In the competitive and highly precise world of aerospace manufacturing, cleanliness, and operational efficiency are of paramount importance. Three different aerospace manufacturers approached Brulin’s team of trusted parts cleaning advisors because they recognized the chemistries they were using weren’t achieving the level of cleanliness they needed to provide.
Previously, these manufacturers relied on Ardrox 6333A, CEE BEE A-7X7, and Mirachem 500 for their cleaning needs. After they identified the problems they faced using these chemistries, they asked our team about the transformative impacts of the AquaVantage® 3887 GD.
Post-transition to AquaVantage® 3887 GD, they realized significant improvements in efficiency, performance, and cost savings. Here’s how we helped them navigate each of their unique situations.
The first customer, a renowned aerospace manufacturer, switched to AquaVantage® 3887 GD for immersion cleaning of maintenance, repair, and overhaul (MRO) engine parts. Previously, they relied on Ardrox 6333A.
This strategic shift was necessitated by their desire for operational improvements, better efficiency, and a healthier work environment.
Before the transition, the manufacturer relied on Ardrox 6333A for their cleaning needs. While this product had served its purpose, the manufacturer was noticing its limitations, particularly in relation to tank lifespan, cleaning effectiveness, and a time-consuming process of pH adjustments.
Additionally, the handling of magnesium parts, known for their susceptibility to corrosion, required isolation — a separate and inefficient procedure that slowed down the overall cleaning process. Furthermore, the strong odor produced during cleaning was a significant concern for the manufacturer, affecting the work environment and the comfort of the operators.
With the transition, the manufacturer noted immediate improvements. One of the first notable improvements was in the rinsing process.
Using AquaVantage® 3887 GD allowed for easier and better rinsing throughout the tank’s life. This not only improved the quality of the cleaned parts but also enhanced the operational flow by reducing time spent on repeated rinsing.
The tank lifespan, a critical factor in operational efficiency and cost-effectiveness, also saw substantial improvements. The tank life extended to over 12 months, double the approximately 6 months lifespan observed with using the previous product. This longevity meant less frequent tank replacements and, subsequently, lower operational costs and disruptions.
Switching to AquaVantage® 3887 GD also eliminated the need for frequent pH adjustments and effectively cleaned magnesium without corrosion, an issue that previously necessitated isolation. A notable reduction in odor was an additional benefit of the transition to AquaVantage® 3887 GD.
By no longer having to make frequent pH adjustments, a previously time-consuming process, operational efficiency improved, and the manufacturer was able to reduce labor costs.
The second customer, another leader in aerospace manufacturing, encountered a major challenge in their maintenance, repair, and overhaul (MRO) operations — the spray wash cleaning of engine parts, specifically the exhaust casings on the Rolls-Royce Pegasus engines.
The complexity and precision required in the cleaning process often resulted in lengthy cleaning cycles. This included exhaustive labor and time-intensive hand scrubbing, making the overall cleaning procedure burdensome.
The previously used Ardrox 6333A had certain limitations for the manufacturer, especially concerning cleaning efficiency and cost-effectiveness. Cleaning processes often extended up to 1.5 hours, significantly slowing down the overall MRO process and adding labor costs.
The manufacturer noted that Ardrox 6333A struggled to effectively remove carbon deposits unless used at a high concentration, leading to increased product usage and associated costs. Additionally, the manufacturer frequently grappled with filter clogging, reducing the effectiveness of the filtration process and often necessitating replacement or extensive maintenance.
Recognizing these operational challenges, the manufacturer sought a solution that could improve cleaning efficiency, reduce labor and time requirements, and enhance cost-effectiveness. The answer was found in AquaVantage® 3887 GD.
Upon making the switch to AquaVantage® 3887 GD, the manufacturer observed a remarkable improvement in their spray wash cleaning processes.
The most noticeable change was the drastic reduction in cleaning time. Laborious processes that previously lasted 1.5 hours were cut down to a mere 15 minutes, a fraction of the original time. This not only improved the efficiency of the cleaning operation but also led to significant labor cost savings.
Moreover, AquaVantage® 3887 GD showcased its efficacy by effectively removing stubborn carbon deposits at only a 5% concentration and a temperature of 180°F. The reduced concentration required for cleaning meant less product usage and, consequently, lower product costs.
The transition to AquaVantage® 3887 GD also brought significant improvements to the filtration process. The manufacturer noticed an absence of filter clogging, a previously persistent issue, leading to improved particulate removal and reduced filter maintenance or replacement requirements.
Making the switch demonstrated a clear edge of AquaVantage® 3887 GD over their previous usage of Ardrox 6333A, substantiating its cost-effectiveness.
The third customer, a key player in the aerospace industry, faced significant challenges with the immersion cleaning of Pratt & Whitney JT8D engine parts. Their previous cleaning agents, CEE BEE A-7X7 and Mirachem 500, were unable to meet their evolving needs. Despite their widespread use in the industry, these cleaning solutions posed several problems for this particular aersopace manufacturer.
First, their tank life was less than four months, leading to frequent tank replacements and associated costs. Second, the cleaning solutions required a high concentration, increasing the expense. In addition, these solutions were not as effective as the manufacturer needed, leading to an increase in rework due to inadequate cleaning and subsequent delays in throughput.
Compounding these issues was corrosion. This manufacturer experienced corrosion that led to damage to the tank elements, resulting in additional costs for repair and replacement. These solutions were also unable to clean all engine materials efficiently, particularly magnesium, leading to increased workload and lower productivity.
Lastly, both solutions caused skin defatting and had a strong odor, creating a less-than-ideal work environment for the customer and their employees.
The search for a more effective and efficient cleaning solution led the aerospace manufacturer to AquaVantage® 3887 GD. Upon making the transition, the company immediately noticed a significant improvement in several areas.
The lifespan of the tank drastically improved, extending to 12 months from the previous 4-month cycle with CEE BEE A-7X7 and Mirachem 500. This tripling of the tank life led to a decrease in the frequency of tank replacements and associated costs, contributing to higher operational efficiency and cost savings.
AquaVantage® 3887 GD also required only half the concentration of the previous products to achieve superior parts cleaning. This lighter dilution translated to lower product consumption and a decrease in overall operational expenses.
Furthermore, the effectiveness of the switch led to a reduction in rework due to better cleaning. This improved cleaning resulted in increased throughput, boosting productivity and reducing delays in the MRO process.
Another significant advantage of AquaVantage® 3887 GD was its less corrosive nature, which preserved the tank elements and extended their lifespan. This characteristic further contributed to cost savings by reducing the need for frequent repairs or replacements.
In addition, AquaVantage® 3887 GD demonstrated the broad material compatibility they needed for their cleaning process. The aqueous detergent is capable of efficiently cleaning virtually all engine materials, including magnesium, which was previously a challenge with the older solutions. This feature increased the cleaning process’s efficiency and speed, enabling higher productivity.
Finally, and perhaps most importantly, AquaVantage® 3887 GD proved to be a more worker-friendly option. The new cleaning solution caused less defatting to the skin, reducing the risk of skin irritation for the operators. Moreover, it produced significantly less odor than the previous products, benefiting the manufacturer’s overall work environment.
The experience of these three aerospace manufacturers demonstrates the significant potential of AquaVantage® 3887 GD to transform operational practices in the sector. The customer satisfaction resulting from the transition serves as a strong testament to the product’s, and our dedicated team’s, exceptional quality and performance capabilities.
By working with Brulin’s team of trusted parts cleaning advisors and switching to AquaVantage® 3887 GD, these manufacturers experienced numerous benefits. Together, we were able to bring them improved efficiency, enhanced performance, better material compatibility, and considerable cost savings.