The most sustainable solvent cleaning technologies for the metalworking industry use non-chlorinated solvents, such as modified alcohols and hydrocarbons, in closed-loop vacuum systems. Filtration and distillation regenerate the solvent inside the machine, oils and residues are recovered, and energy and chemical consumption drop compared with conventional systems.
For a manufacturing shop, sustainable cleaning comes down to very concrete numbers: how much solvent you buy each year, how much waste leaves the department, how much energy each cycle draws. These are the same line items that drive operating costs, which is why the most sustainable choices often turn out to be the most cost-effective over time.
Four elements make the difference, and they work best when combined in the same system.
For decades, solvent cleaning in metalworking relied mainly on chlorinated solvents such as trichloroethylene and perchloroethylene. Today trichloroethylene is on the REACH Authorisation List, and volatile organic compound (VOC) emissions from surface cleaning are regulated by the EU Industrial Emissions Directive 2010/75/EU.
As a result, manufacturers have shifted toward non-chlorinated solvents used in sealed systems. Hydrocarbons perform well on straight oils and greases. Modified alcohols dissolve both oily contaminants and some polar residues, so they cover a wider range of applications. The operational differences between the two solvents are covered in the guide to solvent cleaning for metal parts.
|
Criteria |
Chlorinated solvents |
Hydrocarbons, closed-loop vacuum |
Modified alcohols, closed-loop vacuum |
|
Regulatory framework |
Tightening restrictions: trichloroethylene requires REACH authorization |
Non-chlorinated solvent, handled in a sealed system |
Non-chlorinated solvent, handled in a sealed system |
|
Contaminants removed |
Oils and greases |
Straight oils and greases (non-polar contaminants) |
Straight oils, soluble oils and polar residues |
|
Operator exposure |
Requires careful control |
Limited: the cycle runs in a sealed chamber |
Limited: the cycle runs in a sealed chamber |
|
Solvent regeneration |
Distillation, depending on the system |
Continuous vacuum distillation |
Continuous vacuum distillation |
|
Waste recovery |
Variable |
Oils separated and recovered |
Oils separated and recovered |
|
Overall profile |
Increasingly restricted use |
Sustainable for oily contaminants |
Wide range of applications |
Vacuum is the technology that brings cleaning results and sustainability together. Once the air is removed from the chamber, the solvent reaches blind holes and internal cavities using less liquid. At the end of the cycle, parts dry in the same chamber and the evaporated solvent is recovered.
The closed loop completes the picture. Filtration and distillation extend solvent life, oils removed from the parts are separated and collected, and metal residues stay in the filters. This cuts both solvent purchases and liquid waste for disposal. Compared with conventional aqueous cleaning, the process also eliminates repeated rinse cycles and the process water they consume.
When contamination is mixed, organic and inorganic, some systems combine modified alcohols and aqueous solutions in a single cycle, such as the KP HYBRID line. For fully water-based applications such as deoxidation and pickling, vacuum technology also applies to aqueous systems like the KP WTR line.
The sustainability of an industrial parts washer is assessed with verifiable indicators. These are the figures to request from every supplier before buying.
|
Indicator |
What to ask the supplier |
Benchmark example |
|
Waste recovery |
What percentage of oils and residues is separated and recovered |
Up to 99% with KP Kleen Power technology |
|
Cleaning chemical consumption |
How often the solvent is topped up or replaced |
Up to 95% less than conventional systems |
|
Energy consumption |
How much energy a full cycle requires, drying included |
Up to 40% savings in electrical energy |
|
Life cycle impact |
Is there a third-party verified environmental declaration |
EPD to ISO 14025 for the KP 100 HMA |
|
Monitoring |
Can consumption and machine parameters be viewed |
Remote monitoring with IFP Portal |
The most comprehensive indicator is the Environmental Product Declaration (EPD), which measures the machine’s impact across its entire life cycle: raw material extraction, manufacturing, transport, use and end of life. The data is verified by an independent body in accordance with ISO 14025, making it possible to compare different systems on a like-for-like basis.
IFP Europe, based in Galliera Veneta near Padua, Italy, designs and builds vacuum washing machines that run on modified alcohols, hydrocarbons and aqueous solutions in closed-loop systems. According to the company’s 2025 Sustainability Report, vacuum operation cuts consumption by 45-50% compared with conventional cleaning, and recovery of oils, emulsions and metal residues reaches up to 99% of waste materials, which can be fed back into production or sent for recycling.
The KP 100 HMA has earned an EPD in accordance with ISO 14025, moving the system’s sustainability from claims to verified measurement. The company applies the same principle to its own operations: its photovoltaic system generated more than 103,000 kWh in 2025. IFP Europe is a Società Benefit, the Italian legal form of a benefit corporation, and has achieved B Corp certification. The full story is on the sustainability page.
Yes, when it uses non-chlorinated solvents in a closed-loop vacuum system. Distillation and filtration regenerate the solvent inside the machine, oils are recovered and solvent top-ups stay limited.
Both are non-chlorinated solvents and, in a closed loop, have a similar environmental profile. The choice depends on the contaminant: hydrocarbons suit straight oils and greases, while modified alcohols also handle soluble oils and polar residues.
It depends on the process. Conventional aqueous cleaning requires rinsing, energy for heating and drying, and wastewater treatment. A closed-loop vacuum solvent system reuses the solvent for many cycles and dries parts in the same chamber. The comparison should be based on actual consumption and, where available, on the EPD.
An EPD (Environmental Product Declaration) documents a system’s environmental impact throughout its life cycle, from manufacturing to disposal. It is verified by an independent body in accordance with ISO 14025 and published in public registries such as the International EPD System.
In systems with integrated distillation, oils are separated from the solvent and collected in a dedicated container, while solid residues stay in the filters. These materials can go back into production or be sent for recycling.
Looking to cut consumption and waste in your cleaning department? Explore the KP Kleen Power range or contact IFP Europe’s technical team to find the right solvent and system for your parts.