Industrial Detergents: Types, Applications, and Proper Selection

Household "Fairy" in Production — A Path to Problems

The main mistake we see at enterprises is the attempt to clean industrial equipment with household products. The logic is understandable — "it cleans fat, what's the difference?" The difference is fundamental.

A household dishwashing liquid is designed for a temperature of 40–50 °C, organic fats, and manual application. Industrial contaminants include metalworking fluids, carbon deposits, scale, mineral deposits, and polymer residues. They require different chemistry: higher pH (or lower for acidic tasks), special surfactants, corrosion inhibitors, and controlled foaming. Most importantly, they require a predictable result confirmed in a laboratory.

Industrial cleaning is a technological operation with clear parameters: concentration, temperature, exposure time, and mechanical action. If even one parameter is violated, the part will fail quality control, the coating will not adhere, the weld seam will have defects, and the dairy line will fail a microbiological audit.

In SVK's practice, we receive 5–7 requests every month from enterprises where an attempt to save on chemicals resulted in complaints or production downtime. A typical case is a metal structures plant in Kryvyi Rih, where a household product left a soapy film on parts before powder coating. The result was 300 m² of structures with adhesion defects.

Classification by Chemical Type

Alkaline Detergents (pH 10–14)

The workhorses of industrial cleaning. The base is sodium hydroxide (NaOH), potassium hydroxide (KOH), silicates, and carbonates. Working concentration: 1–5 % (depending on the task). Temperature: 50–85 °C.

Alkaline detergents are effective against organic contaminants: fats, oils, proteins, starch, and blood. The mechanism of action is the saponification of fats and the hydrolysis of protein films. Additional components include surfactants (lowering surface tension), EDTA or NTA chelating agents (binding hardness ions), and corrosion inhibitors (protecting aluminum and non-ferrous metals).

Limitations: alkaline detergents do not work with mineral deposits (scale, milkstone) and are aggressive toward aluminum, zinc, and tin at pH > 12.

Acidic Detergents (pH 1–5)

The base is phosphoric, nitric, citric, or sulfamic acid. Working concentration: 0.5–3 %. Temperature: 20–60 °C (acids work effectively even at lower temperatures).

Purpose — removal of inorganic deposits: scale (CaCO₃, CaSO₄), rust (Fe₂O₃), milkstone, beerstone (calcium oxalate), and cement residues. The acid dissolves the mineral matrix, releasing organic residues, which are then washed away with water.

Limitations: acidic detergents do not remove fat (this requires preliminary alkaline cleaning). Nitric acid is incompatible with copper alloys. Phosphoric acid leaves a phosphate film, which can be either an advantage (temporary anti-corrosion protection) or a problem (surface contamination before coating application). More on surface preparation in the article "Phosphating vs Nanoceramics".

Neutral Detergents (pH 6–8)

The base is a mixture of nonionic surfactants, less often amphoteric ones. Concentration: 1–3 %. Temperature: 30–60 °C.

Used for delicate cleaning of surfaces sensitive to aggressive pH: aluminum parts, plastic components, rubber seals, and painted surfaces. Also used for manual cleaning, where the operator contacts the solution without protective equipment.

The cleaning ability of neutral detergents is lower than that of alkaline ones. They are suitable for light and medium contaminants but will not handle carbon deposits or polymerized oils.

Solvent-Based Cleaners

The base is hydrocarbon solvents, modified alcohols (ethoxylates), and glycol ethers. They work at room temperature (15–25 °C), without dilution with water or with minimal dilution.

Solvents are the only option for removing heavy contaminants: bitumen, polymerized oils, wax coatings, printing inks, and adhesives. Where aqueous solutions are powerless, a solvent dissolves the contamination at the molecular level.

Limitations: fire hazard (ventilation and grounding required), impact on rubber and plastic components, and the need for special disposal. Modern formulas based on modified alcohols are significantly safer than classic petroleum solvents, but still require a separate risk assessment. Definitions of terms (surfactants, chelating agents, saponification) are in the industrial chemistry glossary.

Classification by Purpose

Degreasers

The task is to remove oil and fat films from the metal surface before further processing: painting, welding, electroplating, or gluing. A residual fat film even 0.1 µm thick is the cause of adhesion defects, pores in the weld seam, and uneven coating.

Industrial degreasers are typically alkaline or solvent systems with a high surfactant content. Quality control of degreasing according to ISO 12981 is the water-break test: water spreads evenly over a clean surface without breaks.

If you process metal on a CNC and are looking for an appropriate metalworking fluid that will simplify subsequent degreasing, we recommend the guide to choosing metalworking fluids for a CNC machine.

Descalers

Acidic formulas for dissolving scale, rust, and mineral deposits. Critical for heat exchangers, boilers, steam generators, and cooling systems. Scale 1 mm thick reduces heat transfer by 10–15 % — these are direct energy costs.

General-Purpose Cleaners

Cleaning of floors, walls, and external equipment surfaces. Usually mildly alkaline (pH 9–11) with good foaming. They work in manual cleaning, floor scrubbers, and foam generators.

Sanitizers / Disinfectants

A separate category for the food, pharmaceutical, and medical industries. After cleaning comes the sanitation stage: the destruction of microorganisms. Active substances: peracetic acid (PAA), quaternary ammonium compounds (QAC), and chlorine-containing agents. PAA (peracetic acid) is the gold standard: effective at 100–200 ppm, decomposes into vinegar and water, and does not require a final rinse.

Key Selection Parameters

1. Material Compatibility

This is the number one criterion. The wrong choice of pH or aggressive component = a damaged part.

2. Temperature Regime

General rule: increasing the temperature by 10 °C accelerates cleaning by 1.5–2 times. But there are limitations: at T > 70 °C, proteins denature and "bake" onto the surface (relevant for the food industry). Solvents at elevated temperatures pose a fire risk. The optimum for alkaline metal cleaning: 55–65 °C. For CIP: 70–80 °C.

3. Concentration and Dilution

Each product has a recommended dilution range. Typical values:

• Metal degreasing: 3–5 % for immersion, 5–10 % for spraying
• Alkaline CIP cleaning: 1–2 % NaOH
• Acidic CIP cleaning: 0.5–1 % HNO₃
• General cleaning: 1–3 %

"More is better" does not work: exceeding the concentration leaves hard-to-remove films on the surface, increases water consumption for rinsing, and raises the risk of corrosion.

4. Foaming

A critical parameter that is often ignored. For manual cleaning and foam generators, a high-foam formula is required — the foam holds the product on vertical surfaces. For CIP systems, immersion baths, and automatic washers, low-foam products are needed. Foam in a closed system means airlocks, pump cavitation, and reduced cleaning efficiency.

5. Biodegradability and Ecology

EU Regulation (EC) No 648/2004 requires full biodegradability of surfactants in detergents. For Ukrainian enterprises exporting or working with European customers, this is not a preference, but a must. Labeling and certifications are detailed in the article "Eco-Friendly Detergents: Labeling and Certifications". Requirements for chemical products for export are in the overview of household chemistry requirements for the EU.

Areas of Application

Metalworking: Degreasing Before Coating and Welding

Before applying paint, powder coating, electroplating, or welding, the surface must be free of oils, dust, and oxides. Typical process:

1. Degreasing — alkaline or solvent product, 55–65 °C, 3–10 minutes

2. Rinsing — deionized or reverse osmosis water, 2 cascades

3. Pickling (if necessary) — acidic product to remove oxides

4. Passivation / conversion coating — phosphating or nanoceramic treatment

The quality of degreasing directly affects coating adhesion. A detailed comparison of phosphating and nanoceramic surface preparation systems is in the article "Phosphating vs Nanoceramics".

Food Industry: CIP and Sanitation

Cleaning in food production is regulated by HACCP and ISO 22000. Each piece of equipment has a cleaning schedule approved by a technologist. The main method is CIP (Clean-In-Place), which we will consider in more detail below.

Automotive Industry: Parts Cleaning

Washing of engine parts, transmissions, and hydraulic systems. Contaminants include motor oils, ATF, preservation greases, and shavings. Immersion washers, spray cabinets, and ultrasonic baths are used.

A typical product is an alkaline degreaser with demulsifiers: surfactants separate the oil from the surface, and the demulsifier ensures stratification in the bath, allowing the oil to be collected with a skimmer and extending the solution's lifespan. A separate segment is chemistry for touchless and portal car washes, where the requirements for foaming, paintwork protection, and water repellency differ fundamentally from industrial parts cleaning. On selection and cost optimization — in the article "Car Wash Chemistry".

General Industrial Cleaning

Floors in production workshops (oil stains, metal shavings), external equipment cleaning, hoppers, and tanks. General-purpose products with good foaming and moderate alkalinity work here. For floors with polyurethane or epoxy coatings, only neutral formulas are used.

CIP Cleaning: Clean-In-Place Technology

What Is It

CIP (Clean-In-Place) is the cleaning of equipment without disassembly. The cleaning solution circulates through pipelines, heat exchangers, tanks, and filling lines according to an established program. This is the standard for the dairy, brewing, pharmaceutical, and beverage industries.

The main advantage is repeatability: each cycle is performed with the same parameters (temperature, concentration, time, flow rate), which guarantees a stable result and compliance with HACCP requirements.

5-Stage CIP Cycle

Stage 1 — pre-rinse. Washes away the bulk of the product (milk, juice, beer). Without this stage, organics will "bake" upon contact with the hot alkaline solution. Saves up to 30 % of chemical consumption.

Stage 2 — alkaline cleaning. The main cleaning stage. Sodium hydroxide (NaOH) at 1–2 % dissolves fats, proteins, and starch. A temperature of 70–80 °C is critical: if lower, efficiency is insufficient; if higher, there is excess energy consumption without significant gain. For heavy contaminants (burnt milk, caramelized sugar), the concentration is increased to 3–4 %.

Stage 3 — intermediate rinse. Removes alkaline solution residues before the acidic stage. Mixing alkali and acid means neutralization, i.e., the loss of both reagents.

Stage 4 — acidic cleaning. Nitric acid (HNO₃) at 0.5–1 % dissolves mineral deposits: milkstone, beerstone, and water scale. Without the acidic stage, minerals accumulate, reducing heat transfer and creating a favorable environment for biofilms.

Stage 5 — final rinse and sanitation. Peracetic acid (PAA) at 100–200 ppm is the standard sanitizer. It destroys bacteria, yeast, and spores. It decomposes into acetic acid and water — requiring no additional rinsing at low concentrations. Alternatives: QAC (quaternary ammonium compounds) or chlorine solutions, but PAA is considered the gold standard in the food industry.

Regulatory Requirements

CIP cleaning in food production is subject to:

• HACCP — each cleaning procedure is a critical control point (CCP) or a mandatory prerequisite program (PRP)
• ISO 22000 — food safety management systems
• **EU Regulation (EC) No 852/2004** — general hygiene requirements for food business operators
• ДСТУ ISO 22000:2019 — Ukrainian implementation

Each CIP station must have a validated cleaning program with confirmed parameters: minimum temperature, minimum concentration, and minimum time. Deviations from the program are recorded by the SCADA system and require corrective actions.

Common Mistakes in Industrial Cleaning

1. Increasing Concentration Instead of Diagnostics

"It's not cleaning — I'll add more product." In 70 % of cases, the problem is not the concentration, but the temperature, exposure time, or type of contamination. Doubling the concentration leaves a film on the surface and increases water consumption for rinsing.

2. Ignoring Material Compatibility

An alkaline product with pH 13 on an aluminum heat exchanger = corrosion after 2–3 cycles. Hydrochloric acid on stainless steel = pitting corrosion. Solvent on an EPDM seal = swelling and loss of tightness.

3. Skipping the Pre-Rinse

Direct supply of a hot alkaline solution onto a milk or protein residue "bakes" the contamination onto the surface. Removing such a film later is much more difficult and expensive.

4. Mixing Acidic and Alkaline Products

Neutralization is the loss of both reagents. The worst-case scenario — mixing a chlorine product with acid releases chlorine (Cl₂), a toxic gas. A water rinse is mandatory between the acidic and alkaline stages.

5. Lack of Parameter Control

Without regular measurement of concentration (refractometer, titration) and temperature, the cleaning process degrades. The solution gradually "depletes" — contaminants accumulate, efficiency drops, and the operator does not see it.

FAQ

How do industrial detergents differ from household ones?

Industrial products have a higher concentration of active substances, specialized surfactants (including low-foam for CIP), and corrosion inhibitors, and work in a wider range of temperatures (up to 85 °C) and pH (from 1 to 14). Household products are designed for manual application at 20–50 °C and a limited range of contaminants. Industrial products also undergo compatibility testing with specific materials and have a Safety Data Sheet (SDS).

How often should CIP cleaning be performed?

It depends on the product and equipment. Dairy production — after each shift or product change (every 8–12 hours). Brewing — after each brew or daily. Juice filling lines — every 4–6 hours at room temperature, or after a stoppage of more than 2 hours. The specific frequency is determined by the enterprise's HACCP plan and the results of microbiological monitoring.

Can an alkaline product be used to remove scale?

No. Scale (calcium carbonate and sulfate) is a mineral deposit that dissolves only with acid. An alkaline product can even worsen the situation: at high pH, calcium carbonate precipitates even more intensely. The correct sequence for combined contaminants (fat + scale): first alkaline cleaning (removing organics), then rinsing, then acidic cleaning (removing minerals).

How to check the effectiveness of degreasing?

The standard method is the water-break test (ISO 12981). Water is applied to the cleaned surface: if it forms a continuous film without breaks for 30 seconds, the surface is clean. Breaks in the water film indicate fat residues. For quantitative control, a contact angle meter (measuring the contact angle of wetting) or a UV lamp to detect fluorescent oil residues is used.

SVK Industrial Detergents

SVK develops and manufactures a full line of industrial detergents: alkaline degreasers for metalworking, acidic descalers, specialized CIP formulas for the food industry, and products for general industrial cleaning.

Each product comes with a technical data sheet, dosing recommendations, and material compatibility testing protocols. We work with production facilities ranging from a 10-person workshop to plants with fully automated CIP stations.

"Test Drive" Program: we send samples for testing on your equipment, with your contaminants, at your temperature. Without testing on a real object, we do not recommend a product — there are too many variables to rely on theory.

Get samples for testing →

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Read Also

• How to Choose Metalworking Fluids for a CNC Machine — a complete guide to metalworking fluids for metal processing
• Phosphating vs Nanoceramics — a comparison of surface preparation methods before painting
• Industrial Chemistry Glossary — terms, abbreviations, and definitions
• Requirements for Household Chemistry for Export to the EU — EU regulatory requirements for chemical products
• Eco-Friendly Detergents: Labeling and Certifications — biodegradability, Ecolabel, ISO 14024