oteraccordi. “We have, for example, large, horizontal multi-station presses for cold molding. There are only very few companies in Italy that have such capabilities. We also have a range of chip removal machines for further processing.”
Photo above: Oteraccordi has always placed great emphasis on using the latest technology. The picture shows a horizontal press SACMA 570 used for stamping.
Critical Role of Metal Degreasing in Quality Assurance
Metal parts still to be cleaned after stamping.Oteraccordi uses different metal types, including carbon steel and stainless steel, to produce its large variety of products, from collars, clamping and fixing systems, cast iron, and pickled sheet and hydraulic fittings. Since the parts produced are subjected to subsequent internal/external threading, galvanic treatments, and packing, the finished and semi-finished components must be cleaned and degreased to an extremely high standard.
The volumes and types of metals to be cleaned, along with the complex dimensional and geometric structure of the components, are just a few challenges associated with the metal parts cleaning process. Needless to say, extra care must be taken to ensure that the parts are not damaged during the degreasing phase.
As Oteraccordi continues to win new contracts on the back of its success, it is proving increasingly difficult to maintain quality and efficiency in metal cleaning activities as there are now far more parts to be handled.
For almost three decades, the company had been using an aqueous-based cleaning system for parts cleaning, but it was struggling to maintain consistent results. The significant energy consumption as a result of the long cleaning cycle represented another financial burden on top of the high waste management costs. With the production pace set to intensify further, Oteraccordi felt increasingly compelled to search for an alternative cleaning solution that would enhance quality standards and operational efficiency.
Cleaning with Modified Alcohol: High Performance Results and Eco-Compatibility
During a trade show visit, Oteraccordi encountered IFP, a leading cleaning machine manufacturer for modified alcohols. IFP recommended the virgin-grade, high-performance modified alcohol Dowclene 1601 provided by Safechem, a chemical service company, for the cleaning trials.
Produced synthetically, the distillable solvent Dowclene 1601 has both non-polar and polar properties. This means it can effectively remove non-polar contaminants such as fats and oils, as well as certain water-based contaminations. Its defined and narrow boiling range also makes residue-free drying possible, which results in outstanding cleaning results with high surface tension. Dowclene 1601 is also characterized by low toxicity and good biodegradability. Compared to aqueous cleaning, no water is consumed in the process, and there is also less space requirement.
Combining IFP’s Technology With Dowclene 1601: Cleaning Results Have Us ‘Sold On The Spot’
Oteraccordi decided to invest in the IFP machine model KP 1000 MAX which would run on Dowclene 1601. After a four-month evaluation and testing period, the conclusion for Oteraccordi was clear – the cleaning test outcomes were so satisfying that the company did not even see the need to try out other technologies.
Oteraccordi decided to invest in the IFP machine model KP 1000 Max, which would run on Dowclene 1601. The solvent is delivered in the Safe-Tainer System, a solvent risk management tool from Safechem that ensures the safe transport, storage, and handling of solvents.
The IFP machine operates under full vacuum in all stages, and is designed with two specific ends in mind – reduced energy consumption and oil recovery for reuse in the production cycle. It is also constructed to keep machine maintenance to the minimum.
Equipped with fully self-cleaning chambers, there is no risk of bottom deposits or encrustation, nor is there the need to open tanks, chambers and distillers for cleaning. Improved distillation of the solvent, together with filtration and oil separation systems, ensures an optimized process with extremely low disposal and waste management costs.
Cristiano Ballan noted, “When we saw the first trial cleaning results with Dowclene 1601, we were practically sold on the spot. Also, the ability of the IFP machine to recover processing oil has been a decisive factor for us since it represents further savings and optimization for the company.”
Gains on All Fronts: Operational Efficiency, Energy Savings and Outstanding Cleanliness
The easy-to-use Maxicheck Test Kit contains all necessary accessories for regular monitoring of solvent condition. The tangible gains as a result of the adopted solution have validated Oteraccordi’s decision to opt for modified alcohol technology after years of aqueous cleaning.
“Our cleaning cycle has gone down from 50 minutes to just 20 minutes. What’s more, we’re able to save at least 40% of the energy costs. Apart from consistent good cleaning results, the quality of surface coatings such as galvanizing or zinc plating on cleaned parts has also improved,” Cristiano Ballan summed up the benefits.
Furthermore, Oteraccordi can regularly monitor the solvent condition using Safechem’s Maxicheck Test Kit to ensure optimal solvent management. Results recorded in an operating diary will be forwarded to Safechem, who can readily provide recommendations in case of any abnormalities.
“Since switching from aqueous cleaning to a solvent cleaning system, the way we work has changed for the better. We are really happy with our decision and the resulting outcomes,” Ballan says.
Visit www.safechem.com
