Component Cleanliness & Flushing Rigs

Automated flushing and cleanliness systems engineered for repeatable compliance, cleanliness validation, and high-volume production throughput.

COMPONENT CLEANLINESS & FLUSHING RIGS

Curtis Assemble & Test Ltd (CAT) design and manufacture bespoke component cleanliness rigs engineered to remove particulate contamination and achieve repeatable cleanliness results. Developed for demanding automotive, aerospace, defence, and precision manufacturing environments, our systems support compliance with stringent cleanliness standards and validation requirements.

Using controlled flushing, pulsed flow techniques, and targeted high-pressure delivery, CAT systems remove debris and contamination from complex internal geometries. Integrated monitoring and process feedback ensure cleaning performance remains consistent across every cycle, improving product quality and reducing scrap.

Whether integrated into standalone washing stations, automated production lines, or end-of-line validation processes, CAT cleanliness rigs deliver reliable, repeatable results tailored to component type, geometry, and cleanliness specification.

ADVANCED FLUSHING & CLEANING TECHNIQUES

CAT cleanliness systems utilise proven flushing and wash strategies to achieve high levels of internal cleanliness:

Pulsed flow and reverse flushing to dislodge trapped contaminants
CNC-controlled lances to target specific bore and cavity geometries
Controlled pressure and flow regimes to optimise particulate removal
Air-fluid mixtures to enhance turbulence and cleaning performance
Custom cleaning cycles to balance cycle time with cleanliness levels

These techniques allow components with small internal passages, blind bores, and complex fittings to be cleaned effectively, even when manual or conventional wash processes are insufficient.

MONITORING, VALIDATION & CLEANLINESS ASSURANCE

Cleanliness and flushing rigs can be equipped with a range of monitoring and validation tools to verify process performance. Automated cleanliness measurement and fluid sampling ensure particulate levels remain within specification throughout operation.

Temperature, pressure, and flow control systems maintain consistent cleaning conditions, while filtration and fluid management modules ensure stable process performance across multiple cleaning cycles. Indicator systems, interlocks, and cycle status feedback further enhance operator awareness and traceability.

This integrated approach supports compliance with industry cleanliness standards and helps OEMs reduce failure risk, downtime, and performance issues associated with contamination.

CLEANLINESS & FLUSHING SYSTEM CAPABILITIES

High-Pressure Component Flushing — High-Pressure Component Flushing – Removal of particulate contamination using controlled fluid delivery at pressures up to 300 bar to achieve defined cleanliness levels

Air-Fluid Pulsed Cleaning — Pulsed flow with up to 5% air content improves contaminant removal from blind bores and complex cavities

CNC-Controlled Lances & Targeted Delivery — Precision cleaning of internal features using programmable lances for consistent, repeatable results

Multi-Component Throughput — Systems can clean multiple components per cycle with fixture changes to accommodate different part variants

Cycle Time Optimisation — Cleaning cycles tuned to meet production takt, with proven applications achieving cycle times down to ~10 seconds

Sensor Verification & Interlocks — Placement, geometry, and diameter sensors confirm correct part loading before cycle initiation and prevent incorrect cleaning

Integrated Power Pack & Fluid Management — Mobile or fixed power packs with pumps, tanks, filters, electrical cabinets, and HMI control for setup and basic diagnostics

Cleanliness Monitoring & Sampling — Automatic periodic measurement of flushing fluid cleanliness ensures consistent particulate levels throughout operation

High-Pressure ISO 4113 Compatibility — Systems compatible with ISO 4113 operational fluids and suitable for precision or clean room environments

Dedicated Cleaning Heads & Tooling — Component-specific cleaning heads, jaws, and fixtures engineered for secure holding and correct interface engagement

Multi-Station Configurations — Dual-station and multi-station rigs increase throughput and operational flexibility for production environments

Stainless-Steel Construction Available — Ideal for laboratory, clean room, and contamination-sensitive test applications

Example Cleanliness & Flushing Systems

CAT cleanliness and flushing systems are used across demanding production and validation environments where particulate contamination cannot be tolerated. Typical applications include prototype development, batch validation, end-of-line testing, and process-critical component cleaning.

COMMON APPLICATIONS

Component cleanliness and flushing systems are used wherever particulate contamination can compromise performance, reliability, or compliance. Typical applications include:

Industries We Support

WHAT WE CAN DELIVER

Bespoke cleanliness and flushing rigs tailored to component geometry and cleanliness levels
Multi-component and multi-station configurations to support higher throughput
High-pressure flushing with configurable air-fluid mixtures
Integrated fluid filtration, conditioning, and cleanliness monitoring
Dedicated fixtures, tooling, and cleaning heads for specific part types
Stainless-steel construction options for clean room and lab environments
Mobile or fixed power packs with pumps, tanks, filters, and control
HMI interfaces for setup, status, and operator feedback
Controlled pressure, flow, temperature, and air content for repeatable performance
Full in-house build, commissioning, and validation at CAT
On-site installation, handover, operator training, and documentation

LOOKING TO ACHIEVE STRICT COMPONENT CLEANLINESS LEVELS?

Our engineers work closely with customers to define cleanliness requirements, configure flushing strategies, and recommend the right rig for your components and production environment.

Talk to our engineering team today and we’ll help define the right solution for your cleanliness requirements.

Why Choose CAT?

☑️ Proven expertise in component cleanliness, flushing, and particulate validation

☑️ Bespoke rigs engineered to meet application-specific cleanliness levels

☑️ Strong track record in automotive, aerospace, defence, and precision manufacturing

☑️ Optimised cycle times for prototype and high-volume production environments

☑️ Mobile or fixed installations with full fluid management and filtration

☑️ Full build, commissioning, and validation performed in-house

☑️ End-to-end project delivery with training, documentation, and support

☑ Trusted by OEMs and Tier-1 manufacturers for validation and production environments

Real-World Performance, Real-World Trust

"Solving our design problems with innovative solutions, CAT lead us in the right direction to get the best results possible."

Richard Challis Senior Engineer, Crane Building Services & Utilities

"CAT followed a project plan and delivered on time. Clear and concise technical support was given when required."

Jim Holder

Engineer, Delphi Diesel Systems.

"For almost a decade, Curtis Assemble & Test has supplied Perkins with first‑class cleaning and flushing systems for our global engine assembly operations. They consistently deliver high‑end, bespoke solutions built to the highest standards. Our partnership with Curtis has helped us maintain exceptional levels of quality and customer satisfaction. Their team is reliable, professional, and their expert guidance has been invaluable over the years."

Andy Hurdman

Senior Manufacturing Engineer, Perkins Engines Co Ltd

READY TO DISCUSS YOUR CLEANLINESS & FLUSHING REQUIREMENTS?

Our engineers can advise on flushing strategies, cleanliness levels, cycle times, and rig configurations built around your components and production environment.