Ansaldo Energia cuts manual cleaning by 90%

Ansaldo Energia needed more efficient ways to clean critical components used in power-generation equipment and maintenance operations. Safetykleen introduced tailored parts-cleaning solutions across several departments, reducing manual intervention and helping the business prepare components for machining more efficiently.

The company and its needs

Ansaldo Energia manufactures and services equipment for electricity generation. Its operations include the production and maintenance of complex turbomachinery and other critical components.

Different departments faced different cleaning challenges. Mechanical maintenance teams needed to clean pumps, gearboxes and bearings for inspection and testing. The EDM department needed to clean fragile graphite electrodes without damaging them, while the tooling department needed to remove protective oils, lubricants, swarf and oxidation from components before and after welding.

The company had been relying on traditional cleaning methods. It needed a safer, more consistent approach that could handle delicate and complex components while supporting maintenance, inspection and production activities.

The Safetykleen solution

Safetykleen developed a tailored programme using several cleaning solutions. Two JetKleen machines with low-residue detergent were installed in critical departments: one for mechanical maintenance and one for the EDM department.

A JetKleen XL was introduced in the tooling department to clean burners and swirlers before welding and remove stubborn CNC swarf from hard-to-reach areas. A neutral cleaning product was also supplied for Ansaldo Energia’s existing ultrasonic equipment to remove combustion oxides and rust.

The solutions use water-based products where appropriate, reducing reliance on high-evaporation solvent products. Safetykleen’s All-in-One service also removes the need for Ansaldo Energia to manage machine maintenance and spent cleaning fluid internally.

Using the JetKleen XL has made component preparation easier, reducing machining preparation time by 5% and, above all, reducing manual cleaning and rework caused by swarf trapped in micro-cavities by 90%.

Nur El Gawohary, VP External Relations AE/ER, Ansaldo Energia

Results

90% fewer manual cleaning interventions

JetKleen XL reduced manual cleaning and rework caused by swarf trapped in micro-cavities by 90%.

5% faster machining preparation

The JetKleen XL solution reduced the time required to prepare components for machining by 5%.

Improved component quality

The tailored cleaning processes helped deliver consistent cleanliness for EDM electrodes, components undergoing inspection and parts requiring non-destructive testing.

Reduced maintenance burden

The managed service removes internal responsibility for machine maintenance and spent-fluid management, allowing teams to focus on production and maintenance activities.