UK Engine Remanufacturer relies on MecWash Maxi for complete Aqueous Cleaning Solution

MecWash Systems was contacted by one of its longstanding customers, one of Europe’s largest independent engine remanufacturer and assembler, who supplies some of the world’s leading automotive OEMs. Producing more than 20,000 engines a year, the UK-based company supplies OEMs including Jaguar Land Rover, Ford, Volvo, Aston Martin and JCB – each with their own high standards and expectations.

With demand within the automotive sector for ever higher cleanliness levels in engineered components, the company had witnessed the benefits of MecWash Systems Maxi aqueous washer at one of its own customer’s UK sites. This particular OEM had its own very exacting cleanliness requirements and was using a MecWash Maxi component cleaning system.

The remanufacturer was able to see that the MecWash system was far superior to other options investigated – in particular its capabilities in terms of capacity, cycle time and cleanliness standards were all factors that attracted their attention.

The Maxi is one of MecWash’s ultimate precision parts and drying systems. It has a large cleaning capacity that can combine ultrasonics with high flow flood washing, spray washing, flood rinsing, spray rinsing, dedicated jetting and vacuum drying.

The combination of capacity and quality of cleaning and drying was important for our customer, with its production and manufacturing of more than 20,000 engines a year increasing.

The company not only remanufactures drivetrain and transmission products for OEMs, it also engineers machined components as a Tier 1 and Tier 2 supplier, as well as other component and sub assembly products. It exports 75 per cent of these abroad.

The cleaning is particularly important in the remanufacturing of engines where the company salvages approximately 85 per cent of the material from the exchange unit to build a remanufactured product. The remanufacturing process means that all products without exception must be cleaned and degreased to the very highest standards.

Their own customers are demanding maximum particle levels of under 500 microns and this is becoming an industry standard. Being able to achieve, or ideally beat this standard requires a robust cleaning system, and that’s where the Maxi comes in.

John Pattison, managing director of MecWash Systems said the company’s requirements were not like most other engineering companies.

“For a company that is remanufacturing engines, selecting washing and degreasing systems can be very challenging. The nature of the business means parts can be processed in a wide range of conditions, some with very heavy or tenacious soiling.”

“Components have to be cleaned before they can start to be re-manufactured and then they are cleaned again further down the process, often several times” he said. “That requires a tough cleaning regime.”

He added that the automotive remanufacturing sector was not alone in demanding ever more reduction in particle levels through industrial washing systems. “Sectors such as automotive have been demanding increasing precision in their components in recent years. As the tolerances reduce, the cleaning requirements increase correspondingly.”

“Most OEMs are requiring maximum particle sizes of 500 microns for general components and often much less for fuel, oil or hydraulic circuits. Up until a decade ago that could have been 1,000 microns and few customers would have checked rigorously anyway. Now regular Millipore particle testing is ubiquitous. So you can see how acquiring superior cleaning technology, like the Maxi, has been critical to many businesses.

“A combination of good technology, a good cleaning regime and washing chemicals – where our in-house laboratory develops bespoke detergents for clients’ needs – will mean an effective result is achieved. The MecWash Maxi is always tailored to a customer’s exact demands with bespoke options.”



Horn Mini 108: Targeted Chip Breaking

We are pleased to showcase the HORN Mini system 108 with threading geometry suitable for turning ISO metric internal threads in partial and full profile. The chip breaker geometry enables the production of short chips, even with hard-to-cut and long-chipping materials. This reduces the risk of chip build-up and prevents swarf from becoming entangled around the tool holder, increasing process reliability. Targeted chip breaking also makes it easier to handle chips.


Click here for the full range of Horn Grooving Solutions.

Please contact us for any information you would like to have on any of the products showcased in this video.  Depending on your location, we have the possibility to offer a demo of Horn Tooling solutions.


Horn Circular Interpolation

In this showcase we show the Internal and External machining of components using Horn milling inserts by Circular Interpolation. In this example, we show the concepts using the Horn 328, 628, 313, 328, 632 and 932 Milling systems.


Click here for the full range of Horn Milling Solutions.

Please contact us for any information you would like to have on any of the products showcased in this video.  Depending on your location, we have the possibility to offer a demo of Horn Tooling solutions.



Long Tool Life and Greater Flexibility for the 64T Grooving System


Horn has developed the new IG35 coating for economical machining of Stainless Steels. Based on the latest technology, this new coating offers high hardness and a low coefficient of friction. Due to the thicker coating required when machining stainless steels, standard types based on aluminium titanium nitride (AlTiN) are not always the most economical solution. Use of state-of-the-art coating technologies increases the hardness and lowers the friction.

As a result, IG35 demonstrates significant advantages when machining stainless steels, reducing the risk of built-up edges and offering longer tool life. Compared with existing coatings, IG35 came out on top in wide-ranging tests, with tool life doubled or even tripled in some cases. A copper-coloured top layer helps to improve wear detection.

Horn is also expanding its existing tooling systems and is now offering new solutions for its S64T grooving system tool holders. In addition to square shanks in various designs, users can now also clamp the six-edged indexable insert in cartridges.

These are available from stock in a variety of cutting widths for the insert seat. The clamping cartridges are used in particular with HSK holders and the 960 modular system offered by Horn. The tried-and-tested S64T grooving system is available in a variety of cutting widths. The system can easily be adapted to different machining tasks using various standard chip breaker geometries. The insert is available with a variety of coatings including the new IG35 variety.

Please contact us for more information on the new IG35 Coating and S64T Cartridge System.



Custom FLEX-HONE® Tools


Brush Research Manufacturing understands that some deburring and surface finishing applications require nonstandard Flex-Hones. We are happy to provide you with custom Flex-Hone® Tools.  With the outstanding reputation of the standard Flex-Hones, you can be sure that your custom Flex-Hone® will live up to that reputation as well. We will gladly manufacture Flex-Hone® Tools according to your specifications.

Typical Applications Include:

Automotive Applications
+ Piston Pin Bore
+ Engine Cylinders
+ Block Liners
+ Valve Guides
+ Cam Bearing Bore
+ Crank Bores
+ Brake Cylinders
+ Clutch and Brake Master Cylinders
+ Brake Rotors
+ Connecting Rods

Marine Applications
+ Main Engines
+ Generator Engines
+ Hydraulic Cylinders
+ Air Intake Lines

Oil and Gas Applications
Fluid Power Applications
Aerospace Applications

Industrial Applications
+ Air Compressors
+ Hydraulic Ram Cylinders
+ Hydraulic Motor Bodies
+ Pneumatic Cylinders
+ Valve Housings
+ Pump Housings
+ Surface Finishing of Boiler Components
+ Compressed Air Tool Bodies
+ Finishing of Stainless Steel Tubing
+ Mechanical Decontamination of Nuclear Tube Sheets

Please contact us for any information you require for a custom solution!