Ecoclean: Ultra-fine and High-purity Cleaning. In order to secure a future-proof and competitive market position, numerous companies are restructuring their product ranges. The trend is toward sophisticated solutions for high-tech industries. This not only means higher demands on the precision of components but also extremely strict specifications regarding particulate and film cleanliness, which must be achieved in a process-reliable, economical, and sustainable manner. This requires a different approach to cleaning, a critical examination of the entire production chain and manufacturing environment, and an experienced partner.
In the course of industrial transformation, more and more companies are focusing on the manufacture of high-quality products and components with solid margins. The emphasis is on high-tech industries that promise stable future demand through growth. The extremely high requirements for manufacturing precision in these sectors—such as the semiconductor supply industry, electronics manufacturing, e-mobility, the optical and optoelectronic industry, sensor technology, photonics, thin-film technology, vacuum, laser and analytical technology, and aerospace—also extend to the cleanliness of components. This applies regardless of whether the components are barely visible electronic parts, millimeter-scale connecting elements, precision optics, or meter-sized structural components, and regardless of the materials from which they are made.
Defining cleanliness according to requirements
This trend poses challenging tasks for parts cleaning. Unlike conventional component cleaning, which usually involves removing large quantities of manufacturing residues such as chips and processing media, ultra-fine and high-purity cleaning focuses on removing minimal residual contamination. The specifications for particulate cleanliness extend into the submicrometer range. Depending on the industry, component, and application, film-like residual contamination—such as organic and inorganic residues, ionic residues, and microorganisms—must be removed in a process-reliable and reproducible manner down to nanometer levels. In high-purity applications, such as the manufacture of components for EUV lithography, so-called hydrogen-induced outgassing (HIO) substances must also be taken into account.
The requirements for particulate cleanliness to be met during cleaning are defined by the corresponding surface cleanliness class (ORK) according to EN ISO 14644-9 (SCP – surface cleanliness by particle concentration) or the corresponding VDI guideline 2083, sheet 9.1. Film-chemical, organic, and inorganic surface cleanliness is usually specified by individual requirements or factory standards. In addition, outgassing rates may be evaluated using mass spectrometers.
These demanding tasks require a partner with comprehensive technological expertise and knowledge of the applications and physical principles, as well as practical experience in this field of cleaning and suitable test facilities for cleaning trials under production-related conditions. As an experienced full-service provider of future-oriented and globally available solutions for ultra-fine and high-purity cleaning, Ecoclean meets these requirements.
Selecting the right cleaning process and system technology
In order to meet these very strict cleanliness specifications in a process-reliable, reproducible, and sustainable manner, several cleaning steps are usually required along the manufacturing chain. The following questions play a key role in selecting the optimal solution for the respective cleaning process: What material is the part made of? What are the geometry, dimensions, and weight of the component? What contaminants need to be removed? What cleanliness requirements must be met? Which cleaning process and chemicals are suitable for this?
On this basis, it is possible to determine which and how many cleaning steps are required, using which medium and which process technologies. Other aspects to be taken into account include the required quality of the rinsing medium, the appropriate drying technology, as well as clean part handling and the ambient conditions—for example, connection or integration into a cleanroom or controlled environment.
Cleaning along the production chain
The basis for ultra-fine or high-purity cleaning is oil- and grease-free parts. To achieve and maintain this level of cleanliness, a cleaning process is carried out after various processing steps, such as machining, forming, grinding, or polishing. The effect of the cleaning medium is enhanced by numerous process technologies that can be combined in almost any sequence, such as steam degreasing, spraying, high-pressure cleaning, immersion, ultrasonic and megasonic cleaning, as well as plasma cleaning, injection flood washing, pulsed pressure cleaning (PPC), and ultrasonic plus. These process options ensure that the required cleanliness is consistently achieved, even for geometrically complex workpieces.
For intermediate cleaning processes or parts with less stringent cleanliness specifications, modular single- or multi-chamber systems operating under full vacuum, such as EcoCstretch or EcoCvela, are typically used. Depending on the processing medium, these systems can be operated with environmentally friendly solvents—such as hydrocarbons or modified alcohols—or specially selected water-based cleaners. The design, system engineering, media flow, and treatment of these systems are tailored specifically to ultra-fine and high-purity cleaning applications. Thanks to the process mechanics concentrated in the working chamber (e.g., injection flood washing, ultrasound, and PPC), this type of system also offers advantages when cleaning large and complex workpieces.
Ultrasonic multi-bath immersion systems are the optimal solution for parts made of a wide variety of materials, with high throughput requirements and/or strict cleanliness specifications. In addition to individually designed cleaning systems for high-end applications, the manufacturer offers efficient solutions with the UCMSmartLine and UCMPerformanceLine series, consisting of standardized modules. The electrical and control technology is integrated into the respective modules for the process steps of cleaning, rinsing, drying, loading, and unloading, as well as for the transport system. Together with process mechanics tailored to requirements, such as PPC, this modular design allows the systems to be optimally adapted to each task. The option of upgrading the cleaning system at a later date ensures future-proofing in the event of increased requirements.
Test centre for process design or contract cleaning
Ecoclean determines the right system concept for each application and the optimal cleaning process in its own High Purity Test Centre. The facility includes a Class 7 cleanroom with Class 6 zones, along with various measurement and analysis methods (e.g., microscopy, residual gas analysis, UV light, and fluorescence measurement). In addition to product-specific development of cleaning processes and parameters, the manufacturer also uses the Test Centre to carry out contract cleaning orders. A dedicated packaging station for cleaned parts ensures that the high level of cleanliness achieved is maintained and delivered to the customer.
For Information:
Ecoclean GmbH
Rainer Straub, Head of High Purity Cleaning
70794 Filderstadt, Germany
Tel. +49.711.7006-0
E-mail: rainer.straub@ecoclean-group.net
www.ecoclean-group.net
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