Is Automatic Ultrasonic Cleaning the Answer to Cleaning Injection Moulds?

Regular cleaning and maintenance are essential for prolonging the lifespan of injection moulds. But cleaning injection moulds can be a challenging task. Removing built-up waste plastic, release agents, lubricants and other contaminants thoroughly can be difficult, especially if they have hardened or adhered to the mould surface. Complex mould geometries can make it challenging to reach all the nooks and crannies. And the cleaning methods or chemicals used need to account for mould material, heat-sensitivity and issues with thermal stress.

Cleaning is also a time-consuming process that often employs a combination of mechanical methods (e.g., brushing and scraping) and hand applied chemical agents tailored to the mould’s characteristics.

Now companies like Aptaca Spa, who are looking to improve the efficiency of cleaning and maintaining injection moulds have the option of partnering with Safetykleen, who provide an automated ultrasonic cleaning solution that can significantly accelerate the cleaning process while achieving excellent results.

Aptaca Spa is a manufacturer of disposable and reusable plastic devices for laboratories, hospitals, research institutes, and the chemical and pharmaceutical industries. With numerous plastic injection moulding and blow moulding presses and a wide range of moulds, the company produces items such as test tubes, slides, pipettes, and containers for medical tests.

Previously, Aptaca Spa performed manual cleaning using various chemical products and rags, which was time-consuming and required significant effort. They wanted to find a better cleaning method to enhance productivity.

Safetykleen proposed an automatic and ultrasonic cleaning solution centred around a 150l ultrasonic parts washer, which Aptaca Spa readily embraced. Ultrasonic waves generated by the machine create small bubbles in the washing liquid, burst against the surface of the mould, effectively removing contaminants. An oil separator integrated into the machine handles oil contaminants.

The introduction of the ultrasonic machine and a carefully formulated water-based detergent has led to reduced cleaning times for Aptaca Spa. Previously, manual cleaning took 90 minutes, but with the new solution it only takes 50 minutes. The new approach also improves operator safety by reducing exposure to chemical agents because the machine is an enclosed machine that reuses the cleaning liquid multiple times before replacement by Safetykleen's specialist team, which reduces both the use of chemical products and the waste generated.

Overall, as Aptaca Spa Technical Manager, Simone Buono, explains:

"With the Safetykleen system we have reduced the time dedicated to mould cleaning. Furthermore, the cleaning itself is now more effective and thorough. Also worth mentioning is the ease with which the exhausted product is disposed of."