In the rail industry, efficient and sustainable maintenance practices are critical to promoting safety, operational excellence, and cost-effectiveness. Ensuring tools, parts and machinery are cleaned and well maintained ultimately keeps trains running on time and on track - quite literally. Some of the simplest, most mundane processes can have a cumulatively detrimental effect on an organisation's costs, environmental impact and health and safety.
Traditional cleaning and maintenance methods in the rail sector have often involved hazardous chemicals, high energy consumption, high water consumption and time-intensive processes.
Solvent-based parts washers have been used to clean small to mid-sized components such as gears, motors, axels, engines, bogie parts, and other mechanical systems because they achieve quick results.
However, solvent-based parts washers use chemical solvents to dissolve grease, oils, and other contaminants from metal surfaces, which come with significant risks:
Health and Safety Risks:
Toxic Fumes: The solvents emit VOCs that can be hazardous when inhaled by maintenance personnel, increasing the risk of respiratory and skin problems.
Flammability: Many solvents are highly flammable, posing a fire hazard in workshops.
Environmental Concerns:
Hazardous Waste: Spent solvents must be stored and disposed of as hazardous waste, contributing to environmental pollution. This incurs hidden costs of specialist storage & handling, transportation, training and compliance.
Air Pollution: VOC emissions contribute to air quality degradation and regulatory non-compliance.
Operational Inefficiencies:
Frequent Replacement: Solvents degrade over time, requiring frequent replacement, which increases downtime and costs.
High Energy Use: Some systems require heating solvents to enhance cleaning power, consuming additional energy.
Damage to Components:
Corrosion Risk: Prolonged exposure to aggressive solvents can corrode or weaken sensitive metal components.
Residue Issues: Improper rinsing can leave behind solvent residue, affecting the performance of parts.
Larger pieces of machinery are blasted with 1000's of litres of water, an unsustainable and inefficient method.
Solvents-based parts washers and pressure washers have been a staple in the rail industry for years, but their drawbacks underscore the need for alternatives that can eliminate many of the challenges associated with them, while ensuring superior cleaning performance.
Efficiency Through Process Optimisation
BIO-CIRCLE’s approach addresses these challenges head-on, with advanced systems that simplify and accelerate maintenance tasks. For instance, the BIO-CIRCLE GT Maxi parts cleaner is a game-changer for rail workshops. Its ergonomic design and integrated filtration system allow for efficient manual cleaning of small to mid-size parts and components, such as bearings, gears, axels and motors.
By integrating clever cleaning systems and solutions into their workflows, rail operators can:
Streamline Cleaning Tasks - reduce time spent on manual scrubbing and rinsing
Enhance Worker Safety - use in combination with non-toxic, VOC-free and skin-friendly cleaning solutions such as CB 100 that eliminate exposure to harmful chemicals
Lower Operational Costs - minimise water and energy consumption with systems that operate efficiently at lower temperatures
Lower Cleaning Temperatures, Same Superior Results
One of the standout features of our parts cleaning systems is their ability to deliver exceptional results at reduced cleaning temperatures. This is made possible by the advanced microbial cleaning liquids, such as BIO-CIRCLE L Evo, CB 100, ALUSTAR 500 and the UNO family of liquids that are all VOC-free or VOC-reduced, and based on renewable raw materials. They work to break down oils, grease, and contaminants effectively without requiring excessive heat or using hazardous chemicals.
Lower cleaning temperatures translates to:
Energy Savings: A significant reduction in energy consumption compared to traditional high-temperature cleaning methods.
Prolonged Equipment Life: Reduced thermal stress on sensitive parts and cleaning equipment.
Improved Working Conditions: Cooler operating environments for maintenance staff.
On average, BIO-CIRCLE cleaning systems achieve a better clean 30° lower when compared to other automated parts washers.
Extended Bath Life for Continuous Use
Bath longevity is a crucial factor in rail maintenance cleaning processes. Frequent changes of cleaning baths can disrupt operations and lead to increased costs. Our cleaning systems address this with self-cleaning liquids powered by natural microorganisms. These microorganisms continuously break down contaminants, extending the effective lifespan of cleaning baths.
For example, the CLEANBOX Flex cleaning platform is ideal for cleaning large components like bogies and frames. Its self-cleaning solution ensures longer intervals between bath replacements, boosting productivity and reducing waste. Rail operators benefit from:
Reduced Maintenance Downtime - less frequent interruptions to change cleaning solutions.
Lower Environmental Impact - decreased disposal of used cleaning liquids.
Cost Savings - fewer replacements mean reduced operational expenses.
Applications in Rail Maintenance
Overall Parts Cleaning
BIO-CIRCLE parts cleaning systems, such as the BIO-CIRCLE GT, the BIO-CIRCLE Turbo and the HTW excel in degreasing and cleaning small to medium-sized components. These systems are indispensable for maintenance teams handling gears, axles & motors, as well as more intricate mechanical parts.
Bogie Cleaning
Cleaning bogies is a demanding task that requires robust equipment capable of handling heavy-duty contaminants. The CLEANBOX Flex system’s high-capacity design and efficient cleaning liquids are ideal for cleaning down larger pieces of machinery, with Water Resources Act approved integrated collection tray that prevents contaminated water run off.
Another option for larger parts and machinery is to simply replace high-pressure washers with our foam-based cleaners that sit and cling to the surfaces, gently biodegrading the grease, oil and dirt so it can easily be removed.
Gears & Motors
Precision cleaning of gears and motors is vital for optimal performance. Our systems ensure that these components are free from grease, oil, and dirt, reducing wear and tear and prolonging the life of these expensive parts, while enhancing functionality.
Paint tools & equipment
PROLAQ, a specialist system specifically for cleaning paint & inks from components, tools and machinery is designed to overcome the challenges of cleaning paint tools and managing paint contamination, without relying on solvents and cold cleaners.
PROLAQ uses water-based cleaning liquids with minimal volatile organic compounds (VOCs), making it a safer alternative for workers and the environment. Unlike solvents, PROLAQ solutions do not produce hazardous fumes, reducing health risks for maintenance teams. PROLAQ’s advanced filtration system continuously removes contaminants from the cleaning liquid. This extends the life of the solution, minimising waste and reducing the frequency of replacements, whilst giving consistently good cleaning results. In contrast, the effectiveness of solvents declines with every use as the solvent becomes loaded with contaminants.
Strategic Maintenance: Enhancing Lifespan of Equipment
BIO-CIRCLE surface technology cleaning systems and liquids contribute to strategic maintenance initiatives by promoting proactive care of tools and machinery, rather than replacing old with new. The use of our low environmental impact cleaning systems and effective cleaning solutions minimises abrasive wear on parts, reduces corrosion risks, and improves overall reliability. Over time, this results in:
Extended Component Lifespans - well-maintained parts operate longer and more efficiently.
Reduced Downtime - fewer breakdowns and emergency repairs.
Cost Efficiency - optimised resource utilisation and lower replacement costs.
Sustainability and Compliance
With stringent environmental regulations becoming the norm, the rail industry must adopt greener practices. BIO-CIRCLE’s water-based, VOC-free cleaning solutions align perfectly with these goals. By replacing traditional solvents with biodegradable options, rail operators can significantly reduce their environmental footprint while maintaining compliance with regulatory standards.
Conclusion
BIO-CIRCLE cleaning systems and liquids are revolutionising rail maintenance by delivering cleaner, safer, and more efficient solutions. From reducing cleaning temperatures to extending bath life and supporting strategic maintenance, these technologies empower rail operators to optimise their processes while embracing sustainability. As the rail industry continues to modernise, BIO-CIRCLE stands at the forefront, driving innovation and excellence in cleaning and maintenance prrocesses.
Are you ready to transform your rail maintenance operations? Explore the full range of BIO-CIRCLE systems and see the difference they can make.
Comentarios