The Ultimate Guide to Water-Based Cleaning Formulations: Systems, Additives, and Surfactant Selection

Water-based cleaning agents are rapidly replacing traditional solvents due to their safety, environmental benefits, and cost-effectiveness. However, designing an efficient, stable, and non-corrosive cleaner is not just about mixing raw materials. It is a precise art involving interface chemistry, chelation, and corrosion protection.

This guide reveals the core logic of industrial cleaning formulation design from three dimensions: System Construction, Additive Combination, and Surfactant Selection.

1. Selection of the System: The "Battlefield" of Cleaning

The pH value of the cleaning system determines the cleaning mechanism and the applicable scenarios.

1.1 Alkaline Systems (Most Common)

• Scenarios: Heavy oil cleaning, degreasing.

• Mechanism:

•  Saponification Alkalis react with animal and vegetable oils (saponifiable oils) to form water-soluble soaps.

• Auxiliary Emulsification: For mineral oils (non-saponifiable), alkalis assist surfactants in emulsification and dispersion by neutralizing acidic soils and altering interface potential.

• Common Raw Materials: Sodium/Potassium Hydroxide (Strong Alkali), Sodium Carbonate (Soda Ash), Sodium Silicate, and Alkanolamines (MEA/TEA).

1.2 Acidic Systems

• Scenarios: Rust removal, scale removal, and inorganic deposit cleaning.

• Mechanism: Uses acids to chemically react with metal oxides, dissolving and peeling them off.

• Common Raw Materials: Phosphoric acid, Citric acid, and Methanesulfonic acid (MSA).

1.3 Neutral Systems

• Scenarios: Precision cleaning, sensitive metals (Aluminum/Zinc alloys), and household cleaning.

• Mechanism: Relies entirely on the wetting, emulsifying, and solubilizing capabilities of surfactants.

2. Selection of Additives: The "Special Forces"

Although used in small amounts, additives determine the comprehensive performance and added value of the product.

2.1 Chelating Agents & Dispersants

Calcium and magnesium ions in water reduce the efficacy of surfactants. Chelating agents "lock" these ions.

• Traditional: EDTA-2Na/4Na, NTA.

• Eco-friendly: GLDA, MGDA.

• Dispersants: Polycarboxylates (e.g., PAA) prevent dirt redeposition.

2.2 Corrosion Inhibitors

Must be selected precisely based on the substrate:

• Ferrous Metals (Steel): Sodium Nitrite (Traditional), Molybdates (Eco-friendly), Organic Carboxylic Amines.

• Non-ferrous Metals (Copper/Aluminum): Benzotriazole (BTA) for copper; Sodium Silicate or Phosphate Esters for aluminum.

2.3 Coupling Agents (Solvents)

• Function: Help dissolve oil and increase the compatibility of formulation components.

• Common Raw Materials: Glycol ethers (e.g., BCS, DPM).

3. Selection of Surfactants: The "Main Force"

Surfactants strip dirt from substrates through wetting, permeation, emulsification, and dispersion.

3.1 Non-ionic Surfactants (The Main Cleaning Agents)

They possess excellent emulsification and solubilization capabilities and are unaffected by water hardness.

• Isomeric Alcohol Ethoxylates (XP/XL/TO Series):
  These modern surfactants offer superior penetration and a narrow gel phase compared to traditional AEOs. For instance, products like [RQB-CN75] utilize novel isomeric structures to provide exceptional wetting and deep cleaning for stubborn oil stains.

• Secondary Alcohol Ethoxylates (SAEO):
  Known for their eco-friendliness and rapid wetting. Our [C18A] is a prime example, offering excellent miscibility with water and biodegradability, making it ideal for sustainable formulations.

• Low Foam Types:
  Polyoxyethylene-polyoxypropylene block polyethers or end-capped ethers.

3.2 Anionic Surfactants (Auxiliary & Synergy)

They provide wetting and dispersion and significantly increase the cloud point (temperature resistance) of the formulation.

• Sulfonates: Sodium Alkylbenzene Sulfonate (LAS), Sodium Xylenesulfonate (SXS).

• Carboxylates:
  Fatty acid soaps are common, but for high-performance needs, modified carboxylates are preferred. For example, [CE100A] is an isomeric alcohol ethoxylate carboxylate that delivers unmatched cleaning power for tough oil stains, especially in immersion baths heated above 50°C.

• Specialty Anionics: Sulfosuccinates (Aerosol OT) for rapid wetting; Phosphate Esters for high-alkali systems.

4. Expert Tips for Formulation Design

1. The HLB Rule:
   For mineral oil cleaning, when selecting non-ionic surfactants, adjusting the mixed HLB Value to between 11-13 usually yields the best emulsification results.

2. Cloud Point Control:
   Cleaning efficiency is highest near or slightly below the cloud point of the non-ionic surfactant. If high-temperature cleaning is required, anionic surfactants must be added to raise the cloud point.

3. Foam Management:
   For Spray Cleaning applications, foam control is critical. Standard surfactants will cause pump cavitation. You must choose specialized low-foam surfactants, such as alkyl end-capped modified ethers like [DTL1], which are designed to produce zero foam even under spray pressure while maintaining high cleaning efficiency.