The short answer
Replace trichloroethylene by converting to an inhibited aqueous degreaser run at 55–65 °C with adequate agitation. Existing vapour degreasing tanks can usually be converted to submersion systems at low cost by adding recirculation. Expect lower cost per part, no solvent permits, and rust protection of 10–15 days after washing.
- Replacing TCE since
- 2000, in Indian plants
- Aqueous wash temperature
- 55–65 °C
- TCE wash temperature
- 90–100 °C
- Environmental load
- 1 L TCE can pollute 1,000,000 L of water
- Post-wash rust protection
- 10–15 days
Trichloroethylene cleans well. That is the honest starting point, and it is why plants stay with it. But the reasons to leave have compounded: the health evidence, the handling restrictions, the storage risk, and — the one that usually decides it — the running cost once you account for evaporation losses and controlled handling.
Roovel Solutions has been replacing TCE, diesel, kerosene and naphtha on Indian production lines since 2000. What follows is the comparison we put in front of plant managers, and the changeover sequence that works.
The head-to-head comparison
| Factor | POWER CLEAN | Trichloroethylene |
|---|---|---|
| Scope | Multi-purpose across metals and non-metals | A specific metal degreaser |
| Emissions | Eco-friendly, non-toxic chemistry | Emits hazardous toxic vapours |
| Use form | Completely soluble, used diluted | Used in concentrated form |
| Handling | Non-corrosive, proven operator acceptability | Corrosive; needs secluded areas and proper exhaust |
| Health | Non-hazardous in normal use | Long-term concerns: liver, kidney, increased cancer risk |
| Storage | Non-explosive | Barrels known to explode in storage |
| Environment | Easy to handle, mix and dilute | 1 litre can pollute a million litres of river water |
| Reuse | Can be recycled | Cannot be recycled |
| Temperature | 55–65 °C | 90–100 °C |
| Shelf life | Indefinite | Evaporation losses in storage |
| Rust protection | Protects parts 10–15 days | No rust inhibitors |
What actually changes on the shop floor
The honest difference is process steps. A vapour degreaser can wash, rinse and dry in effectively one operation. Aqueous cleaning is three: wash, rinse, dry — sometimes with multiple wash or rinse stages. That is the trade you are making, and in exchange you get better process control, repeatability, far lower operating cost and no solvent compliance burden.
- Wash removes the soil — chemistry plus heat plus agitation.
- Rinse removes the cleaning agent, ideally with DM water for precision work.
- Dry removes the water, because water left on the part is what causes corrosion.
A staged changeover plan
- 1Map the current process: parts, metals, soils, cycle time, cleanliness standard and the real reason TCE was chosen.
- 2Study the contaminants. The soil, not the habit, determines the replacement chemistry.
- 3Validate in the lab on your actual parts, checking cleanliness, compatibility and bath life.
- 4Convert or specify equipment — adapt the existing tank with recirculation, or specify a spray/ultrasonic system sized to throughput.
- 5Run a supervised trial on the line with agreed pass/fail criteria, and measure against the current process rather than against a datasheet.
- 6Move to supply with dosing control, skimming and filtration in place, and train operators on concentration and bath maintenance.
What you gain
- Lower cost per component cleaned, and lower overall cost
- Better and more consistent cleaning
- Reduced inventory — one chemistry replaces several
- Better regulatory compliance and easier waste management
- Worker safety, and no special storage precautions
- Rust protection built into the wash rather than bought separately
There is a wider reason too. Industrial solvent exposure has been the subject of long-running health research, including studies associating trichloroethylene exposure with Parkinson's disease. The safest exposure to a chlorinated solvent is none.
We come to your plant, study the process with your team, and guide the switch end to end — at a lower cost of ownership, legally and safely.
Plan your TCE replacementFrequently asked questions
What can replace trichloroethylene for metal cleaning?
An inhibited aqueous degreaser in most cases. Water-based alkaline concentrates such as POWER CLEAN XL, NF-14 and LF cover the majority of machining and assembly soils at 55–65 °C. Where immersion is not yet possible, a hydrocarbon or citrus solvent such as PC-S 342 acts as a drop-in replacement.
Do I need to buy a new washing machine to stop using TCE?
Often not. Existing vapour degreasing tanks can be converted to aqueous submersion systems quickly and at low cost. Adding recirculation pumps and jetting to provide mechanical agitation is the main change, and it can usually be done to existing equipment.
Is aqueous cleaning as effective as TCE?
For the great majority of industrial soils, yes — and it is more controllable, because you can adjust time, agitation, concentration and temperature independently. Aqueous requires wash, rinse and dry stages rather than a single vapour step, which is the real process trade-off.
Will parts rust after switching from solvent to water-based cleaning?
Not when the process is set up correctly. Power Clean formulations carry rust inhibitors that protect washed and dried parts for roughly 10–15 days, and grades such as SP are designed specifically for flash-rust-prone mild and carbon steel. For longer storage, add a dedicated rust preventive.
How much does switching from TCE cost?
Capital cost is often minimal if existing tanks can be converted. Running cost typically falls, because concentrates are diluted heavily, the bath is recyclable rather than evaporating, and solvent handling and permitting requirements disappear.
