Why does foreign object contamination occur? What is the brush design that should be reviewed at manufacturing sites?

In manufacturing sites, foreign object contamination countermeasures are a crucial issue for maintaining product quality and achieving stable production. Foreign object contamination not only leads to product defects and complaints but can also cause line stoppages and significant losses in some cases.
While equipment and operations are reviewed to address such risks, one often overlooked factor is "brushes." Brushes are used in various processes such as cleaning, conveying, and removal, and their design and selection can sometimes be a cause of foreign object contamination.
Here, we will explain the risk of foreign object contamination in manufacturing sites and the concept of brush design as a countermeasure.
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Main Causes of Foreign Object Contamination in Manufacturing Sites
Foreign object contamination occurs due to various factors, regardless of the industry. The main causes include:
・Metal fragments due to wear or damage to equipment parts
・Fragments due to deterioration of resin parts
・Residual dust and swarf
・Shedding of fibers and bristles
・Residue due to inadequate cleaning
These issues do not only occur in isolation; problems can also become apparent when multiple factors combine.
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Specific Examples of Problems Caused by Brushes
In manufacturing sites, problems related to brushes are not uncommon. Typical examples include the following phenomena:
・Bristles falling out and contaminating products or equipment
・Worn bristles remaining as fine foreign objects
・Foreign objects accumulating inside the brush and reattaching
・Insufficient contact with the target object, leading to ineffective removal
・Damage to products or equipment due to excessive contact
Many of these issues are characterized by occurring not so much due to the quality of the brush itself, but rather due to a mismatch in design or selection for the intended application.
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Key Points for Brush Design to Reduce Foreign Object Contamination Risk
① Structural Design to Suppress Bristle Shedding
The bristle tufting method and fixing structure significantly impact the risk of bristle shedding.
To reduce the risk of foreign object generation, consider the following points:
・Tufting structure with high fixing strength
・Tufting density appropriate for the application
・Structural design suitable for the operating environment
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② Bristle Material Selection According to Operating Environment
In manufacturing sites, conditions such as abrasion, chemicals, temperature, and moisture affect brush deterioration.
To maintain appropriate performance, it is important to select bristle materials from the following perspectives:
・Abrasion resistance
・Chemical resistance
・Balance of flexibility/rigidity
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③ Brush Shape Suitable for Target Object and Process
The shape of the brush significantly affects foreign object removal performance and work efficiency.
The following are key points for selecting the appropriate shape according to the application:
・Roll brushes (for continuous processing and conveying applications)
・Channel brushes (for gaps and edges)
・Tufted brushes (for complex shapes)
By using these appropriately, it is possible to optimize contact and removal performance.
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④ Design Based on Anticipated Wear and Replacement
Since brushes are consumables, their design must account for performance degradation over long-term use.
To achieve stable operation, the following points are important:
・Selection of highly durable materials
・Structural design that facilitates replacement
・Setting appropriate operating conditions
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Case Study: Application in Food Manufacturing Sites
These brush design principles are particularly important in food manufacturing sites, where quality requirements are high.
In food factories, the following risks exist:
・Contamination by bristle materials
・Residue due to inadequate cleaning
・Deficiencies in hygiene management
To address these challenges, the following measures are required:
・Structure designed to suppress bristle shedding
・Bristle materials considering hygiene
・Brush design adapted to equipment shape
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Response by Industrial Brush Manufacturers
ON Kansai Brush Co., Ltd. designs and manufactures custom brushes tailored to applications and equipment specifications, leveraging its brush design technology cultivated for the manufacturing industry.
Based on past experience, we address the challenges of each site by optimizing elements such as bristle material selection, tufting methods, and brush shape and size according to the application.
Furthermore, our ability to handle small-lot, high-mix production allows us to flexibly respond to needs such as adapting to different specifications for each piece of equipment, verification during improvement and prototyping stages, and supplying replacement parts.
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Summary
In manufacturing sites, foreign object contamination countermeasures require not only equipment and management systems but also the design of the components used.
Brushes play a crucial role among these components, influencing both risk and efficiency through their design and selection.
Appropriate brush design can be expected to yield the following effects:
・Reduction of foreign object contamination risk
・Improvement of cleaning efficiency
・Reduction of workload
ON Kansai Brush Co., Ltd. proposes optimal brushes tailored to applications and equipment.
Please feel free to contact us regarding any brush-related challenges or improvements.