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Case Study
MAHLE Behr Italy needed a more efficient way to clean the reusable plastic crates used to transport thermostats and other components. An Aquakleen Automatic parts washer reduced cleaning hours by 50%, while improving flexibility, cleaning quality and operator safety.
MAHLE is a global automotive component manufacturer. MAHLE Behr Italy specialises in developing and producing thermostats for combustion and electric engines and supplies components from its Grugliasco site in returnable plastic crates.
The crates must be cleaned between uses to prevent contamination and meet customer cleanliness requirements. Manual cleaning required significant labour and took too long, leading MAHLE Behr Italy to investigate more efficient alternatives as part of an internal cost-reduction programme.
The company considered several options, including a bespoke washing tunnel, but needed a solution that could deliver the required cleaning quality without a large footprint or significant capital investment.
Safetykleen recommended an Aquakleen Automatic parts washer combined with a non-hazardous water-based detergent. The machine was installed for a trial so the team could validate cleaning quality and cycle times in real production conditions.
The tests showed that multiple crates could be cleaned thoroughly in around two to three minutes at 75°C. The compact footprint, lower cost than a washing tunnel and complete managed service made the solution suitable for the site.
Safetykleen provides regular maintenance and replaces the cleaning fluid every four weeks, while the managed service also handles waste removal. The machine is supplied without an initial capital investment from MAHLE Behr Italy.
With Safetykleen’s support in identifying the best solution, we achieved the efficiency and quality objectives we had set for cleaning our returnable packaging.
Daniele Cremonini, Production Manager, MAHLE Behr Italy
Annual cleaning time fell from 2,348 hours in 2017 to 1,164 hours in 2020.
The proportion of cleaning time saved through automation increased to 30.42% in 2020.
Aquakleen Automatic delivered the cleaning performance required by MAHLE Behr Italy and its customers during the trial and subsequent operation.
The non-hazardous cleaning fluid and enclosed machine reduce operator exposure to VOCs and other potentially harmful substances.
A machine available on site and ready to use reduced dependence on external crate-washing capacity and helped avoid delivery delays.
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