7 Mistakes When Using Industrial Cleaners

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Industrial cleaning agents are designed to handle even the toughest dirt – from grease and oils to chemical residues. However, their effectiveness depends not only on the quality of the raw materials but also on proper handling. Mistakes in storage, dilution, or application can lead to reduced performance, surface damage, or even safety risks. In this article, we will look at seven of the most common mistakes and practical tips on how to avoid them.

1. Underestimating safety data sheets and labelling

Safety Data Sheets (SDS) and labelling according to CLP/GHS regulations are not merely a formality but a key source of information for the safe handling of industrial cleaning agents. A common mistake is their superficial reading or ignoring hazard symbols, such as warning pictograms for corrosivity, flammability, or toxicity. For example, agents containing strong acids or alkalis (e.g., sodium hydroxide) require specific protective equipment, such as acid-resistant gloves and safety goggles. Without knowledge of these requirements, there is a risk of chemical burns, eye damage, or even systemic poisoning from inhaling fumes.

Another issue is the lack of awareness of first aid instructions provided in the Safety Data Sheet. In the event of skin contact with a concentrated cleaning agent, immediate rinsing with water for at least 15 minutes is often necessary, rather than just wiping with a cloth. It is equally important to know whether the substance is water-miscible or whether it releases toxic gases upon contact with water (e.g., some chlorinated hydrocarbons). Regular training of employees on this information can prevent serious injuries and reduce the risk of work-related absences.

2. Incorrect Dilution of Concentrates

Many industrial cleaning agents are supplied as concentrates that must be diluted with water before use. The mistake lies either in insufficient dilution, which leads to waste and unnecessary environmental burden, or in excessive dilution, which reduces effectiveness and prolongs cleaning time. For example, alkaline cleaning agents for metal degreasing are typically diluted in a ratio of 1:10 to 1:50, but the exact ratio depends on the type of contamination and material. When diluting, it is crucial to follow the manufacturer’s instructions and use measuring containers or dosing systems.

Another risk is incorrect mixing order. Concentrates should never be diluted with hot water, as this can cause a rapid release of heat or gases, especially with acidic or alkaline substances. Always add the concentrate to water, not the other way around, to prevent local overheating and potential splashing. For precise dosing, it is advisable to use automatic dispensers, which minimize human error and ensure consistent results.

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3. Inappropriate Storage Conditions

Storing industrial cleaning agents requires adherence to specific conditions to prevent degradation of active substances, leaks, or chemical reactions. A common mistake is storage in unventilated spaces, where vapors of flammable or toxic substances can accumulate, increasing the risk of fire or poisoning. For example, solvents such as acetone or isopropyl alcohol should be stored in a cool place, away from direct sunlight and heat sources, ideally in closed metal cabinets with ventilation.

Another issue is the joint storage of incompatible substances. Acidic and alkaline agents must not be stored next to each other, as in the event of a leak or spillage, a violent chemical reaction may occur, releasing heat or toxic gases. Similarly, flammable substances must be kept separate from oxidizing agents, such as peroxides or nitrates. Storage areas should be equipped with clear labeling, separate sections for different categories of substances, and absorbent materials in case of leaks.

4. Ignoring Material Compatibility

Industrial cleaning agents are often aggressive and can damage materials they come into contact with. A common mistake is using a universal cleaning agent on all surfaces without considering their chemical resistance. For example, acidic cleaning agents can corrode metals such as aluminum or zinc, while alkaline agents can damage painted surfaces or plastics. Before use, it is essential to verify the compatibility of the agent with the material, either by consulting the technical documentation or conducting a test on a small, inconspicuous area.

Another risk is the prolonged exposure of cleaning agents to sensitive materials. Even if immediate damage does not occur, repeated use of an inappropriate product can lead to surface degradation, loss of gloss, or mechanical strength. For example, some surfactants may cause cracking in plastics or rubber seals. For sensitive materials such as electronic components or optical instruments, it is advisable to use special cleaning agents with low aggressiveness and short exposure times.

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5. Mixing different types of cleaning agents without verification

One of the riskiest practices in an industrial environment is the uncontrolled mixing of different cleaning agents. Many users assume that combining two effective products will lead to better results, but the opposite is often true. For example, mixing acidic and alkaline cleaning agents can trigger a chemical reaction that releases toxic gases such as chlorine or ammonia, which endanger the health of workers. Equally dangerous is combining chlorine-containing products with ammonia or organic acids—this can result in the formation of corrosive or explosive compounds.

Before mixing any products, it is essential to consult the safety data sheets of both and verify their compatibility. In practice, the safest approach is to use one product at a time and thoroughly rinse the surface with water after its application before proceeding to the next step. If combining multiple agents is necessary, it is advisable to consult the supplier or a chemical process expert. Always remember that even seemingly harmless ingredients can cause serious problems when improperly combined.

6. Inadequate Protection of Workers and the Work Environment

Industrial cleaning agents often contain aggressive substances that can harm workers' health or contaminate the environment if handled improperly. A common mistake is underestimating personal protective equipment (PPE)—for example, working without gloves, protective goggles, or respirators when handling concentrates. Many users rely on the belief that “they can manage without protection,” which can lead to skin irritation, burns, or long-term health issues such as respiratory diseases.

Equally important is ensuring adequate ventilation of the workspace, especially when working with volatile substances or aerosols. In enclosed spaces, vapors can accumulate, which, if limit values are exceeded, cause dizziness, nausea, or even loss of consciousness. Before starting work, it is necessary to check that safety requirements under REACH and CLP regulations are met and ensure that all workers are trained in the use of specific products. Regular inspection of PPE and its replacement after damage or expiration is a matter of course.

7. Neglecting Maintenance and Calibration of Application Equipment

Application equipment, such as sprayers, dosing systems, or high-pressure cleaners, plays a key role in the effective and safe use of industrial cleaning agents. A common mistake is insufficient maintenance of this equipment, which leads to premature wear, leaks, or incorrect dosing. For example, clogged spray nozzles can cause uneven distribution of the product, reducing cleaning efficiency and increasing chemical consumption. Equally problematic is the use of damaged hoses or connections, which can lead to leaks and contamination of the surroundings.

Regular calibration of dosing systems is essential to ensure the correct dilution ratio of concentrates. Too low a concentration reduces cleaning efficiency, while too high a concentration may damage materials or increase the risk of chemical reactions. It is recommended to keep records of equipment maintenance and calibration and perform them according to the manufacturer's instructions. If in doubt, it is advisable to consult an expert who can help optimize the process and avoid unnecessary costs for repairs or equipment replacement.

Accurate Information Is the Foundation of Safe Work

Every cleaning agent requires an individual approach—from storage conditions to application methods. GCG Group provides detailed Safety Data Sheets (SDS) and technical specifications for every raw material supplied, helping to prevent errors and optimize processes. If you have any doubts about compatibility or correct usage, do not hesitate to contact our experts. Get in touch—or browse our catalog of over 1,300 products.