Industrial Strength

When we think of cleaning or selling to industrial facilities, we generally envision large smokestacked facilities with big machines and dirty buildings. And surely this picture represents a segment of the industrial market. Today, however, an industrial customer can also be a high-tech manufacturer (anything from nano technology to solar panels), a small-to-large machine shop, an international aerospace research institute, or a pharmaceutical giant. All these can have millions of square feet of production, office, warehouse, computer, and cleanroom space to maintain.

According to the U.S. bureau of Statistics, there are an estimated 338,309 manufacturing facilities with close to 12 million employees, accounting for 11 percent of the U.S. workforce. They earn an estimated US$660 billion in wages each year. These facilities all have special cleaning needs that must be met on a regular basis, which spells opportunities for distributors to sell products and cleaning professionals to sell services—big time!

Regardless of the specific type of manufacturing facility, cleaning plays an important role in maintaining a safe, healthy, and positive working environment in all areas. At the same time, cost control and effective management of the cleaning function is always a primary concern, leading many facilities to outsource their cleaning in order to concentrate on their primary business of manufacturing, assembly, or processing.

Basic Start

Cleaning tasks in industrial facilities start with the same basics as any facility, such as office, restroom, and floor care, then progress to more challenging areas specific to their niche that require the use (and sale) of specialized chemicals, equipment, and procedures.

When dealing with a small manufacturer (5,000 to 50,000 square feet), cleaning will focus on several sets of small restrooms, a front office area, one or two employee lunch rooms, a production area, and one or more small supervision and quality-control offices off the production area. The cleaning here is not much different than other types of nonindustrial facilities, with the exception that the offices, restrooms, and lunchrooms in/near the production areas normally get heavier traffic and will typically be dirtier than what you would find in these areas elsewhere; it is not uncommon for large amounts of soil related to the manufacturing process to get on floors and surfaces and tracked into adjoining office areas. This often creates unique cleaning challenges. In some cases, it also can mean health and safety hazards, including exposure to toxic products and materials and even fire and explosion threats related to airborne and settled dust common to many manufacturing processes. For this reason, In some manufacturing locations, cleaning workers may not actually service production areas or equipment other than to sweep, vacuum, or clean the floors; dump the trash; and service the restrooms. And in some areas, even these tasks are done by equipment or machine operators and or their helpers. No matter the extent of cleaning being performed, in industrial sites more than anywhere, appropriate personal protective equipment (PPE) is required and must be worn in all production areas at all times. This includes such items as safety glasses or goggles, gloves (cloth or liquid proof), hard hat, ear plugs, hard tipped shoes, knee pads, and in certain cases, a dust or vapor respirator and other PPE.

Areas & Surfaces

Let’s now take a look some common surfaces, areas, and cleaning tasks related specifically to industrial and manufacturing facilities, keeping in mind that there are many variables depending on the specific type of facility.

Floors. It is not uncommon to find several types of floor coverings in the same facility. You may have specialty flooring or bare, painted, sealed, or polished concrete in the aisles and production areas; ceramic, quarry, or VCT tile in the restrooms; vinyl sheet coverings in cleanrooms; and carpeting in office and engineering areas. You could also have wood, metal, or epoxy type coatings in other areas.

Basic tasks include sweeping, dust mopping, or vacuuming, which may be followed by wet cleaning with a disinfectant or degreaser or specialty detergent, depending on the needs of the area. On concrete, epoxy, quarry, and ceramic tile, degreasers are commonly used if oils and grease are present. On topically coated VCT or vinyl sheet flooring, a neutral detergent is preferred to prevent damaging the tile or finish. In larger facilities, wet cleaning and often the sweeping can be done with a walk behind or riding scrubber/ sweeper, depending on the surface and square footage.

Carpeting. Due to the proximity of the extra soil in even the nonproduction areas of industrial buildings, it is important to vacuum carpet daily and spot clean when visibly soiled. Large-walk off matting at transition points between carpeting and production areas helps prevent soil tracking and protect more sensitive surfaces and areas from contamination. Carpeting in the actual production areas is generally not a good fit because of high levels of difficult to remove soils and contaminants. If carpeting is present, protective entry matting and frequent interim and deep cleaning will be needed to keep it clean, healthy, and presentable.

Manufacturing/production area. In addition to the floor care procedures mentioned above, the actual manufacturing areas of facilities pose some special cleaning concerns:

• Trash cans may be heavy and messy, so plastic liners and rolling carts should be used where needed.
• Water control is important to prevent slip and fall injuries, electrical shock, and damage to equipment or surfaces that may be sensitive to water or moisture.

Warehouse. Daily, frequent, or constant tasks, including sweeping, mopping or auto-scrubbing of concrete flooring, are common in most warehouse facilities. These are work areas, so you must be aware of your surroundings, which means staying out of traffic corridors and watching for fork lifts, carts, trucks, and automated equipment. For safety, it is especially important in these areas to constantly pick up debris and liquids to eliminate slip, trip, and fall hazards. Also keep your tools and equipment out of traffic areas and under your direct control at all times.

Machinery

Care must be taken around machinery and equipment to avoid contact or entrance into operational areas. These areas are generally identified by yellow and black striped markings on the floor or with physical barricades. Find out and be sure your staff is informed if these areas are to be cleaned or are off limits.

If you are expected to clean equipment and machinery, or be in close proximity to these items, training will be provided regarding safety precautions, any lock outprocedures, and specific chemicals, equipment and procedures to be used. However, below are a few basics:

• Make sure all equipment is off, cool, and properly locked out before cleaning.
• Remove as much soil with a plastic putty knife or dustpan as possible. Do not use abrasive materials or sharp tools that will scratch or mar the surface.
• Absorb any excess oils or liquids with rags or pads.
• Test all cleaners or solvents in a small area before proceeding. If the color of the paint is coming off on the rag or cloth, the chemical being used is too strong.
• Avoid the use of water-based cleaners on bare metal surfaces unless the cleaners are made especially for this use. Petroleum solvent, citrus, or soy-based cleaners are commonly used. A light coating of machine oil is sometimes applied to bare iron or metal surfaces after cleaning to prevent rust, but do not do this unless instructed and trained to do so properly.
• Do not over apply solutions (theyshould not drip or run down the surface). Rather, re-clean the surface one or two times (as needed) to obtain the desired results.
• Dispose of all waste materials and contaminated rags and solutions as instructed. Wear appropriate gloves, clothing, and PPE to keep liquids off

Equipment, Supplies & Chemicals

Using the right equipment to do the job will reduce the time and effort it takes and often eliminates the need to use a ladder or scaffolding that may pose additional safety risks. Use only those tools and products provided by or approved by the company. Clean all tools and equipment after each use and return them to secure storage.

In addition to floor machines, auto scrubbers, some other equipment that is often used in industrial locations include a backpack or heavy-duty vacuum with the appropriate filter (HEPA) and an extension tube with a brush or other customized attachment on the end. This is often a great tool for vacuuming high, low, or hard to reach surfaces or areas to remove powders, dust, and residues that have settled on surfaces such as vents, rafter, ledges, pipes, shelves, floors, walls and equipment. Other equipment you are likely to use include pressure washers, scissor lifts, and hoists along with testing and monitoring devices. If you are unfamiliar with any of the tools or chemicals you will be using, ask your supervisor for specific instruction before proceeding.

Management

The cleaning of industrial and manufacturing facilities is important and challenging work. All employees should receive adequate training, support, and supervision. Written procedures and policies should be developed and followed for the cleaning of all areas, equipment, and surfaces. Cleaning should not be an afterthought or secondary responsibility. To prevent cleaning from becoming a problem or overly expensive, it should be taken seriously, properly supported, and professionally managed.