METALWORKING FLUIDS
Sustainable innovations in metal cleaning: A low- temperature revolution
Dr Sara Pasquale, R&D European Head of Cleaners and Rust Preventives, FUCHS Lubricantes
In an era defined by the urgency of climate action, industrial cleaning processes are undergoing a quiet but significant transformation. Metal cleaning, vital to sectors such as automotive, aerospace and manufacturing, is one such domain being reimagined in the pursuit of sustainability. Traditionally reliant on high temperatures and harsh chemicals, cleaning regimes have often come with a high environmental and economic cost. Today, however, a wave of innovation is enabling industries to maintain performance standards while reducing their ecological footprint—chief among them, the shift to low-temperature cleaning systems.
The case for cooler cleaning
Heating is a major contributor to the carbon footprint of manufacturing processes. In metal cleaning, even modest reductions in temperature can yield considerable energy savings and, by extension, reductions in greenhouse gas emissions. Lower temperatures also lessen strain on equipment, extend service life, and decrease maintenance needs. Yet, such benefits come with challenges: lower heat can compromise cleaning efficiency, reduce corrosion protection, and pose microbiological risks.
To mitigate these issues, researchers and chemical engineers are developing cleaning agents specifically engineered for effectiveness at reduced temperatures. These include solutions designed for use in complex metalworking procedures—from annealing to pickling—where residues and contaminants must be removed without compromising the integrity of the material.
Balancing performance and sustainability A successful transition to low-temperature processes demands more than just a switch in chemicals.
16 LUBE MAGAZINE NO.188 AUGUST 2025
A holistic approach is required: assessing existing systems, upgrading infrastructure, retraining staff, and introducing more precise process control technologies. For example, surfactants—the active agents that dissolve oils and greases—must be rebalanced to function optimally at lower heat, preventing issues such as foaming, spotting, or diminished wetting action.
Moreover, microbiological contamination remains a concern. Lower heat may not be sufficient to inhibit bacterial growth, especially in systems with long bath life or where water is recycled. Addressing such challenges necessitates the use of stabilisers and additives that prevent microbial proliferation without increasing toxicity or environmental load.
Figure 1: Lab study showing surface tension against foamability to determine the most suitable surfactant packages
Innovations in action Across Europe, some industrial groups are already reaping the rewards of adopting low-temperature cleaning technologies. In Spain, one corporate
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