MicroCare, LLC

Elizabeth Norwood is a Senior Chemist at MicroCare, LLC, which offers precision cleaning solutions. She has been in the industry for more than 25 years and holds a BS in Chemistry from the University of St. Joseph. Norwood researches, develops and tests cleaning-related products. She currently has one patent issued and two pending for her work.

Environmental legislation continues to shape the development of specialty cleaning fluids. As requirements around solvent use, emissions and worker safety evolve, fluid manufacturers must develop formulations that address environmental and workplace considerations while retaining the cleaning performance required by industrial processes.

The previous move away from some legacy solvents shows how regulations have influenced cleaning chemistry. Trichloroethylene (TCE) and n-propyl bromide (nPB), for example, had long been classified as Substances of Very High Concern and were subject to authorization under EU and UK REACH. Perchloroethylene (PERC) also carried classification and workplace exposure controls.

These are established examples rather than new developments. However, they demonstrate why fluid manufacturers and industrial users must remain alert to further changes. Cleaning fluids are often integral to controlled or validated production processes, so replacing an established chemistry can require considerable preparation.

The cleaning fluid that takes its place should not only meet the new regulatory requirement. It must remove contamination, remain compatible with the materials being cleaned and provide consistent results without reducing throughput or affecting subsequent production stages.

Developing New Formulations

Legacy fluids became widely used because they combined effective solvency with fast drying and reliable process performance. Replacing them means maintaining the advantages while meeting the current and future regulatory requirements.

Modern cleaning fluids may offer low global warming potential, zero ozone depletion and nonflammability for safety, but they still must remove soils from machined metal parts, electronic assemblies and medical devices without damaging the substrate.

Fluid manufacturers must therefore understand how the chemistry will behave in use. Solvency, surface tension, drying behavior, material compatibility and stability within the cleaning system all contribute to its overall suitability.

Chemistry to Match the Application

Precision cleaning fluids, when used inside a vapor degreaser, are used to remove contaminants including heavy cutting oils, light assembly lubricants, grease, wax, flux residues, fingerprints and particulates. These contaminants have distinct characteristics and may require different levels of solvency, which means there is no universal replacement for every established cleaning fluid.

The component materials must also be considered. Aluminum, steel, titanium and specialist alloys may respond differently to cleaning fluids, while composites and other sensitive materials can require careful evaluation. The objective is to remove the target contamination without causing an unwanted surface reaction or change in appearance.

Part geometry complicates things further. Low surface tension allows cleaning fluids to enter blind holes, internal channels, tight spaces and intricate features. Components with complex geometries may also require adjusted cycle times, specialized fixturing or additional mechanical action to achieve consistent cleaning.

The required level of cleanliness will often be determined by the next production stage. Components being prepared for coating, bonding, anodizing or soldering may have exceptionally low tolerance for residual contamination. Even tiny amounts of oil or other residue can affect adhesion, surface finish or product reliability.

For this reason, replacement chemistry must be selected for the complete application rather than just randomly chosen from a list of regulation approved fluids.

Azeotropic and Cosolvent Options

Azeotropic fluids are well suited to heated cleaning applications such as vapor degreasing because they maintain a consistent composition through repeated boiling and condensation cycles. They can also balance solvency, boiling point, surface tension, flammability and drying characteristics in ways that may be difficult to achieve with a single solvent.

Replacement chemistry must be selected for the complete application rather than just randomly chosen from a list of regulation approved fluids.

Co-solvent cleaning offers another choice for difficult soils, pairing a higher-solvency fluid to dissolve stubborn contamination with a second fluid for rinsing and drying.

Process Considerations

The cleaning equipment and operating process are also part of fluid selection. Many modern cleaning fluids can be used in existing vapor degreasers with minimal modification, helping manufacturers introduce an alternative without replacing the entire system. Compatibility must nevertheless be confirmed before any change is made.

Modern fluids are chemically stable and recyclable within closed-loop vapor degreasing systems. During operation, the cleaning fluid can be recovered, distilled and reused, extending fluid life and reducing consumption and waste.

Safety Data Sheets and regulatory documentation are essential when assessing any formulation. Descriptions such as “safe” or “environmentally friendly” should not replace a detailed review of the fluid’s classification, handling requirements and suitability for its intended use.

Testing and Collaboration

Preparing for regulatory change means identifying potential alternatives and understanding what would be required to introduce them into an established process.

Laboratory trials using representative components and production contaminants can assess cleaning performance, material compatibility and the resulting cleanliness. This work can also help define parameters such as vapor temperature, cycle duration, rinsing and drying requirements. Production trials then establish whether the formulation can deliver repeatable results without affecting throughput or subsequent processes.

Compatibility information, trial results, Safety Data Sheets and technical documentation provide the evidence needed to support validation and update operating procedures.

Collaboration between the cleaning fluid manufacturer and industrial user is important throughout this process. By considering the contamination, materials, equipment and required outcome together, they can develop and test an application-specific solution.

Regulatory requirements will continue to influence specialty cleaning chemistry. Assessing alternatives before a change becomes necessary gives manufacturers time to validate a new fluid properly, helping them meet evolving requirements without compromising cleaning quality or process performance.

Image Notes:

1.Vapor Degreasing: Many modern cleaning fluids can be used in existing vapor degreasers with minimal modification.

2. Change: Changing environmental regulations are driving new cleaning formulations.

3. Lab Testing: Lab cleaning trials help confirm cleaning performance.