Smaller batches, wider product ranges and tighter residual contamination limits are changing component cleaning in manufacturing. Karl Roll has developed the Focus, a compact, enclosed solvent cleaning system for loads up to 50 kg. The machine is intended to provide reproducible results in applications requiring high levels of cleanliness. It also limits the need for ancillary equipment, as well as energy use and solvent consumption.
Manufacturers increasingly need to process changing product mixes and smaller quantities. Previously, larger series were often cleaned in fixed cycles. This trend affects accurately machined components, medical parts and supply chains with demanding cleanliness specifications. Karl Roll positions the Focus for these conditions. The machine operates under full vacuum and uses hydrocarbons or modified alcohols. According to the manufacturer, it requires only an industrial power connection and compressed air. Therefore, it reduces the need for extensive peripheral equipment. Its working chamber accepts loads up to 565 mm by 365 mm by 250 mm. The maximum load weight is 50 kg. The system is therefore intended mainly for companies with limited cleaning volumes and stringent particle and film contamination limits.
Separate media circuits support process control
The Focus is a closed solvent system that operates under full vacuum. This configuration is intended to support stable cleaning and drying processes. It also helps reduce emissions. The standard version has two solvent tanks with separate media circuits and bypass filtration. Users can therefore separate pre-cleaning from fine cleaning. This may be relevant when residual contamination limits are particularly strict. The two-tank configuration can also support other process requirements. One tank may be used for cleaning, while the second is used for preservation. This option is intended for steel components and other parts requiring temporary corrosion protection after cleaning.
Two pumps empty the working chamber quickly after processing. According to Karl Roll, this reduces cycle time. It also limits the period during which removed contamination can settle on the components again. Ultrasonic cleaning is integrated into the working chamber. Its frequency can be adjusted to the application. The required ultrasonic action depends on the component geometry, material and type of contamination. The system includes a loading aid for manual handling. For higher levels of automation, automatic loading and unloading equipment can be added. Barcode scanning is also available. It supports traceability and unmanned production processes.
Distillation and heat recovery reduce medium use
Operating costs in solvent cleaning depend on more than cycle time and equipment purchase. The service life of the cleaning medium, filtration, maintenance and energy demand also influence operation. Karl Roll states that the Focus was developed with particular attention to the energy consumption of the vacuum pump, heating system and drain pump. An integrated distillation unit continuously treats the solvent during operation. Oil and dissolved contaminants are separated from the medium. An automatic oil drainage system then removes the separated oil from the process. This is intended to extend the usable life of the solvent. It also reduces the frequency of medium replacement.
The system uses heat recovery from the distillation process. Insulation around heated media further limits energy losses. A filter unit collects particles removed from components. An automatic lid-locking mechanism is available for manual filter changes. It is designed to prevent incorrect closure of the filter housing. This helps prevent solvent vapour from escaping. Together, these measures address process reliability, occupational safety and controlled cleaning medium use in smaller-batch production.
