How to Choose Dry Ice Blasting Equipment

Choosing a dry ice blasting machine can be confusing. There are several things that should be considered when comparing different blasting units with each other or with your current cleaning method. Below you’ll find two checklists; one for comparing dry ice blasters to other methods and one for comparing dry ice blasting units.

Dry ice blasting	VS	My old method
	Faster cleaning
	More effective
	No damage to equipment
	Better for the environment
	Faster set up/tear down time
	ROI
	Total

Dry ice blasting cleans faster than traditional methods. This is due to the fact that it utilizes several different effects at once. Firstly there’s the speed of the pellets. Next there’s the thermal effect that drops the temperature of the contaminant and shrinks it. Finally, the dry ice pellets sublimate into CO2 gas, which forces the contaminant off the surface. Because of its nonabrasive nature, dry ice blasting can clean equipment while it’s still hot and in place.

While cleaning with something that turns into a greenhouse gas may seem like it harms the environment, dry ice cleaning is actually one of the most eco-friendly cleaning methods available. This is because the dry ice pellets are made from recycled CO2, which gives it a “second life” before releasing it into the atmosphere.

Dry ice blaster 1	VS	Dry ice blaster 2
	Overall performance
	Ease of use
	Hopper size and performance
	Hose flexibility
	Nozzle combinations and accessories
	Customer Support
	Total

Comparing dry ice blasting equipment is a lot like buying a car; your decision is personalized for your needs. But everyone looking at purchasing a dry ice blasting solution (or even a car for that matter) considers the performance of the machine to be a top priority, and it’s safe to say that dry ice blasters (and cars) perform differently.

When it comes to equipment maintenance, you want something that’s easy to use. Dry ice blasting machine manufacturers have a variety of different machine designs, but it’s important that you choose a machine that is fairly easy to use; especially if this is your first dry ice blaster. For example, having an easy access control panel is a key attribute for dry ice blasting equipment. The qualities of the blasting hose are also an essential part of choosing a machine. A system that allows the hose to remain flexible throughout blasting is a lot easier to use than one with a rigid hose.

A dry ice blasting machine should be able to be used for a variety of cleaning. One way a manufacturer makes this possible is by also supplying a variety of nozzles that help switch from delicate to heavy duty cleaning. Being able to use different accessories also allows for easier access when cleaning. For example, an extension pipe is often a preferred solution for cleaning hard to reach places.

Finally, the customer support offered by the manufacturer should also be considered. Whether you’re new to dry ice blasting or not, your manufacturer should be available to show you the best way to operate your equipment.

Case Study: Cleaning transformer substations

Dry ice blasting has revolutionized equipment maintenance in virtually every industry. Electrical equipment is no exception. A perfect example of this can be seen in transformer substations. Pictured below, these substations are held to strict regulations concerning power current supply. These regulations state that the substations have to be checked regularly to eliminate risks such as flashovers, breakdowns, and fires cause by accumulated layers of dust and dirt. Each station is required to be inspected once every 5 years.

As I’m sure you can imagine, when waiting 5 years between inspections some of these stations are in such bad shape that just cleaning with a vacuum won’t cut it. To remedy this service contractors have been cleaning with high water pressure. Unfortunately this does not yield the desired results and causes a few problems for operators.

Firstly, the transformer substation cannot be cleaned in drift with voltage. Next, the transformer cannot operate while it is wet. It must be completely dry before it can begin to run again, which takes up to 5 days. Finally, the cost of pressure washing the transformers is astronomical! This is because during the cleaning process, a mobile power station is needed to replace the transformer. On average, the capacity of the mobile power station is 75% of the transformer. Therefore it requires 1200 liters of diesel per day.

What’s the difference with dry ice cleaning? 

One of the main benefits of cleaning with dry ice over water is there is no cleanup afterward. The dry ice turns into a gas upon contact with the surface of the equipment. This process, known as sublimation, increases the effectiveness of the dry ice as a media. This is because it represents the expansion of the dry ice, which causes the contaminant to lift off the surface.

DRY Ice Blasting

The biggest advantage of using dry ice blasting equipment has over pressure washing is that the substations don’t need to be turned off for 5 days for maintenance. Dry ice blasting is a completely dry process. This means it eliminates the lengthy downtime required by power washing.

The cost breakdown: 

Cleaning time – 4 hours x 47.60	$190.40
Using a mobile power station (6 days)	$5875.11
Total	$6065.51 (€4460)

 

Dry Ice Blasting

Cleaning time – 2 hours x 102	$204
Dry ice consumption (220 x 2.38)	$523.60
Use of portable compressor – 1 day	$272
Total	$999.60 ~ $1,000 (~€500)

The Fantastic 4 Reductions of Dry Ice Blasting

Next to its effective cleaning, the primary advantages of dry ice blasting lie in its ability to reduce. From costs to waste, here are the reductions of dry ice blasting:

 

Equipment Damage

One of the hidden expenses of traditional cleaning methods is the cost to replace equipment. Processes that include wire brushes, sand blasting, and chemicals cause wear on machine parts; shortening their life of use. Implementing dry ice cleaning is the best way to ensure a longer life for your equipment. This is because dry ice blasting is a non-abrasive cleaning method. The dry ice pellets turn into CO2 gas upon contact with the surface of machine parts; making dry ice blasting about as damaging as if you were to breathe on your equipment (though infinitely more effective). Paired with the power of your facility’s compressed air and the thermal effect from the temperature of the dry ice (-109˚F/-79˚C), dry ice blasting is only way to successfully clean your equipment without damaging it.

Downtime

The most difficult part of cleaning machinery is the lost production time. Think about it, you’re stopping production to wait for parts to cool down long enough so they can be dismantled and cleaned. How much of a loss in production is that? Now think about what it would be like if you could cut that time by 80%. That’s what dry ice blasting can do for you. With ice blasting it is possible to clean parts while they are hot and in place. There are many facilities that are able to clean equipment while it is still in use. This is because dry ice is nontoxic and safe to use on electrical components.

Payroll Costs

As you already know, traditional cleaning methods take a lot of time, which increases wages for maintenance workers. Because dry ice blasting can be done in a fraction of the time of other methods, which eliminates typical, lengthy cleaning time. Because the dry ice pellets turn into a gas, there is no secondary cleanup. This further reduces the time needed for cleaning.

Waste Disposal

Another hidden cost associated with traditional cleaning methods is the cleaning after the cleaning. With most blasting methods there is always a media that needs to be cleaned up. Because dry ice pellets turn into a gas there is nothing to clean up afterward besides the removed contaminant making dry ice blasting equipment the most efficient cleaning solution available.

Downtime vs Setup Time and how Dry Ice Blasting Reduces Them Both

Downtime is exactly what it sounds like; the time during which a machine is out of action, or unavailable for use. Setup time is essentially the downtime associated with changing a piece of equipment from making the last part of a production batch to making the first good part of the next batch. 60-70% of downtime is associated with equipment maintenance and cleaning.

Why not just increase the speed of machinery or ask people to work faster?

Think about the time it takes to process or assemble the units you produce. This time is an added value of transforming raw material into something valuable. Do you think your customers are willing to pay for the extra efforts for this? Probably not, so…

How Do You Reduce Downtime without hurting the customer?

How much of your downtime is allocated toward cleaning something? Imagine if you could cut that time in half; and that’s what dry ice blasting can do for you.

To understand how, you first need to look at how you’re cleaning your equipment now. Chances are you’re stopping production, waiting for parts to cool, taking everything apart, cleaning each piece individually, putting it all back together, and starting the machine up. Now take a second and think about what it would be like to skip all those steps. Not only is setup time being reduced, but it’s being eliminated!

This is made possible because three main factors

 

1. The Dry Cleaning in Dry Ice Cleaning

One of the biggest reasons dry ice blasting is such a time saver, is it eliminates the need to cover up electrical components to protect them. In fact, dry ice blasting is a preferred method for cleaning them. While people blasting with other medias need to go out of their way to cover sensitive equipment, those using a dry ice blaster don’t have to worry about it. This is because dry ice blasting is a dry process. The dry ice pellets turn into gas upon contact with the surface of your equipment, leaving no secondary mess behind.

2. No Cool Down Time

Even if you don’t have to disassemble your equipment, chances are you still have to wait for it to cool before you can clean it. Most cleaning methods can damage parts if they’re still hot. Dry ice blasting, on the other hand, can not only clean parts while they are still hot, but in some cases, it works better that way.

This is due to both the thermal effect and the sublimation of the dry ice. The sudden drop in temperature causes the surface of the contaminant to crack. When the dry ice goes from a solid to a gas (sublimation) the effect lifts the contaminant off the surface. There is no damage to the equipment because this happens so quickly.

3. Customization

Dry ice blasting is one of the most versatile cleaning methods available. While not all dry ice blasters are created equal, the best manufacturers also supply different accessories to help you adjust your cleaning experience. Different nozzles and extension pipes can make a huge difference in the cleaning success of your dry ice blasting equipment.

For more information on how dry ice blasting can reduce downtime in your industry click here.

Keep Dies from Dying

Did you know die castings are used in 90% of all finished manufactured products? Contributing over $7 billion to the US economy and over 50,000 jobs, this industry is a fundamental component of the country’s market. (www.diecasting.org) Die casting is a metal casting process where molten medal is poured into a mold under high pressure. The mold is created by two steel dies. The process is similar to injection molding, and proper mold maintenance is an essential component to a consistent product.

As with other molding processes, the equipment is under extreme pressure (no pun intended) that causes damage to the parts.

So what are maintenance professionals doing to solve this problem?

Wire brushes and metal scrapes often do more harm than good when used to remove hardened metal from die plates. The scratching shortens the life of the equipment. The utilization of dry ice blasting has caused a significant increase in the life of die cast tooling by eliminating the wear and tear from traditional abrasive methods. The nonabrasive nature of the dry ice pellets allows for an effective cleaning of the die without causing harm to machine parts.

Overall Improvement

Besides helping preserve the surface of the equipment, dry ice cleaning helps eliminate other maintenance problems with the machinery. Dry ice blasting reduces cleaning time by about 50% meaning cleaning can be done more frequently, and makes touch up cleaning much easier.

The frequent cleaning makes it easier for machine operators to detect other problems in the machine because it keeps the surface of the equipment visible.

The Breakdown on Buildup

Besides removing buildup from the molds, utilizing a dry ice blaster eliminates the media buildup commonly associated with other media blasting methods. Dry ice turns into a gas upon contact, which eliminates the need to sweep up blasting media after cleaning.

To learn more about the process check out this video:

Can cleaning with CO2 really help the environment?

According to the EPA Carbon Dioxide (CO2) is the primary greenhouse gas emitted from human activity. It accounted for 82% of human-made greenhouse gases emissions in 2012. It is mainly emitted from fossil fuels being used for transportation and energy. (EPA.gov)

How can cleaning with a greenhouse gas help the environment?

 

 Recycle, Reuse, Relax

Dry ice blasting uses CO2 in its solid form that starts out as a gas. The same CO2 gas we’re all emitting is being taken and pressurized into liquid CO2 which is then pressed into solid blocks or dry ice pellets. Basically making solid CO2 is delaying the emission of the gas into the atmosphere.

So why don’t we just make a bunch of dry ice?

The shelf life of dry ice depends on the quantity purchased. The amount you might use for Halloween could turn back into a gas in 24 hours, while the dry ice needed for a dry ice blaster will last 1-2 weeks depending on the container and how often it’s opened.

There’s no quick fix for reducing greenhouse gas emissions, but utilizing dry ice blasting equipment in manufacturing is a great way to give our CO2 emissions a second life.

What else?

Replacing the use of chemicals like Scotch Bright with dry ice cleaning can do wonders for the environment and your bottom line. Instead of using solvents that are often ineffective and dangerous to dispose of, dry ice turns right into a gas on contact; so there’s no after mess and no further damage to the environment.

5 Things You Didn’t Know About Dry Ice Blasting

It Eliminates Equipment Damage

One of the big differences between dry ice blasting and other blasting methods is the nonabrasive nature of the dry ice pellets. Other blasting media like sand or metal shots remove part of the surface as it is removing the contaminant. Overtime this cause significant wear on machinery, which leads to breakage, costly repairs, or replacements.

Increased Safety

Contrary to what your high school science teacher told you, dry ice is very safe, especially compared to other blasting media. I know what you’re thinking; how can something that’s -109˚F (or -79˚C) be safe?  It’s nontoxic, nonhazardous, flame resistant, and it’s not electrically conductive. Ice blasting is a lot safer to handle than chemicals and solvents too, because it doesn’t need to be disposed of afterward.

No Residual Buildup

Dry ice blasting is often compared to magic because once the job is done, POOF! The pellets disappear. While other blasting media builds up in hard to reach places, dry ice pellets sublimate on contact. This means while Mr. Sandblaster is cleaning up after the clean up, Mr. Dry Ice Blaster is already done with his job. This means machine parts can be cleaned more frequently without the lengthy downtime.

More Effective

I know, I know, everybody says their cleaning method is better than everyone else’s, but dry ice blasting is scientifically proven to be more effective than other methods. The not so secret to success of dry ice blasting lies in the combined strength of the high traveling speed of the dry ice pellets and the thermal effect of the dry ice. The speed of the pellets causes fractures in the contaminant and the low temperature allows the pellets to penetrate it; aiding in the easy removal of the substrate.

It’s fun!

While this shouldn’t be your main reason for purchasing dry ice blasting equipment, the effectiveness and ease of use make dry ice blasting more enjoyable than other cleaning methods. How else can you increase the efficiency and productivity of your plant while cleaning?

FounDRY ICE BLASTING

The foundry industry is plagued with multiple cleaning challenges. Core boxes and core machines are constantly covered with sand and carbon buildup, molds and vents are plastered in grease and other residue, and traditional methods like hand scraping with wire brushes require lengthy downtime, but result in little effect. Proper core box cleaning is essential for a consistent product.

The Problem with Traditional Methods

When using wire brushes and even sandblasting, production needs to stop and parts need to be disassembled to be cleaned. In addition to the downtime, these methods often result in heavy wear and tear on equipment. Wire brushes often etch equipment, and sand blasting is notorious for wearing down mold surfaces. Sand blasting also has the added disadvantage of grit entrapment. The particles from the blasting get caught in machine parts and further erode their surfaces.

Chemicals are another cleaning method commonly used in foundry. Aside from the heavy cost associated with using them, chemicals are extremely dangerous to handle and dispose of.

Dry Ice Blasting

Elimination of downtime is one of the biggest benefits of dry ice blasting. In many cases, downtime is reduced up to 50% by switching from manual cleaning to dry ice cleaning. This also helps reduce labor hours accumulated from manual cleaning. Aside from eliminating the need to disassemble machinery for cleaning, dry ice blasting is a much faster process than traditional methods.

Another benefit dry ice blasting has over other cleaning solutions is that it is nonabrasive. The dry ice pellets penetrate the contaminant and sublimates (turn into a gas) upon contact with the surface, so there is no unwanted wear and tear on equipment. The sublimation also eliminates the need for secondary waste cleanup. Because dry ice blasting is such a fast process, it can be done regularly, which eradicates the threat of clogged vent holes.

The biggest advantage of using a dry ice blaster over traditional methods like chemicals is it reduces liabilities. Chemicals are dangerous to work with, while dry ice is nontoxic. Dry ice blasting also greatly decreases the costs of using chemicals for cleaning, because dry ice pellets are less expensive.

For more on dry ice blasting in the foundry industry check out this video!

An Interview

This week I sat down with Chuck Lawrence, an area sales manager at IceTech America, to learn more about dry ice blasting.

Question: What exactly is dry ice blasting?

CL: Dry ice blasting is an environmentally friendly cleaning process used in a wide variety of industries and for a wide variety of applications. It is somewhat similar to other more traditional basting methods, such as sand, soda, and water blasting.

Question: What’s the benefit of cleaning with dry ice over other media?

CL: The biggest difference is that the dry ice media is 100% nonabrasive, 100% dry, and leaves zero secondary waste behind from the media to clean up or contain. For the majority of applications, these are also the biggest benefits. Dry ice blasting can also increase production rates for manufacturers as it gives them the ability to clean in place. In addition to saving time, it can also help to save money in most cases as well.

Question: How does it work?

CL: IceTech Dry Ice Blasting Equipment is designed to operate utilizing compressed air and standard 110v power. The machine is manually fed with 3mm high density dry ice pellets. These pellets are accelerated at a high rate of speed through the system, and when they contact the substrate, vaporize back into a gaseous form.   The kinetic energy created, combined with the thermal effect, causes the contamination to be removed and the surface cleaned.

Question: Is it safe?

CL: Dry ice blasting is just as safe, if not safer, than the other more traditional types of media blasting. Of course, proper PPE precautions should always be taken when operating dry ice blasting equipment, as with any other blasting equipment. I always encourage proper hearing protection as the equipment can be quite loud in certain environments. It is also critical to wear a decent pair of gloves to avoid grabbing the cold nozzles with bare hands. So long as you are blasting in an open environment, meaning not an area considered confined space, you need not worry about ventilation. Only if you are blasting in a confined space will you need take proper ventilation into consideration.

Question: What happens to the contaminant once it’s blasted off?

CL: It really depends upon the makeup and thickness of the contaminant. Sometimes there is a small amount of debris to either vacuum or sweep away. Best news, however is that there will be zero dry ice left to clean up or contain as it will sublimate back into a gas upon contact.

Question: How do you know dry ice blasting is the right process for your facility?

CL: Basically it comes down to your current cleaning process. Are you getting the best possible results? Not just meaning the cleaning process itself, but the cost and environmental factors that go along with your current process. If the answer is NO, then you should at least explore whether or not dry ice cleaning could provide a viable solution. IceTech offers free, on-site demonstrations of our equipment. We would come to your facility fully equipped, to include the dry ice media and even compressed air if need be. You would simply need to provide us with standard 110v power to plug into and some dirty samples or equipment you would like to see cleaned. This live demonstration gives you, the potential customer, the opportunity to see how well the dry ice blasting process works, and at the same time gives us the ability to fit your facility with the proper sized equipment. We can then assist you in determining an actual return on investment and justification for a change in cleaning processes.

If you would like to contact Chuck, you can email him at cl@icetechworld.com.

Molds and Mold

One of the amazing things about dry ice blasting is its versatility. Not only can it be used in almost any industry, but it can clean in basically every kind of condition. Want some examples? Let’s start with an industry that affects nearly all consumer goods: plastics.

The Plastic Industry

According to The Plastics Industry Trade Association (SPI) plastics make up the third largest US manufacturing industry. Creating $374 billion in shipments and employing roughly 900 thousand workers, this industry benefits us from a consumer and an economic standpoint. (plasticsindustry.org)

How are plastic things made? Basically hot, liquid plastic is poured into a mold, usually metal, under high pressure. The plastic then cools inside the mold and, voilà; plastic part!

                       So what does this have to do with dry ice blasting?

As I’m sure you can imagine, these molds can get really dirty really fast! Requiring daily cleaning, the mold cavities are a major concern in the industry’s quest to maintain today’s high quality standards. Obviously daily cleaning can be incredibly time consuming, but here is where cleaning with dry ice can make a big difference. Using dry ice blasting can reduce plastic mold maintenance by about 80% from traditional methods!

How exactly does it do that? Using a dry ice blaster makes it possible to clean the molds while they are hot and still in place. With other methods, the molds need to be cooled, removed, cleaned separately, and then put back into place. It also eliminates secondary waste. Aside from cleaning up what’s been blasted off, there is nothing else to clean up afterward. With other methods like chemicals or water, there is always something that needs to be cleaned up and disposed of.

The Other Mold

Another great thing about dry ice cleaning is its ability to sanitize. Using water to clean machine parts creates a breeding ground for bacteria and mold. This makes dry ice blasting ideal for food processing plants. It helps plants keep up with the demanding regulations of the food industry. It eliminates the concerns that come with secondary waste disposal from water and chemicals. Without using the typical chemicals, dry ice blasting removes microbiological films, like bacterial yeast and mold.

Another problem the food industry faces with sanitation is finding a solution that doesn’t alter the taste or appearance of its products. Dry ice blasting machines use recycled CO2, which is odorless, colorless, and tasteless. Meaning it has no effect on the food.

As with the plastic industry, there is a huge time and cost savings from traditional methods, because it eliminates the need to stop production, take apart the machines, clean them, and put them back together.

Being more effective than using chemicals and wire brushes, dry ice blasting is much more beneficial for the equipment than traditional methods. It’s non-abrasive, so it doesn’t cause harm to the equipment.

For more information on dry ice blasting and the food industry click here.