In the high-stakes environment of Surface Mount Technology (SMT), the transition to high-density component arrays, such as 01005 chips, QFNs, and BGAs, has made cleaning a non-negotiable process step. Residual flux, solder balls, and process contaminants are no longer just cosmetic issues; they are primary drivers of electrochemical migration, parasitic leakage, and poor conformal coating adhesion. The InJet® series represents the industry standard for automated, horizontal high-pressure spray-in-air cleaning. These closed-loop, zero-drain systems are engineered to provide a 100% clean surface, ensuring that every assembly meets the rigorous requirements of IPC-A-610 standards. By replacing manual or inconsistent batch cleaning with a validated InJet® process, manufacturers eliminate the “Cost of Poor Quality” and secure the reliability of mission-critical electronics.
For the process engineer, the primary challenge is ensuring that cleaning fluids penetrate the microscopic stand-off gaps beneath low-profile components. The InJet® series utilizes a unique horizontal spray technology with high-pressure manifolds that apply cleaning agents from both the top and bottom. This configuration, combined with DCT’s “Tenzide-free” (surfactant-free) cleaning agents, allows for higher operating pressures without the risk of foaming or secondary residue entrapment. The horizontal orientation is specifically chosen to minimize shadowing, ensuring that the fluid reaches the center of high-density arrays. Every parameter—temperature, pressure, and concentration—is fully controlled and documented, providing the repeatability necessary for Tier 1 automotive and medical manufacturing.
From a financial perspective, the InJet® system is an investment in margin protection. While the initial CAPEX might be higher than simplified batch cleaners, the Total Cost of Ownership (TCO) analysis reveals substantial long-term savings. InJet® machines are designed for automated fluid regeneration, which typically reduces chemical consumption by 40-60% compared to systems that require manual batch changes or draining. Through advanced 2PR filtration and phase separation technologies, the bath life is significantly extended, lowering annual chemistry costs from approximately US$ 12,000 in low-end systems to US$ 4,500 in an InJet® setup. With the reduction in labor and the recovery of high-value PCBAs that would otherwise be scrapped, most InJet® systems achieve a full Return on Investment (ROI) within 12 to 18 months.
Operational safety and environmental compliance are cornerstones of the InJet® design philosophy. By utilizing a closed-loop, zero-drain architecture, these systems eliminate the need for expensive waste disposal of hazardous solvents and prevent the risk of factory fires associated with flammable alcohols like IPA. This safe, VOC-free automation significantly improves a facility’s ESG credentials. For project managers, the InJet® series offers effortless integration into existing production lines through full MES (Manufacturing Execution System) connectivity. Every cleaning cycle is logged, providing full traceability and a “Validated Process Guarantee” that satisfies the most demanding quality audits from global customers.
The InJet® range is designed to be flexible, supporting everything from high-mix, low-volume prototypes to large-scale mass production:
| Model Configuration | Technology | Key Capability | Target Application |
|---|---|---|---|
| InJet® 388 CRD | Vertical Spray-in-Air | 1-chamber, 2-tank automated cycle | PCBAs, Stencils & Squeegees |
| InJet® 888 CRD | Horizontal Spray-in-Air | One chamber Batch Cleaner | Maintenance Reflow Oven Solutions |
| InJet® 388 TWIN | Dual Horizontal Spray | Zero cross-contamination chambers | Multi-process rework centers |
| InJet® 388 CCRD | Vertical Spray-in-Air | One Machine, Two Applications | Two Tanks for Cleaning Agents |
Q: What is the typical cycle time for an InJet® system?
A: A standard cleaning, rinsing, and drying cycle for PCBAs typically takes approximately 35 minutes. For maintenance cleaning of heavily contaminated solder frames or reflow oven filters, cycles may be longer depending on the thickness and age of the baked-on resins.
Q: How does horizontal spray compare to vertical spray systems?
A: Vertical spray-in-air technology provides superior “under-component” penetration. By spraying from two arms simultaneously while the parts are held verticaly, shadowing is virtually eliminated. This ensures the fluid reaches the center of large BGA packages where horizontal spray systems often struggle.
Q: Is the system compatible with water-based and solvent-based fluids?
A: InJet® machines are primarily optimized for aqueous (water-based) processes, which represent the future of industrial safety. While some models can handle specific solvents, the highest efficiency and safety are achieved using DCT’s Decotron® water-based fluids.
Q: What maintenance is required for the cleaning machine itself?
A: InJet® systems are industrial-grade builds featuring high-quality stainless steel and manual welding. Routine maintenance involves checking filter status and fluid levels, all of which are automatically monitored by the system software, which provides timely notifications for consumable replacement.
Protect your people, your plant, and your profit margins. Contact our technical sales managers today to schedule a demo or a process validation test. Our specialists are ready to help you implement a zero-defect cleaning solution that guarantees long-term reliability for your electronics.
100% RESPONSIBILITY FOR THE CLEANING PROCESS
We take full responsibility for the functionality of the cleaning process.
Complete cleaning solutions
We can offer complete cleaning solutions for all existing applications.
Quality of cleaning systems
We manufacture cleaning systems exclusively in stainless steel because it has long-term advantages.
pure quality of cleaning agents
We care about the functionality of the cleaning chemistry, but also about ecology.
Technical and economic improvements
With every project, our greatest motivation is to bring the customer a better technical and economic solution.
Development and customization
By continuously developing our cleaning technologies, we are moving forward and responding to developments in the electronics industry.
Democenters Worldwide
We give customers the opportunity to actually test the cleaning solution.
Direct service Support
For us, service support does not end with the installation, it begins.
Our references show the diversity of our customers and how we have been able to
to tailor our services to their needs and expectations.
