Cleaning Handbook 3rd Edition

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STHE

AQUEOUSCLE

ANINGHANDBOOK

M

cLAUGHLIN/ZISM

AN

T H E

AqueousCleaning

HandbookA GUIDE TO CRITICAL-CLEANINGPROCEDURES, TECHNIQUES, AND VALIDATION

AqueousCleaning

Handbook

ince their first use in healthcare and laboratorysettings, aqueous critical cleanerscleanerswhich leave no interfering residueshavefound increasing application in a wide range ofindustries as an environmentally benign alter-

native to ozone-depleting compounds and haz-ardous solvents.

This book distills and presents practical infor-mation covering the history of such cleanerswhat

they are, how they work, and how to make best useof them in cleaning products and components inelectronics, metalworking, precision manufacturing;pharmaceutical, food-and-beverage, and chemicalprocessing; and many other industrial applications.

It is written by a medical doctor, Alan Zisman,and a director of aqueous-cleaner marketing,Malcolm McLaughlin, who also has academictraining and professional experience in chemistry.Both are employed by Alconox, Inc., a New Yorkfirm which has been a leading developer and sup-

plier of aqueous cleaners for laboratory, healthcare,and industrial applications for more than 50 years.

ABOUT THE AUTHORSMalcolm McLaughlin, M.A. is Vice President,Marketing, for Alconox, Inc., a leading developer andmanufacturer of critical-cleaning aqueous detergents. Heearned his M.A. in Chemistry from Columbia University.Alan Zisman, M.D. is President and Director of Alconox,Inc. He earned his M.D. at Columbia Universitys Collegeof Physicians and Surgeons.

S

Malcolm C. McLaughlin, M.A.

Alan S. Zisman, M.D.and the

Technical Services Staff of Alconox, Inc.

$39.95 Third Edition

2002 Handbook Cover 9/24/02 11:33 AM Page 1


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T H E

AqueousCleaningHandbook

AqueousCleaningHandbook

A GUIDE TO CRITICAL-CLEANINGPROCEDURES, TECHNIQUES, AND VALIDATION

Malcolm C. McLaughlin, M.A.

Alan S. Zisman, M.D.

and t he

Technical Services Staff of Alconox, Inc.


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ContentsFOREWORD v

INTRODUCTION ix

CHAPTER ONEWhat Is an Aqueous Cleaner? 1

CHAPTER TWOThe Chemistry of Aqueous Cleaning 9

CHAPTER THREEAqueous-Cleaning Processes 19

CHAPTER FOURSelect ing an Aqueous-Cleaning Detergent 41

CHAPTER FIVETest ing an d Selec ting a Det er gen t and Clean in g Syst em 5 1

CHAPTER SIXIndustrial Cleaning Applicat ions 65

CHAPTER SEVEN

Standard Operat ing Procedures 97

ii i

1998 Alconox, Inc. 2000 Alconox, Inc.

Second Printing 2002 Alconox, Inc.

Third Printing

All rights reserved under Pan-American Copyright

Conventions.Published in the United States by

AL Technical Communications, LLC,White Plains, NY

Unauthorized reproduction of this book is forbidden by law.

International Standard Book Number0-9723478-0-1

Library of Congress Catalog Card Number2002110614

Special thanks to Peter Levin, Elliot Lebowitz, andAndrew Jacobson of Alconox, Inc.; J im Morris-Lee, Mary Kane, Steve Smith

and Mea Andreasen of The Morris-Lee Group; without whose tireless(but now at least not thankless) help this book would not have been possible.

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ForewordM ost cleaning practitioners are familiar with the story: thescientists who developed chlorofluorocarbons (CFCs), first asrefrigerants and then as solvents, had struck upon what theythought were safe, inert materials. CFCs would replace petro-leum-based chemicals known for their health hazards. CFCswere relatively inexpensive, readily available and most impor-

tantly, they worked.What the researchers did not know was the impact these

chlorine-containing substances would have on the ozone layer:that portion of the atmosphere responsible for shielding theearth from some of the solar systems most harmful ultraviolet(UV) rays.

Chlorine (Cl) atoms participate in the destruction of ozone(O3) as they randomly make their way into the upper atmos-

phere. The reaction is catalytic with the potential for one (1) Clatom to destroy thousands of O3 molecules. The introductionof hydrochlorofluorocarbons (HCFCs) as secondary replace-ment chemicals reduced but did not eliminate this danger.

CFCs and HCFCs also increase global warming by interfer-ing with the atmospheres natural ability to radiate heat awayfrom the planet. This exacerbates the Greenh ouse Eff ectmostnoticeably impacted by fossil fuel burning.

The international M ontreal Protocol treaty and the U.S.Clean Air Act Amendments govern the usage and productionof most of these compounds, including VOC (volatile organic

Foreword v

CHAPTER EIGHTCleaning Validat ion 119

CHAPTER NIN E

Wastew ater Treatment and Cleaner Recycling 129

CHAPTER TENMeasuring Cleanliness 141

CHAPTER ELEVENEnvironmental Health and Safet y Considerat ions 155

APPENDIX

I Clean Air Act Amendments 162I I Cleaner Types f rom Alconox, Inc. 163I I I Detergent Select ion Guide 164IV Glossary of Essential Terms 165

V Applicat ion Case Histories 171Opt ical Substrate 171Metal Valves 172Pharmaceutical Equipment 173Glass 174Filter Membranes 175

Wine Tast ing Glasses 176Laboratory Pipets 177VI Index 179

For every book printed, Alconox, Inc. will donate one dollar toAmerican Forests to support forestry conservation and tree-plantingprojects. American Forests has been promoting protection and sus-tainable management of forest ecosystems since 1875. For informa-

tion, contact Alconox, Inc., 30 Glenn Street, White Plains, NY 10603,USA, 914-948-4040, fax 914-948-4088, [email protected],www.alconox.com.

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IntroductionToday, the terms precision or critical cleaning include anycleaning process where residue can cause a failure in the func-tion of the surface being cleaned. In general industry thisincludes electronic component cleaning and surface prepara-tion of metals prior to coating or bonding. It can also includecleaning applications in industries such as chemicals, food

and beverage, pharmaceuticals, and cosmetics where solidsand liquids come into contact with plastic, glass, and metalpiping and processing equipment.

Current practice for critical cleaning includes the use ofvolatile solvents, corrosive chemicals, and aqueous detergents.In todays hazard-sensitive workplace, however, many compa-nies are closely examining their use of volatile-solvent and cor-rosive-chemical cleaners. In that regard, aqueous cleaning rep-

resents an economical, environmentally benign alternative. Inmany cases aqueous cleaning is also the best available technol-ogy and provides a viable long-term solution to environmentalissues.

It is important that these cleaners not contain high con-centrations of volatile organic compounds or solvents due totheir air-pollution and ozone-depletion potential. They shouldalso be formulated to minimize worker hazards yet still delivercritical-cleaning performance in the intended application.

This handbook is designed to help laboratory and plantpersonnel select aqueous cleaners and systems more wisely

Introduction ix

mission to educate the public about aqueous cleaning.Readers, prepare to learn well from this Handbook.

Carole LeBlancToxics Use Reduction Institute

University of Massachusetts Lowell

*The term cleaner pr oducti onrefers to safer, greener, and more sustain-

able manufacturing methods and materials and notthe production ofchemical cleaners.

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CHAPTER THREE

Aqueous-CleaningProcesses

Before testing aqueous cleaners, it is important to understanda few basic processes regarding their use. The major variablesin cleaning using aqueous methods include:

1. Precleaning handling

2. Cleaner

3. Agitation

4. Temperature

5. Cleaning time

6. Rinse used7. Drying method

8. Postcleaning handling

The way parts and substrates are handled prior to cleaningcan have a significant impact on their degree of difficulty incleaning. Soils can be more difficult to clean if they are:

Allowed to dry, set up and cross link Stored in a dirty environment Stored in a humid or corrosive environment.

As a rule, it is important to clean parts as soon as feasibleafter they are soiled. In some instances it makes sense to takeparts directly from a manufacturing process and put them intoa soak solution where they may be able to sit for extendedperiods of time prior to cleaning.

Alternatively, parts can be placed in protective packaging,

dipped in a protective coating or immerse in oil or grease tokeep them in a state that will not increase the burden on thecleaning process.

Aqueous Cleaning Processes 19

REFERENCES

Personal interview, University of Massachusetts at Lowell, Toxics UseReduction Institute.

Alkal in e Cleaner Recycle H andbook, Membrex, Inc., Fairfield, NJ , 1994, p.5.

Ibid., pp. 45.Ibid., pp. 35.Closed-Loop Aqueous Cleanin g, University of Massachusetts, Toxics Use

Reduction Institute, Lowell, MA, 1995, p. 6.Ibid, p. 10.Salinas, M. Water Works.Parts Cleani ng, Vol. 1, No. 2; July/August,

1997.Seelig, S.S.Making Aqueous Systems Work. CleanTech 97 Proceedi ngs,

Witter Publishing, May, 1997.Quitmeyer, J . All Mixed Up: Qualities of Aqueous Degreasers.Precision

Cleaning, Vol. 5, No. 9; September, 1997.Rolchigo, P.M. and Savage, G. The Fundamentals of Recycling Alkaline

Cleaners Using Ultrafiltration. CleanTech 96 Proceedi ngs, WitterPublishing, May, 1996

Davidson A S & M ilwidsky B, Synthetic Detergents, 7th Ed.LongmanScienti fic and Techn icalcopublisher J ohn Wiley & Sons, New York,1987

RESOURCES

www.alconox.comwww.stepan.comwww.pilotchemical.comwww.rhodia-ppd.com

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Selecting an Aqueous Cleaning Detergent 41

CHAPTER FOUR

Selecting anAqueous-Cleaning

DetergentThe major requirement in cleaning electronic parts, assem-blies, precision parts, and metal surfaces is that there be noresidues that interfere with further use or processing of thecleaned surfaces. The cleaning method should be noncorrosiveto the component and the detergent chosen should exhibitexceptional free-rinsing qualities.

Critical cleaning requires careful selection of cleaningchemistry and methods to ensure adequate performance with-out sacrificing either worker safety or benign environmentalimpact. Current solvent cleaners may have ozone-depletingpotential or Clean-Air-Act-Amendment-regulated volatileorganic compounds (VOCs). Current corrosive mineral acid orcaustic cleaners may present worker exposure hazards andenvironmental disposal problems. The use of appropriate

aqueous cleaners can replace the use of volatile organic andozone- depleting compounds for cleaning. In addition, suitableaqueous cleaners can be milder and easier to dispose of thanmineral acid or caustic cleaners.

In practice, it is important to be able to choose from arange of detergents to find one that performs well with thecleaning method and is suitable for the soils and surfaces needed to be cleaned. (See Table 4A) K ey considerations include:



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REFERENCESEnvironmental Health and Safety Considerations for further


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Selecting an Aqueous Cleaning Detergent 4948 The Aqueous Cleaning Handbook

REFERENCES

Aqueous Cleaning Chemistries, Precision Cleani ng, December 1996, p. 22.Selecting An Aqueous Cleaner by Malcolm McLaughlin, Precision

Cleani ng 97 Proceedi ngs.

RESOURCESwww.alconox.comwww.cleantechcentral.comwww.clean.rti.orgwww.cleanersolutions.org

Environmental Health and Safety Considerations, for furtherdiscussion.

ENVIRON M ENTAL CONSI DERATIONSEnvironmental considerations include concern over volatile

solvents with ozone-depleting potential and volatile-organiccompound content that is regulated by The Clean Air ActAmendments. Any detergent chosen should be biodegradableand readily disposable, and contain no RCRA Hazard Classifi-cation or EPA Priority Pollutants.

Surfactants are not generally viewed as a menace to theenvironment. Nonetheless, their environmental attributesoften receive as much attention as their technical propertiesand economic aspects. One reason may be the mental imagemost people have of foaming streams and rivers, formed overthree decades ago, has not faded entirely. This foam resultedfrom non- or poorly-biodegradable surfactants which are nolonger used in modern aqueous cleaner formulations.

Then, too, public environmental awareness has increasedmarkedly in recent years. In fact, environmentalism has tran-scended from a social attitude to an almost metaphysical level,or at least to a position that compares with spirituality. A large

portion of the public wants to do the right thing, environ-mentally speaking. To this end, regulations are enacted andproducts are being designed and marketed. We have enteredthe age of environmental marketing and are forming attitudesabout environmental attributes, sometimes without adequatecomprehension of the scientific disciplines that are required.

Much of the discussion of the environmental acceptabilityor preferability of surfactants centers on the standard against

which measurement is made and on the designation of what isenvironmentally important.

Both the issues of health and environmental safety areimportant and extremely complex. Again, for a more completedescription for health, safety and environmental issues seeChapter Eleven.

CHAPTER FIVE


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Testing and Selecting a Detergent and Cleaning System 51

CHAPTER FIVE

Testing and SelectingA Detergent and

Cleaning SystemTesting and selecting an aqueous cleaning system involves aseven-step process:

1. Identify the key reason you are developing the system.

2. Select an evaluation method that will allow determi-nation that key cleaning criteria are satisfied.

3. Select a test cleaning system that includes a cleaning

method, rinse method, and a drying method.4. Select a test substrate for cleaning.

5. Select a test soil and method for applying the test soilto the test substrate.

6. Select an aqueous cleaner for evaluation.

7. Perform tests and optimize your selected system.

ID ENTIFY REASONS FORCHANGIN G CLEANI NG SYSTEM SIt is important to identify the key reasons for a new system sothat the selection process satisfies all of the reasons a new sys-tem is desirable. The following table outlines some of the rea-sons for setting up new systems and the kinds of parametersthat must be evaluated for each.



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CHAPTER SIX


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Industrial Cleaning Applications 65

IndustrialCleaning Applications

Today, new applications for aqueous cleaning are found in a

wide range of industrieslaboratory science, healthcare, phar-maceuticals, food-and-beverage processing, metalworking,and precision manufacturing of glass, plastic, and metal com-ponents.

This chapter describes key considerations in aqueouscleaning for each of these industries.

HEALTHCAREThe ultimate goals of healthcare cleaning procedures are tokeep instruments and equipment clean and sterile, prolong theirworking life, minimize cross-contamination, and reduce med-ical waste. The ideal detergent for getting reusable items cleanhas a neutral-range pH, in order to prevent corrosion or othersurface degradation. When proteinaceous soils from blood orbody fluids must be cleaned, adding enzymes to a cleanermeans the instruments will come clean with soaking and gentle

cleaning rather than abrasive scrubbingthus prolonging theirworking life and decreasing the chance of cross-contamination.

Cleaning in a healthcare setting often means preparing asurface for sterilization. It is very important to have a clean sur-face with no dirt on it so that when a sterilization process is car-ried out you do not wind up sterilizing the dirtleaving unster-ilized surfaces beneath the dirt. In short, effective sterilizationrequires effective cleaning.

Although healthcare instruments themselves are oftenmade up of robust plastics or stainless steel, the trays they are



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CHAPTER SEVEN


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Standard Operating Procedures 97

Standard OperatingProceduresA large part of successful cleaning relies on having a sound,reproducible procedure. This, of course, aids in making it easi-

er to train operators so that cleaning is consistent. The follow-ing are sample standard operating procedures for manualcleaning, ultrasonic cleaning, machine washer cleaning, andlarge-tank cleaning.

In some cases, these standard operating procedures werewritten for specific detergents and temperatures for specificsoils. As a result, they may need to be adapted to meet specificapplications. However, they provide examples of what should

be included in a standard operating procedure.The following are lists of the items to consider, includingin different types of standard operating procedures (SOPs),that can be adapted to the needs of people writing cleaningprocedures.

In general a good SOP should present a list of materialsand people involved, the surface being cleaned should be iden-tified, and the eight key variables for cleaning effectivenessshould be defined:


1) precleaning handling2) cleaning chemistry/

concentration3) time4) temperature

5) type of agitation6) rinsing conditions7) drying conditions8) postcleaning handling

Where cleaning solutions are re-used in baths or sumps,the control parameters and equipment used should be defined

(such as conductivity or pH) the limits should be defined, the


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CLEANING PROCESS FLOW FOR PARTS

Specified Temperature Check Control Check/ Trigger Alert TriggerLimits (Degree C) Frequency By Chart Equipment Points Level Actions

> 2 Megohm s R/ T Once/ Day Technician Trend Cond m eter < 5Megohm s 1 Change DI

CLEANING PROCESS FLOW FOR PARTS

STEP STEP CHEM ICAL WATER BATH CHANGE CONTROLS/NUM BER DESCRIPTION USED USED AGITATION TIM E (M IN.) NO PARTS. PARAM ETERS

Incom ing DI water Resist ivity


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> 2 Megohm s R/ T Once/ Day Technician Trend Cond m eter < 5Megohm s 1 Change DIcolumn

5.5-8.0 Once/ Day Technician Trend pH m eter Out of spec 1

As required All IQC tech Insp report 10 x Glass 1% failure 1 InformCustomer

500pcs/holder

1% R/ T

R/ T

3% 60-70 Control Box 65 5 Concentrat ion

10.4-11.4 Once/ Day Technician log bk pH m eter Out of spec 1 Increase/ Dilute

2-4kg/ c R/ T

3% 60-70 Control Box 64 5 Concentrat ion

10.4-11.4 Once/ Day Technician log bk pH m eter Out of spec 1 Increase/ Dilute

2-4kg/ c R/ T

> 2 M egohm s R/ T

> 2 M egohm s R/ T

> 2 Megohms

55+ 5 Once/ Day Technician Control Box 50-60

Technician Spin Machine 1

90 10_ Technician Control Box 95 5 1 Check tem pprobe

150 10_ Technician Control Box 150 5 1 Check tem pprobe

0.1% fail QC tech Insp report Microscope10 1 Sort ing100

Corrosion 95+ 5_ 3pcs/ lot Technician Insp report Visual No Corrosion 1 Rework

Standard Operating Procedures 109

Incom ing DI water Resist ivity

pH

Incom ing Inspect Visual

Material input Qty/ load

1 Init ial Presoak Alcojet Manually 3 min 100K Concentrat ion

Rinse(water jet) Water Manually 1min

2 1st Ultrasonic Clean Alcojet DI water Ultrasonic 5 1min 100k Concentrat ion

(40KHZ) pH

Rinse(water jet) DI Water Manually 1 min Pressure

3 2nd Ultrasonic Clean Alcojet DI water Ultrasonic 5 1min 100k Concentrat ion

(40KHZ) pH

Rinse(water jet) DI Water Manually 1 min Pressure

Rinse(DI water jet) DI Water Manually 1min Resist ivity

8 DI rinse ( immersion) DI water Air 5min Resist ivity

9 Final DI rinse DI water Ultrasonic 2min Resist ivity(immersion)

(40KHZ)

11 Spin init ial dry Machine 2 min

12 Dryer Hot air 10m in

13 Oven Dry Hot air 45m in Every Lot

Outgoing inspect Visual

Performance test DI water 4 h Every Lot Visual

Packing Plast ic tray/ bag As Required

Storage As Required

ALERT LEVEL: 1. INFORM SUPERVISOR OR QC/ENGINEERING/PRODUCT MANAGER



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Function Possibility Prog. 11

COLD W.F.I RINSE 1 0 to 30 m in


6. On Drying models, a drying step with temperatures up to110 degrees Centigrade can be performed. All drying air isHEPA filtered.

7. Postcleaning handling of the washed items must be per-


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Standard Operating Procedures 113112 The Aqueous Cleaning Handbook




HOT W.F.I RINSE 0 to 30 m in

HOT W.F.I TEM PERATURE up to to 95 C

During the inspection and qualification of the GMPWasher, verification of the effectiveness of the inventory sys-tem as described above must be demonstrated. Testing proto-

cols must be established. An example is as follows:

One test protocol for establishing cGMP washer operationthat can be used can be done by the riboflavin U.V test:

Soil the parts with a Riboflavin solution.Let them dry for 2 hours and then soil them again.Let them dry overnight.Perform the cycle 11 as follows (this cycle must have no

drying).

After cycle, the wet parts are checked with an U.V lamp.Does Riboflavin remain?

Test 1 Yes / NoTest 2 Yes / No

Glassware: Test 1:Test 2:Test 3:

After all of the preparation of the cycle description, loadpatterns and testing of the spray coverage is completed, theoperators must be trained to load/unload the racks is an ef-ficient manner.

formed in compliance with internal company proceduresthat assure cGMP compliance.

POSSIBLE SETTINGS FOR WASHER CYCLES

Function Possibility Prog. 11

PREWASH 1 PERIOD 0 to 30 min

PREWASH 1 TEM PERATURE up to to 95 C

PREWASH 1 DETERGENT 0 to 6 min







WASH PERIOD 0 to 30 min

WASH TEM PERATURE up to to 95 C

WASH DETERGENT 0 to 6 min

W.F.I RINSE 1 0 to 9

ACID RINSE PERIOD 0 to 30 min

ACID INTAKE 0 to 6 min

W.F.I RINSE 2 0 to 9


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CHAPTER EIGHT


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Cleaning ValidationCleaning validation is typically performed for pharmaceuticaland other GMP manufacturing processes. These include phar-maceutical, bio-pharmaceutical, bulk-pharmaceutical, med-ical-device, cosmeceutical and clinical-diagnostic manufactur-ers. The validation is specific to the detergent and methodused for cleaning.

To perform a cleaning validation one needs a validationmaster plan. The validation is best done during InstallationQualification (IQ), Operational Qualification (OQ), andPerformance Qualification (PQ) of manufacturing equipmentand operations. The validation provides documentation andevidence of reproducible successful cleaning. The validationconsists of a final report and a set of procedures to maintain a

validated state.The master validation plan would typical dictate that the

final report will have sections such as the following:

Objective

Responsibilities

Equipment/products/ procedures

Tests Acceptance limits

Analytical Methods Sampling procedures and recovery

Cleaning process design

Data analysis

Assumptions

Change control/maintenance

References

The objective of the validation might be to ensure product,

Cleaning Validation 119118 The Aqueous Cleaning Handbook


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CHAPTER 10


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Measuring CleanlinessM easuring cleanliness can be done at different levels depend-ing on the technique employed. Processes which detect clean-liness at levels as low as 0.01 grams per square centimeter in-

clude: Visual inspection

Low power microscope inspection

Wiping and visual inspecting

Water break tests

Atomizer tests

Nonvolatile residue inspection

Surface UV Fluorescence detection Tape test.

The next level of cleanliness measurements detects soils atthe 0.01 to .001 gram per sq. cm levela level of detection issuitable for aerospace, electrical, automotive and many sur-face preparation applications. This level of detection can beachieved through Millipore filter measurement techniques

Optical microscopy Extraction

Oil evaporation

Oil soluble fluorescence

Gravimetric analysis

Surface Energy tests

Contact angle measurement

Particle counting

Measuring Cleanliness 141140 The Aqueous Cleaning Handbook


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CHAPTER 11RESOURCESwww.alconox.comwww.astp.comwww.photoemission.comwww.pmeasuring.com


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Environmental Health and Safety Considerations 155

EnvironmentalHealth and SafetyConsiderationsThe key environmental health and safety advantages and dis-advantages of aqueous cleaners both derive from the fact thatthey use water for cleaning and rinsing. Water is inherentlyenvironmentally sound and a substantially safe chemical towork with. Water is a recyclable natural resource. Yet, as pop-ulations grow, clean surface water will become increasinglyscarce. Water can also be a transport medium for various pol-

luting or hazardous chemicals that may derive from the use ofaqueous cleaning in specific instances.One way to look at the environmental health and safety of

a cleaning process is to consider:

How hazardous is the cleaning process?

How hazardous is the effluent resulting from the clean-ing process?

How sustainablein terms of energy and resourcesis

the process?

All critical cleaning is a spectrum that ranges from pollut-ing hazardous processes to clean and safe processes; clean,safe, and reduced waste processes; and clean, safe, and sus-tainable processes. Aqueous cleaning can, in fact, play a roleall along this spectrum.

It is, of course, possible to use aqueous cleaners with haz-

ardous ingredients that are used to clean hazardous soils that



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A di

Protection) sewer connection/extension permits, and anyRCRA (Resource Conservation and Reclamation Act) haz-ardous waste class or Clean Water Act regulations. State andlocal environmental regulations should also be considered.

In the long run, it may be wise to conduct a full scale envi-ronmental audit no matter what type of cleaning system youare using. Such an audit may result in changes in the way you


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Appendix 161160 The Aqueous Cleaning Handbook

AppendixI List of AbbreviationsI I Cleaner Types from Alconox, Inc.

I I I Detergent Selection Guide

IV Glossary of Essential Terms

V Application Case Histories

VI Index

currently manufacture and clean. In fact, after conducting afull-scale environmental audit many companies turn to aque-ous cleaning as a means to more easily and safely achieve reg-ulatory compliance. (A program of regular re-auditing canassure continued regulatory compliance.)

When compared with many of the hazards of nonaqueousand semiaqueous cleanerssuch as those containing ozone-depleting fluorocarbon solvents, carcinogenic organic sol-

vents, and flammable componentsaqueous cleaners are asound choice for safe, environmentally sound cleaning. Bychoosing the safest, most environmentally sound aqueouscleaner that will perform to your cleaning requirements, themajority of cleaning problems can be solved with more thanacceptable levels of worker safety and environmental impact.

ADDITIONAL READING

Precision Cleani ng, December 1995, article Environmental Auditing:Learning from Common Pitfalls and Issues, p. 1318.

Journ al of Surfactants and Detergents, Vol. 1, No. 1, January 1998, articleSurfactants and the Environment, by Larry N. Britton.

RESOURCES

www.alconox.comwww.epa.govwww.osha.gov


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APPENDIX V

Application


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ApplicationCase Histories1. OPTICAL WAX

MORE HEAT FOR FASTER CLEANING

An optical lens manufacturer had been using ALCONOX pow-dered detergent in a heated ultrasonic bath for years to remove awax from the lens during manufacturing. As production grew,this system was not able to clean fast enough. By increasing thetemperature, adequate cleaning performance and speed wereachieved.

Initial Problem Solution

Time 10 min 5 m in

Temp 60 deg C 70 deg CAgitat ion ultrasonic ultrasonic

Chemist ry 1% ALCONOX 1% ALCONOX

Rinse deionized water deionized water

Dry air air

Problem cleans to slow

3. PHARM ACEUTICAL TABLET COATIN G EQUIPM ENT

SOIL CHANGE CAN REQUIRE CLEANER CHANGE

A pharmaceutical company had been using a typical high alkalinecleaner for manual cleaning of tablet coating equipment. Thisworked fine with their standard tablet coatings. When the compa-ny started to make tablets with enteric coatings, they observed

that their standard cleaner could not even get their coating equip-ment visually clean. By changing to an acid cleaner that was

2. PRECISI ON M ANUFACTURING PROCESS OILS

HIGHER CONCENTRATION INCREASES BATH LIFE

For years, a metal valve manufacturer had been using LI QUI-NOX liquid detergent in an immersion tank that was made upand depleted in one shift to remove process oils from metalvalves. As production grew, the number valves and quantity of

oils to be removed increased. The valve manufacturer observedthat toward the end of the day the tank did not clean as well as at


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a e s a da d c ea e cou d o e e ge e coa g equ pment visually clean. By changing to an acid cleaner that waseffective on the water insoluble inorganic salts used in the entericcoating they were able to get their equipment clean.


Time 10 min 10 min

Temp 50 deg C 50 deg C

Agitat ion manual manual

Chemist ry 1% High Alkaline 2% CITRANOXRinse deionized water deionized water

Dry air air

Problem system could not clean enter ic coat ingon tablet coating equipment

o s o be e o ed c eased e a e a u ac u e obse edthat toward the end of the day the tank did not clean as well as atthe beginning of the day. By increasing the concentration ofdetergent, the manufacturer was able to increase the soil capacityof the solution and thereby extend the bath life to meet his needs.


Time 20 m in 20 min


Agitat ion soak soakChemist ry 1% LIQUI-NOX 1.5% LIQUI-NOX

Rinse deionized water deionized water

Dry air air

Problem tank did not last long enough

5. W ASTE TREATM ENT FI LTERS

ENZYME CLEANER CURES BIOFOULED FILTERS

A small scale in-house waste treatment filtration plant was beingused to remove oils from a waste stream at a manufacturingplant. The filter membranes were typically cleaned with a highalkaline cleaner at high heat. Finally bio-fouling began to occur in

the filter and the resulting proteinaceous soils would crosslinkand become tenacious when exposed to the hot alkaline cleaning

4. ARCHITECTURAL GLASS M ANUFACTURER SEES S POTS W HENSETTING UP M ANUFACTURI NG IN A SITE WITH HARD WATER

DEIONIZED WATER STOPS WATER SPOTS

An architectural glass manufacturer had one plant where theyused DET-O-J ET cleaner to clean glass prior to coating. In theirexisting plant the tap water was soft without much dissolved cal-

cium or magnesium in it. The manufacturer was able to cleanand rinse sheets of glass in a conveyor spray system using tap


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g p p gsolution. The filter flow rates and pressures would not recoverafter cleaning. The solution was to treat with TERG-A-ZYMEenzyme cleaner at moderate temperatures to restore the filters totheir normal flow rates and pressures.


Time 1 hour 1 hour


Agitat ion circulate circulate

Chemist ry high alkaline 1/ 2% TERG-A-ZYM E

Rinse tap w ater tap water

Dry none needed none needed

Problem fouled f ilter membranes

gand rinse sheets of glass in a conveyor spray system using tapwater to rinse prior to air knife drying. When they set up anotherplant in another part of the country they kept getting water spotsbecause the local water at the new plant site was hard water witha lot of dissolved calcium and magnesium in the water. Byswitching to a deionized water rinse at the new plant and by beef-ing up the air knives, spot free drying was achieved.


Time 10 s/ f t 10 s/ f tTemp 55 deg C 55 deg C

Agitat ion spray spray

Chemist ry 1/ 2% DET-O-J ET 1/ 2% DET-O-J ET

Rinse hard tap water deionized water

Dry air knife air

Problem water spots

7. LABORATORY PIPETS FAIL TO DELIVER

INCREASED AGITATION IMPROVES CLEANING

An analytical laboratory had been using volumetric pipets to pre-cisely measure volumes of analytical reagents. When they cali-brated their pipets they found that their old pipets were not asreliable as brand new ones. The problem was traced to incom-

plete cleaning. The old cleaning process involved soaking thepipets in a static soak bath and then rinsing them in a siphon

6. WINE TASTING GLASSES

ELIM INATING D ETERGENT FRAGRANCE RESID UES

The world renowned wine critic Robert Parker observed in hisbook BORDEAUX, I cant begin to tell you how many dinnerparties I have attended where the wonderful, cedary, blackcurrantbouquet of 15- or 20-year-old Pauillac was flawed by the smell of

dishwater detergents... In fact the human palate is very sensitiveto fragrances found in many detergents. A major supplier of wine


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p p g ppipet rinser before air drying. By adding ALCOTABS tablets tothe siphon pipet rinser, a concentration of detergent becameavailable for cleaning during the higher agitation rinse process tocomplete the removal of residues that had been loosened duringsoaking. After the ALCOTAB had completely dissolved in thesiphon rinser, rinse water continues to flow and rinsing iscompleted.

Initial Problem SolutionTime 8 hours 8 hours

Temp ambient ambient

Agitat ion soak soak followed by circulate

Chemist ry lab detergent lab detergent plus ALCOTABS

Rinse DI water DI water

Dry air air

Problem soaking alone could not remove allreagent residues in pipets


g y g j pptasting glasses found that he was able to satisfy the needs of hisdiscerning clientele by suggesting they use free-rinsing, fragrance-free LIQUI-NOX cleaner instead of the depositing fragrance con-taining household dishwashing detergents they had been using.


Time 30 sec 30 sec


Agitat ion manual manual

Chemist ry dish detergent 1% LIQUI-NOX

Rinse tap water tap water

Dry air air

Problem Fragrance residues on w ineglassesinterfered with wine bouquet

APPENDIX VI

IndexA 69 8 93 9 2 3 32


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178 The Aqueous Cleaning Handbook Appendix 179

IndexAAbsorption, 25, 27, 145, 151, 153Acid cleaners, 44, 46, 84, 165Acrylic, 86, 91Activated carbon, 130-132, 135Additives, 9, 12, 15-16, 75ADI carryover, 123

Aggressive, 22-23, 38-39, 42, 46-47, 56, 90, 134-135, 167Agitation, 13, 17, 19-20, 22, 23,

28, 30-31, 34, 38, 39, 43, 52, 54,55, 56, 57, 62, 68, 77, 80, 92,97, 101, 103, 108, 116, 171-177

Air knife, 26, 59, 107, 174Air pollution, 52Air/solution interface, 20, 28, 80Alkaline, vii, 11-13, 14, 16-18, 37,

44-46, 56, 66, 68-69, 80, 82-85,89, 90-94, 107, 137, 139, 158,159, 163, 165-167, 173, 175

Alkaline cleaner, 17, 46, 165Alkaline salt builders, 11Aluminum, 34, 39, 42, 44, 60, 66,

78, 88, 91, 107, 110, 164Aluminum foil, 110Amphoteric surfactant, 10

Analytical method, 119-120, 125-126Anion, 135, 151Anionic surfactant, 9-10, 125,

165, 167Anodized part, 88Anti-redeposition, 9, 15, 20Aquatic toxicity, 157Aqueous, iii, vii-x, 1-2, 4-9, 13-

16, 18-20, 23-25, 27, 31, 39, 41-

44, 46, 48-49, 51, 61-62, 65, 67-

69, 87-93, 95, 127, 131-132,134, 138-139, 151, 153, 155-160, 165-166, 168

Aqueous cleaner, ii i, vii, ix-x, 1-2,4, 6-9, 13-16, 19-20, 27, 41, 46,48-49 51, 61-62, 67-68, 87-91,93, 95, 127, 155-160, 165-166,168

ASTM, 142, 145, 153Atomic absorption (AA), 145Atomizer, 141, 143, 146Automatic syphon washing, 81

BBatch cleaning, 35, 78Bath dumping, 46Bath life, 14, 34, 37, 130, 135,

172Bench-scale, 54, 57-60, 63Bench-scale testing, 57-60Bioburden, 122, 124, 165Biodegradable, 14, 45, 48, 156-

157Biotechnology, 78, 128Blender, 71Blood, 65-66, 78, 80, 83, 164Blood-born pathogens, 66Blow-drying, 26BOD, 129, 131, 162Body fluids, 65-66, 78, 80, 164Builder, vii, 1, 9, 11-12, 14, 135,

165-167

CCalcium, 6, 11-13, 15, 24, 32,

135, 166, 168, 174

Carbon, 3-4, 86, 121, 124-126,


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Terpene, 3, 5Test, 51, 54, 59-61, 119, 141, 144,

148Test acceptance limit, 119Test cleaning, 51, 54, 61Test soil, 51, 60Test substrate, 51, 59Testing, 19, 54-55, 57-62, 68, 82-

83, 86, 113, 120, 122, 145-146Testing iii vi 51 113 153

VVacuum drying, 25, 33, 39Vapor degreasers, 5Vesication, 86Visual inspection, 54, 61, 141-

142, 144VOC, v, 4, 8, 45, 162

VOCs, 3-4, 41Volatile, v, ix, 2-4, 8, 41, 44-45,48 52 59 61 91 156 158 159


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Testing, iii, vi, 51, 113, 153Time, vii, x, 12, 17, 19, 22-23, 25,

28, 31, 34-35, 38-39, 43, 46-47,52, 54-57, 61-63, 71, 73, 75, 77,80, 89, 97, 99-100, 105, 110-111, 114, 116-117, 124, 132,139, 147-149, 152, 156-157,171-177

Titration, 27, 37, 121, 125-126Total alkalinity, 135Toxicity, 47, 52, 82, 88, 120, 122,

127, 138, 157Trace analysis, 82, 144-145Trace metals, 80, 82, 164

UUltrafiltration, 18, 114, 133-135Ultrasonic, 12-13, 20, 22, 29-32,

34-36, 44, 57, 66-68, 78, 80-83,85, 88, 90-92, 97, 104, 106-108,110, 146-147, 163-164, 171

Ultrasonic cleaning, 20, 22, 29,35, 57, 67, 78, 81, 91, 97, 104,106-107, 110, 147

Ultrasonically agitated rinsing,23

USP, 111, 125UV, v, 121, 126, 131, 141, 143,

145, 151, 162, 169UV spectroscopy, 121

48, 52, 59, 61, 91, 156, 158-159,162, 164, 168

WWash cycle, 29, 72, 81, 111Waste treatment, 52, 94,175Waste-treatment filtration, 94Wastewater treatment, iv, 129,

130, 131Water break, 141-143, 146Water drop surface energy test,

148Water testing, 82Wax melting points, 61Waxy or oily soils, 22Wetting, 1, 9, 11, 13-14, 20, 43,

56, 90, 150, 153, 169

Wetting agent, 1, 9, 11, 169WFI, 68, 74, 79, 111, 121White residue, 86-87Wiping and visual inspecting,

141, 142Worker safety, 41, 52, 158, 160

ZZero-discharge, 156


Cleaning Handbook 3rd Edition

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