Performance

When evaluating the total cost of ownership of a cleaning system, it is essential to quantify the throughput in terms of parts processed per unit time. Assuming equal purchase cost, a system that processes twice as many parts per hour effectively reduces the cost per part by half. Not all cleaning systems are interchangeable. In open-top degreasers, vapor collapse occurs when parts are introduced, causing a delay as the system waits for heaters to regenerate vapor, resulting in minimal cleaning during this phase. Vacuum vapor degreasers supply vapor rapidly, enabling internal and external flushing of parts within seconds, thereby significantly reducing actual vapor contact time.

After draining in an open-top degreaser, parts are transferred into the dwell area for drying, which typically takes longer than in closed, vacuum-assisted drying systems. Operators determine when parts are sufficiently dry in the dwell zone, whereas closed systems utilize vacuum drying, allowing for immediate readiness for subsequent batches.

For processes requiring immersion, open-top degreasers can match the throughput of airless systems, given that submersion and transfer to the vapor phase require only one to two minutes. Conversely, automated airless systems facilitate rapid transfer of liquids and vapor cycles, eliminating operator-dependent steps and ensuring cycle-to-cycle consistency.

Many process modalities—such as immersion, ultrasonic agitation, superheating, drying, heated immersion, and clean immersion—are compatible with airless systems. Additionally, process sequences can be combined; for example, alternating cool spray or vacuum drying can cool parts between vapor degreasing cycles.

Complete chamber and part drying enable subsequent treatments like passivation or sterilization. Theoretical throughput of vacuum vapor degreasers often exceeds that of open-top systems by more than 200%. Cost comparisons should include throughput capacity, as higher efficiency can lead to substantial cost reductions.

For instance, a field-deployed system transitioned from an open-top vapor degreaser (OTVD) to a VPS Vacuum Cycling Nucleation (VCN) unit. Processing a large component, the OTVD requires approximately 1 hour per cycle, often necessitating a secondary cleaning to meet brazing quality standards. The VCN system reduces cycle time to 25 minutes by employing a sequence of vapor degreasing, VCN-assisted soaking, a supplementary vapor phase, and vacuum- and heated-circulation drying. This results in a four- to eightfold increase in throughput with a purchase price under $300,000. Consequently, the effective throughput cost ranges from $38,000 to $75,000, depending on cycle efficiency.

See COSTS for additional savings achievable through vacuum vapor degreasing. When evaluating all operational and capital costs, the VCN system offers immediate and significant economic advantages.