ActOn Case Studies
Reconditioning turbochargers involves a complex process where thorough cleaning is essential to restore components to like-new condition. Residues like carbon deposits, rust, and grease must be removed efficiently to ensure optimal performance. BRIO Ultrasonics designed a specialised solution for this challenge: the BR-450 MS ultrasonic industrial cleaning machine. This case study explores how this ultrasonic cleaning system was implemented to meet the needs of a leading European turbocharger remanufacturer.
The client, a prominent player in the European automotive remanufacturing sector, sought a solution to streamline and optimise its cleaning process for turbocharger parts. Traditional cleaning methods often proved insufficient in removing deep-seated contaminants, such as burnt carbon and grease, from delicate turbocharger components. Additionally, they were looking for a system that could handle high volumes, improve process speed, and meet rigorous environmental standards regarding water and energy consumption.
Recognising the need for a more efficient, eco-friendly, and automated cleaning process, the client turned to BRIO for an advanced ultrasonic industrial cleaning solution.
To meet these specific demands, a highly customised ultrasonic cleaning system was designed around the BR-450 MS model. The solution featured nine separate stages, enabling comprehensive cleaning and finishing turbochargers in a single integrated process.
Key stages included:
The system is equipped with several automated features, such as:
The BR-450 MS also integrates energy-saving technologies, such as the ability to reuse water across different stages, making it both cost-effective and environmentally responsible
At the heart of the solution is the BR-450 MS, a multi-stage ultrasonic industrial cleaning machine that uses high-frequency sound waves to create cavitation bubbles. These bubbles remove contaminants from even the most intricate and hard-to-reach parts of turbocharger assemblies.
This model includes nine large 450-liter tanks, each serving a different purpose in the cleaning and treatment process. The size of these tanks allows the system to handle multiple turbocharger components in a single batch, reducing downtime and increasing throughput. Custom-designed baskets are used to hold parts in place during the process, ensuring that they receive uniform cleaning.
In addition, the BR-450 MS integrates a number of advanced features for enhanced performance:
The implementation of the BR-450 MS machine delivered significant improvements in both cleaning quality and operational efficiency for the client.
Cleaning Performance: turbocharger components were cleaned to an exceptional standard, free from carbon deposits, rust, and grease. The pickling and passivation stages further ensured that the parts were not only clean but also protected against future corrosion.
Efficiency Gains: by utilising the multi-stage BR-450 MS system, the client was able to process larger volumes of turbocharger parts in less time. The integration of automated features reduced the need for manual labor, further speeding up production while maintaining precision.
Energy and Cost Savings: thanks to its energy-saving features, the BR-450 MS system reduced energy consumption by 30%, aligning with the client’s sustainability goals. The automated water management system also contributed to a significant reduction in water usage.
To learn more about ActOn’s Ultrasonic Cleaning Technology click here. For further information regarding the finishing process or to request a free Trial email our technical team.