Small changes for big impact

INDUSTRIAL CLEANING and maintenance might not always take centre stage in the manufacturing world. But its importance cannot be underestimated. The global industrial cleaning market is set to become worth more than £60 billion by 2030¹ thanks to the demand for increased efficiency, hygiene and sustainability in industrial facilities​​ all over the world.

Cleaning is not just about keeping operations looking tidy. It plays a critical role in making sure equipment lasts for a long time, as well as reducing downtime, and maintaining worker safety. When done correctly, cleaning safeguards production quality and ensures compliance with ever-tightening health and safety regulations. Yet, despite its significance, cleaning strategies are often overlooked. And when that happens, it can lead to inefficiency, hidden costs and safety risks.

In industrial settings – where even an hour of unplanned downtime can cost manufacturers tens of thousands of pounds – getting the cleaning process right is more than just a practical necessity; it’s a strategic imperative. The tools and products used for cleaning may seem like minor details, but they can have a major impact on the overall operational performance. So, choosing the right solution for the task at hand is crucial in enhancing productivity, ensuring worker wellbeing, and contributing to a cleaner, more sustainable environment.

One critical yet often overlooked detail is the choice of wiping products for cleaning and maintenance, for example. The wrong product might lead to higher costs, wasted time, and potential safety risks, whereas the right solution can significantly enhance both performance and sustainability.

The hidden costs

Industrial facilities face a range of cleaning challenges – from oil spills to heavy debris. And each cleaning task requires a specific solution. Yet, in many cases, facilities default to what is available – whether that is overusing generic blue rolls or relying on rags and laundered cloths which are commonly not suitable for industrial use.

Common challenges include:

• Clutter from misplaced cleaning tools: Inconsistent storage methods for blue rolls, rags and cloths might cause trip hazards or contamination. Rolls left scattered on floors or under benches not only create safety risks but also waste valuable storage space​.
• Over- or under-specification: Using a high-performance wipe for tasks that require a basic hand towel can cause unnecessary expenditure. Conversely, a cheap paper towel may fail to handle industrial-grade spills, increasing consumption and overall costs​​.
• Waste: Traditional blue rolls or rags are prone to wastage. Employees often pull excessive lengths of material, only to throw it away after minimal use. When there is a spill, facilities can quickly deplete their resources by relying on materials that are just not fit for purpose​.

The impact of these practices is not always immediately obvious. However, they can result in excessive product consumption, lost time, increased risk of contamination, and ultimately, financial losses.

The cost of using the wrong cleaning products

Consider the ripple effects of using the wrong cleaning tools in an industrial setting. The initial cost of a subpar product may seem negligible. But the hidden expenses and inefficiencies it creates can snowball into significant operational challenges.

Increased waste
While many of us default to using traditional rags, poor quality blue rolls or all-purpose cloths for a wide range of cleaning tasks, they often lack the durability and absorbency needed for heavy-duty cleaning. For example, cleaning an oil spill with a low-grade paper towel may require meters of material to achieve the desired result. This not only wastes resources but also drives up costs associated with frequent restocking and disposal.

Overconsumption isn’t limited to cost implications. It has a toll on the environment too, with excess waste increasing landfill contributions and adding to a facility’s carbon footprint – all of which directly contradicts corporate sustainability goals​​.

Unplanned downtime
Improper cleaning can lead to residue build-up or insufficient removal of contaminants, which, over time, compromises equipment performance. For instance, using a low-absorbency material to clean critical components of a machine might leave behind moisture or debris, leading to malfunctions. All of this adds up to ‘unplanned downtime’, something which costs manufacturers up to $50 billion a year, according to Forbes.²

Today, with inflation and higher production loads amplifying every disruption, a single hour of downtime costs 50% more than it did just a few years ago​.³ The wrong choice in cleaning products might seem insignificant, but its impact on operational efficiency can be profound.

Compromised safety
It’s not just about inefficiency, of course. Improper cleaning tools and methods can create risks for worker health, safety and wellbeing too. Safety hazards increase significantly when cleaning products fail to perform as expected. For example, laundered cloths are often inconsistent in quality, size, and material, making them unsuitable for precise cleaning tasks. These tools can leave behind lint, dust, or even dangerous contaminants like metal shavings, which pose risks to both equipment and human health​.

The cost of these exposures – ranging from sick days to potential lawsuits – can far outweigh any perceived savings from using lower quality cleaning tools.

Inefficient resource allocation
Beyond safety and downtime, the wrong cleaning products can lead to poor resource allocation across a manufacturing facility. Consider a high-performance wipe that costs more per unit but is engineered for oil and grease removal. Using this product for a simple hand-drying task not only wastes money but also reduces availability for its intended purpose.

Similarly, cheap alternatives used for heavy-duty cleaning often fail, resulting in workers having to redo tasks or use more material than necessary. This cycle of inefficiency increases labour costs, disrupts workflows, and adds unnecessary strain to operations

Reputation and compliance risks
In sector such as food manufacturing or pharmaceuticals, inconsistent cleaning practices can lead to contamination and regulatory violations. For example, improperly cleaned surfaces may fail hygiene audits, resulting in fines, recalls, or reputational damage. In a world where sustainability and transparency are increasingly valued by consumers, companies cannot afford the fallout from poor maintenance practices.

Missed sustainability goals
Many facilities are under pressure to align with corporate sustainability targets. Traditional cleaning solutions like rags or laundered cloths often require significant resources for transportation, laundering, and disposal, creating unnecessary waste and emissions. 

On the other hand, disposable, task-specific wipes, when used correctly, reduce overconsumption and contribute to measurable waste reduction​. Facilities that fail to adopt sustainable cleaning strategies risk falling behind in a market that increasingly prioritises environmental responsibility.

The wrong cleaning product might seem like a minor inconvenience at first, but its cumulative effects can erode a facility’s operational efficiency, financial stability, and reputation. Facilities must take a proactive approach, investing in task-specific solutions that align with their operational demands. By doing so, they can avoid the pitfalls of inefficiency, waste, and safety risks while enhancing overall productivity and sustainability.

Optimising industrial cleaning

Kimberly-Clark Professional’s extensive experience in industrial settings reveals a number of critical insights into effective cleaning strategies. For example, you need the right product for the right task. Cleaning spills from oil, grease, or chemicals requires specific materials engineered for those challenges. For instance, synthetic fibres resist harsh chemicals, while high-density wipes handle abrasive surfaces​​.

Meanwhile, you can reduce waste with smart dispensing solutions. Innovations such as the WypAll Midi-Roll system provide controlled, single-sheet dispensing. The 2-in-1 system allows users to use exactly the right number of wipers dispensed by the users preferred method, for each wiping task. This minimises overuse and waste, reducing consumption by up to 15%​​.⁴

Portable and space-efficient systems eliminate clutter and ensure that cleaning tools are always within reach, helping to reduce delays and improve safety​. 

Bridging maintenance and cleaning

Effective maintenance strategies – whether predictive, preventive, or reactive – depend on seamless integration with cleaning practices. Maintenance tasks often involve cleaning debris, removing contaminants, or applying lubricants, which require appropriate cleaning solutions.

For example, advanced wiping solutions help detect and prevent equipment issues before they escalate. Clean surfaces enable accurate monitoring of machinery performance.

There is also a need to shift behaviours in the workplace by breaking the habits we have at home. Far too often, we dispense far more kitchen roll or toilet paper than is necessary. Right now, we do the same at work because there is a perception that one or two sheets of wipes or cloths will not do the job. It is an industry-wide challenge that companies must work hard to change.

Invest in the right tools

Addressing cleaning challenges in industrial environments is not just about reducing costs – it’s about creating safer, more efficient, and sustainable workplaces. Choosing the right wiping solutions may seem like a small detail, but its impact is significant.

By adopting task-specific products, streamlining storage, and prioritising worker safety, facilities can achieve long-term cost savings, enhanced productivity, and compliance with health and safety standards.

The next time you assess your cleaning strategy, ask yourself: are you using the right tools for the job? Because in industrial cleaning, small changes truly can lead to big impacts.

Catherine Grinstead is UK & Eire industrial customer marketing manager at Kimberly Clark Professional. For more information, visit www.kcprofessional.com