Q1. Can we provide a weaker concentrate for the cleaning material?
A1. The standard concentration of cleaning medium is 10% solution. Using lower concentrations will negatively affect the cleaning efficiency. The concentration gradually falls as the medium is being used for cleaning. If it falls below 7%, the cleaning time increases significantly. To identify how much concentration has been used, we measure medium conductivity. (SEE Q & A 9 FOR MEASURING MEDIUM CONDUCTIVITY.) A client can measure the conductivity and define what concentration is still available in the tank. If it falls, below 7%, we recommend adding more cleaning medium to increase concentration back to 10%. 1% equals 1kg of cleaning powder. To honor the machine warranty only DME approved and recommended cleaning mediums should be considered. DS1 and DS2 are currently offered. Visit our e-Store for additional information.
Q2. What calibration requirements are there for the fluid flow measurements and is it NIST traceable?
A2. The flow measurement is for reference point only, it is not NIST traceable. The flow meter is internally certified by its manufacturer.
Q3. Other solutions are not recommended to be left in the holding tank due to their caustic nature. Does this hold true for DS1 or DS2?
A3. The tanks are made of polyethylene, material highly resistant to acids. The hydraulics are made of high-grade stainless steel. It is ok to keep the DS1 or DS2 10% solution in the tank (this is what they are made for).
Q4. Does DME offer medium for the neutralization process?
A4. The neutralization process is not directly associated with the CoolingCare unit, and because of its caustic nature, and varying legislation regarding post processed waste removal, DME has decided not to offer Sodium Hydroxide (N10) for the neutralization process. It was determined that most companies choose not to neutralize their waste, as it is time consuming and the cost savings may not be significant.
Q5. Can you explain the neutralization process using Sodium Hydroxide (N10)?
A5. Sodium Hydroxide is not a cleaning medium. It is used for neutralization of the post processed cleaning medium waste. Sodium Hydroxide is caustic medium that neutralizes the acid to neutral pH value. The standard pH value of the post processed waste will be low, approx. 1.1 pH. In order to increase the pH value to neutral, water like pH, it is necessary to add some product with high pH, in our case Sodium Hydroxide. Normally it will take approximately 2-3 kg of Sodium Hydroxide to neutralize the pH of 100L tank. The neutralization process should never be carried out in the machine, as the reaction causes quick temperature increase. It is important to let the cleaning medium cool down before adding Sodium Hydroxide. If we add Sodium Hydroxide to cleaning medium that has a temperature of 50 degrees Celsius, it will easily go up to 80 degrees Celsius in a matter of minutes.
It is important to note that even if the cleaning medium is neutralized to water-like pH, it is still not allowed to put it down the drain. The client must find an external company that will collect the waste and utilize it. The only difference is, in most cases the neutral waste will be cheaper to collect compared to the medium with low pH value. It is worth mentioning though, most companies decide not to neutralize their waste despite higher utilization costs, mostly because it is time consuming.
Q6. Is the neutralizer required to use with the solutions DS1/DS2?
A6. It is not required and has no bearing on the CoolingCare Machine function or efficiency. This is a customer specified process. Neutralization is a process where low, acid-based pH value is increased to neutral value, 6, 5 pH. It does not, however, allow to put the waste down the drain. It is recommended to have a dedicated company collect the post processed waste and dispose it in accordance with local regulations. The pH value of the waste may affect its price. Waste with neutral pH is cheaper to dispose of than the same waste with low pH.
Q7. Is the neutralizer used for disposal or just to provide neutralization to the cleaning lines after the process?
A7. See above. The cleaning lines are rinsed with water (coming either from diagnostics tank or mains water connection). The leftovers of cleaning medium are flushed away so that the pH value in the cooling lines is neutral at the end of the process. Clients can add corrosion inhibitors to water in the diagnostics tank for some additional protection of channels (this only makes sense if the mold is not used for production immediately after the cleaning process)
Q8. We needed some guidance about usage for the media, so we can help customers determine how much to order?
A8. The average yearly consumption is approx. 350 – 400kg per company with one machine, assuming they exchange the cleaning medium once a week. Intensive cleaning will require exchange of cleaning medium on a weekly basis. Please remember these values refer to DS1 and DS2 media. Amount will vary depending on the number of CoolingCare units in house, the number of molds and channels being cleaned, the frequency of cleaning (PM program), and severity of contamination.
Q9. Are there strips to determine if the media is still good, or if past its life expectancy, or expired?
A9. The machine is provided with a manual device for conductivity measurement. We are currently working on a module with a conductivity probe built-in the machine for automatic measurement and feedback on the cleaning medium condition. This is currently being tested and should be available in a few months’ time. This will be additional, payable option. (SEE ADDITIONAL INFORMATION Q AND A 1)
Q10. Could the media be left in the container, or does it need to be cleaned out after each use?
A10. It can be left in the container; however, it is important to keep the temperature in the container above 20 degrees of Celsius. In lower temperatures the re-crystallization process may occur, where crystal structures grow on internal elements in the tank (heater, floaters, etc.). If a longer machine downtime is planned (e.g. holidays), the container should be emptied, cleaned and filled with water. Machine self-rinsing should then be performed (machine function). If the machine is stopped for the weekend, it is not necessary to remove the medium.
Q11. Is there a media that would be suited for 90% of the applications?
A11. Experience shows in most cases companies have high iron content in water. Many companies try to control the level of calcium and magnesium (water hardness), so the situation where pure calcium carbonate scale is rather rare. In most cases DS1 should be a good choice. It is based on oxalic acid, which is capable of dissolving corrosion-based deposits with ease.
Q12. What type of hose is recommended?
A12. DME has accessory kits that provides the necessary hose and fittings. DME has received vendor approval for the hose provided in our accessory kit. DME uses red and blue Push Lok hose. Temperature range, -40-212F (air 150 degrees, water 180). This brand name hose can be used with anti-freeze, water, air, gasoline, diesel and lubrication oils. We recommend hoses that are made of materials resistant to aggressive agents. They should also be thick and resistant to grinding against some sharp edges (e.g. tables, palettes). There is a lot of hose movement involved when the machine is working in pulsation mode.
Q13. Can the media be stored in a metal 55 gallon drum while waiting for pickup or in storage?
A13. No, the media must be stored in plastic drum or container.
Q14. Can plastic baffles be cleaned using the CoolingCare unit?
A14. No, the manufacture does not recommend the use of the CoolingCare unit if plastic baffles are in the mold.