Is your cleaning process as efficient as you think it is?

Your PCBs come out of the cleaning machine spotless. Quality inspections show no issues, and production is running according to plan. At first glance, everything seems to be under control.

But does a clean end result automatically mean your cleaning process is fully optimised?

Not necessarily.

Many manufacturers assess their cleaning process based on visible results or the purchase price of the cleaning agent. In reality, the greatest opportunities for improvement often lie in less obvious factors such as energy consumption, operating temperature, maintenance, process settings and cleaning bath lifetime.

By periodically reviewing the entire cleaning process, you can often reduce costs while improving production reliability, without making major investments.

A clean result doesn’t tell the whole story

The purpose of a cleaning process is straightforward: to remove flux residues, dust and other contaminants so that the PCB continues to perform reliably.

However, an effective cleaning process is about much more than producing a clean board.

Ask yourself questions such as:

• Is the system consuming more energy than necessary?
• Is the cleaning bath being replaced at the right time?
• Are the process settings still matched to the products currently being manufactured?
• Could the same cleaning performance be achieved more efficiently?

These are the questions that ultimately determine the profitability of your production process.

Look beyond the purchase price of the cleaning agent

When selecting a cleaning agent, many companies focus primarily on the price per litre. While understandable, this provides only part of the picture.

The total cost of a cleaning process depends on many factors, including:

• energy consumption;
• water consumption;
• maintenance;
• cleaning bath lifetime;
• maintenance-related downtime;
• equipment productivity.

A cleaning agent that appears more expensive initially may significantly extend bath lifetime or reduce energy consumption. In that case, the overall operating cost may actually be lower.

That’s why it pays to evaluate the complete process rather than focusing on a single cost factor.

Temperature: higher isn’t always better

One of the most common misconceptions is that higher cleaning temperatures automatically deliver better cleaning results.

In reality, the optimum temperature depends on several factors, including the type of flux, the cleaning agent and the nature of the contamination.

Thanks to advances in modern cleaning chemistry, many applications can now be cleaned effectively at lower operating temperatures. This offers several potential benefits:

• lower energy consumption;
• reduced stress on the equipment;
• longer cleaning bath lifetime;
• a more stable cleaning process.

This doesn’t mean that lower temperatures are always the best choice. It does mean that existing process settings should be reviewed regularly.

Small adjustments can make a big difference

Optimising your cleaning process doesn’t necessarily require investing in new equipment.

In many cases, relatively small adjustments can deliver significant improvements.

For example:

• re-evaluating the cleaning temperature;
• optimising the cleaning cycle;
• monitoring cleaning bath quality;
• selecting the most suitable cleaning agent for the application;
• periodically reviewing process parameters.

When these factors are properly aligned, you not only improve process efficiency but also achieve more consistent cleaning quality.

How do you know if your process is still optimised?

A simple way to assess your current situation is to ask yourself a few critical questions.

• Is the cleaning process temperature reviewed on a regular basis?
• Do you look beyond the purchase price of the cleaning agent?
• Do you know how much energy your cleaning process consumes?
• Are your process settings still aligned with your current production requirements?
• Is cleaning bath quality monitored systematically?

If you’re unable to answer several of these questions with confidence, it’s probably time to take another close look at your cleaning process.

Efficient cleaning means continuous improvement

A cleaning process is never static. Products change, production volumes evolve, and cleaning technology continues to advance.

That’s why it’s important to review your process periodically and determine whether your current settings are still the best choice. Even small improvements can have a significant long-term impact on energy consumption, operating costs and process stability.

Conclusion

An efficient cleaning process is about much more than producing a clean PCB. It’s about finding the right balance between quality, reliability and cost efficiency.

By looking beyond the purchase price of a cleaning agent and regularly evaluating the complete process, manufacturers can often achieve greater savings and performance improvements than they initially expect.

At Smans, we believe that an optimised cleaning process starts with the right knowledge and the right technology. That’s why we help manufacturers not only select the most suitable cleaning solution but also optimise the entire cleaning process. We do this in close collaboration with our partner, KOLB Cleaning Technology, a leading specialist in industrial cleaning solutions.

Wondering how much you could improve your cleaning process? Get in touch with our specialists. Together, we’ll identify opportunities to improve cleaning quality, increase process efficiency and reduce the total cost of cleaning.