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Why the Electronics Industry Is Talking About Cleaning

In the latest episode from What’s New in Electronics Radio, host Iain Hazlewood welcomes Alex Timney, Graham Dickson and Steve Collier from GEN3 for a conversation that’s quietly becoming one of the most important topics in modern electronics manufacturing (Listen here)

Manufacturers often think of cleaning as a “box-ticking” task — but in today’s electronics landscape, it’s mission critical. Leftover flux, particulate and residues can compromise reliability, longevity and performance. In the latest What’s New in Electronics podcast, GEN3 experts unpack why cleaning technology deserves strategic attention. They also highlight an industry-wide shift as co-solvent systems fall out of favour — and what’s taking their place. 

Why Cleaning Matters More Than Ever

With tighter component spacing, finer pitch connections, and increasingly sensitive substrates, even tiny residues can cause corrosion, leakage or failure modes long before a product reaches the field, and realistically, that’s the best possible scenario where failures are concerned; because a failure IN the field can have catastrophic consequences. Cleaning is not just about removing visible contaminants — it’s about ensuring chemical and ionic cleanliness that meets evolving performance & safety standards.

From Co-Solvents to Aqueous: What’s Changing

Historically, co-solvent cleaning provided a balance of water and organic solvent to remove flux residues without flammable pure solvents. But regulatory pressures on VOCs (Volatile Organic Compound) and evolving flux chemistries have exposed limitations in co-solvent performance — especially where stringent cleanliness and environmental compliance are needed.

Aqueous solutions and specialised chemistries are now rapidly gaining ground for:

  • Greater environmental compliance
  • Lower VOC emissions
  • Improved process safety
  • Better suitability for high-density, modern assemblies 

What This Means for Manufacturers

The shift away from legacy co-solvents means manufacturers must reassess their cleaning processes. Choosing the right chemistry isn’t just about cleaning power — it’s about process compatibility, disposal, sustainability, cost, and long-term reliability. The right solution can improve yields, reduce contamination-related field failures, and provide measurable confidence in production processes.

So Where Do You Go From Here, and How Gen3 Can Help?

With co-solvents on the decline, manufacturers now have access to a broad portfolio of cleaning technologies — particularly through the GEN3 and Zestron partnership. Here’s how their combined solutions compare and what to consider when selecting the right approach.

1. Modern Water-Based & MPC® Chemistries

Water-based cleaners — particularly those built using MPC® (Micro Phase Cleaning) technology — deliver several advantages:

Pros

  • Low environmental impact: Very low VOC values and more environmentally friendly than many solvent systems. 
  • Good Solvency: Water-based systems rinse more easily, reducing residues. 
  • Broad compatibility: MPC chemistries can handle a variety of flux types and contaminants. 

Cons

  • pH considerations: Many water-based systems are alkaline, which enhances cleaning power but may require careful material compatibility analysis (e.g., sensitive alloys or coatings), but GEN3 can guide you through this transition.
  • Disposal: Wastewater streams must be managed responsibly, potentially with filters or separation systems to comply with local effluent regulations.

These chemistries are particularly useful as replacements for traditional co-solvents, providing strong cleaning performance with fewer environmental concerns.

2. FAST® & HYDRON® Technologies

Other Zestron innovations include FAST® (for enhanced wetting) and HYDRON® (stable single-phase) cleaners:

Pros

  • Reduced cleaner consumption: Longer bath life can lower operational costs. 
  • Robust performance across contaminant types. 

Cons

  • Chemical handling: Operators must understand the appropriate pH range for specific substrates and how to maintain bath concentration.
  • Waste management: Even water-based chemistries require responsible handling to meet environmental standards.

3. Targeted Solvent Options

Zestron also offers modern solvent cleaners designed for water-free or semi-aqueous processes, often with high flash points and improved safety compared to traditional alcohols like IPA. 

Pros

  • Strong cleaning in water-free workflows
  • High flash points for safer handling 

Cons

  • Still require VOC and disposal oversight
  • May not meet all environmental targets if unrestricted solvent use is a concern

Disposal, pH & Environmental Frameworks

When comparing chemistries, consider:

  • pH: Alkaline cleaners are effective but may affect sensitive materials; neutral pH options are gentler but may require longer cycle times depending on residues.
  • Disposal: Water-based wastes often need pre-treatment (e.g., filtration or neutralisation) to meet discharge regulations.
  • Environmental compliance: Low-VOC and low-hazard formulations align better with sustainability and emissions targets.

How GEN3 & Zestron Support Manufacturers

GEN3 is the only strategic partner and UK distributor of the full range of Zestron cleaning chemistries and services — bringing deep technical expertise alongside industry-leading products. 

Through this collaboration, manufacturers gain:

  • Tailored chemistry selection: A cleaning solution that fits your specific application, whether stencils, PCBs, power modules or maintenance tasks. 
  • Process validation: Access to analytical services such as ionic contamination analysis, SIR/ROSE testing and objective evidence reporting. 
  • Training & technical support: Expert guidance and process coaching to implement and optimise cleaning reliably. 
  • Bath monitoring tools: Tools like Zestron’s Bath Analyser kits and Zestron Eye help maintain concentration and performance over time. 

By linking tailored chemistries with validation and monitoring, GEN3 and Zestron help manufacturers transition away from outdated co-solvent systems toward solutions that deliver both performance and sustainability.

Conclusion: A Cleaner, Smarter Future

The shift in cleaning technology mirrors broader trends in manufacturing: a demand for higher reliability, lower environmental impact, and data-driven process control. Through new chemistries, thoughtful evaluation of pH and waste management, and partnerships like that between GEN3 and Zestron, electronics manufacturers are better equipped to tackle modern challenges — and ensure their products can endure the real world.