Nicoll improves sustainability with ultrasonics

For more than 65 years, Nicoll has specialised in water drainage and management systems, designing sustainable, easy-to-install and innovative solutions. The company wanted to optimise the cleaning of the injection moulds used to manufacture its products while protecting employees and reducing environmental impact. Safetykleen’s automated ultrasonic cleaning solution met these requirements with a closed-loop process and a tailored water-based cleaning solution.

• 25 % faster cleaning
• Improved health and safety
• Improved sustainability

Challenge

Plastic injection moulds become coated with grease and rust as a result of the pressure and high temperatures used during manufacturing and therefore require regular maintenance.

In the production workshops, moulds were cleaned regularly using ultrasonic fountains with diluted caustic soda and an anti-corrosion bath. During more intensive maintenance, the tool shop used a degreaser and manual brushing in a biological fountain.

The existing approach made cleaning more time-consuming and complex, particularly for large and intricate moulds. Nicoll wanted a solution that would improve efficiency while prioritising employee health and safety.

To increase cleaning efficiency and speed while protecting its employees, Nicoll’s teams turned to Safetykleen’s complete parts-cleaning service.

We let Safetykleen manage everything: oil changes, maintenance, replenishment and waste. It gives us real peace of mind and provides a safer solution for our teams.

Carl Sauvetre, Tool Workshop Manager, Nicoll, Cholet

The Safetykleen solution

Following comparative trials, Nicoll selected Safetykleen’s Sonickleen ultrasonic cleaning solution.

After several chemistry trials, our teams formulated a tailored water-based cleaning solution, free from VOCs and CMR substances and designed for ultrasonic cleaning. It also contains corrosion inhibitors to help prevent rust formation.

The ultrasonic cleaner operates in automatic one-hour cycles, improving speed and efficiency. Ultrasonic cavitation removes contamination from the moulds, including complex geometries and difficult-to-reach areas.

An automatically generated wave also helps keep the surface of the bath clean. The machine is large enough to accommodate Nicoll’s moulds.

The first advantage of the Safetykleen solution is that it better protects the health of my teams by removing caustic soda from our cleaning process. The second is the time saving and efficiency – I was impressed by the results of the ultrasonic machine. Safetykleen also takes care of product replacement and draining, which is a real benefit for our business.

Nicolas Bondu, Mould Maintenance Manager, Nicoll, Cholet

Results

A safer solution for teams

To replace solvent- and caustic-soda-based products, Safetykleen formulated cleaning solutions that are classified as non-hazardous, non-flammable and non-volatile. The ultrasonic machine operates in a closed loop to reduce splashing and exposure, while automated cleaning reduces the physical demands of repetitive manual tasks.

Increased productivity and cleaning quality

The solution can clean several moulds at the same time and provides up to 25% faster cleaning. Operators load the parts, start the cycle and can focus on other tasks while the machine runs. Ultrasonic technology also cleans complex shapes and areas that are difficult to reach by hand.

The teams can work in a cleaner environment with machines kept ready for use through Safetykleen’s technical support and regular servicing.

A complete cleaning service

Safetykleen’s service covers more than the machine and cleaning chemistry. We replenish the cleaning solution at agreed intervals, provide regular machine maintenance and collect used products for compliant treatment. Nicoll’s teams can rely on Safetykleen to manage the parts-cleaning process from end to end.

Reduced environmental impact

The water-based cleaning solutions are treated after use in accordance with applicable requirements. Waste does not need to be stored on site because Safetykleen collects and manages it as part of the service, including treatment at ICPE-classified centres.