How Dry Ice Blasting Compares to Traditional Industrial Cleaning Methods

Industrial facilities have dozens of cleaning methods to choose from, each with strengths and weaknesses that make it better suited for certain jobs. Sandblasting removes heavy rust but creates dust and surface damage. Pressure washing handles large areas quickly but leaves everything soaked. Chemical cleaners dissolve tough buildup but require disposal and protective equipment. Dry ice blasting operates differently than any of these approaches, which makes direct comparisons tricky but worth examining for facilities trying to improve their maintenance operations.

The Abrasion Question

Sandblasting and media blasting work by hitting surfaces hard enough to knock contaminants loose. The trade-off is that they also remove thin layers of the underlying material with each pass. This works fine on thick steel structures that can handle some surface loss, but it’s a problem for precision equipment, thin-walled components, or anything with tight dimensional tolerances. The abrasive media also gets everywhere, requiring extensive cleanup and creating disposal challenges when the media becomes contaminated.

Dry ice pellets are softer than most industrial materials, so they remove contamination without gouging or etching the surface underneath. A turbine blade or electrical component can be cleaned repeatedly without degrading over time from the cleaning process itself. The pellets also sublimate into gas rather than scattering across the floor, which eliminates the cleanup phase that follows abrasive blasting. Facilities that switched from sandblasting often cite this lack of secondary mess as one of the biggest operational improvements.

Water and Drying Time

Pressure washing and steam cleaning rely on water volume and temperature to break down and flush away contaminants. These methods handle large surfaces efficiently and don’t require expensive consumables beyond water and detergent. The problem is that water takes time to dry, which extends downtime. Electrical equipment can’t be powered up while wet. Metal surfaces start corroding if moisture lingers. Some facilities need to run heaters or fans for hours after cleaning just to get equipment dry enough to restart.

Dry ice blasting introduces no moisture whatsoever. Equipment can go back online immediately after cleaning because there’s nothing to evaporate or drain away. This matters most in facilities with tight production schedules where every hour of downtime costs money. The method also works on electrical panels, motors, and control systems that would be off-limits to water-based cleaning. Plants that previously scheduled cleaning during long weekends or shutdown periods often find they can maintain equipment during regular shift breaks instead.

Chemical Handling and Disposal

Chemical cleaners excel at dissolving specific types of contamination. Degreasers cut through oils and lubricants. Acidic cleaners remove mineral deposits and rust. Alkaline solutions handle organic buildup. The challenge is matching the right chemical to each job, storing hazardous materials safely, protecting workers during application, and disposing of contaminated waste according to environmental regulations. These requirements add labor, equipment, and ongoing costs that compound over time.

Dry ice uses food-grade carbon dioxide that poses no disposal concerns. The only waste is the contamination that gets removed, which is often easier to handle than chemical-soaked rags or contaminated solvent. Facilities reduce their inventory of hazardous materials and simplify their environmental compliance paperwork. Workers also appreciate not having to suit up in respirators and chemical-resistant gear for routine maintenance tasks.

When Each Method Makes Sense

No single cleaning approach works best for every situation. Heavy rust removal on structural steel still favors abrasive methods. Large outdoor areas benefit from pressure washing’s ability to cover ground quickly. Certain chemical reactions can’t be replicated with physical cleaning alone. What’s changed is that dry ice blasting now handles many jobs that used to default to these traditional methods simply because better options weren’t available.

Facilities that evaluate their cleaning needs comprehensively often end up using multiple methods strategically rather than relying on one approach for everything. The difference is choosing each method based on what it does well rather than just using whatever’s familiar. nexAir’s KnowHow™ comes from working with operations across different industries to match cleaning challenges with practical solutions, helping facilities Forge Forward with maintenance strategies that balance effectiveness, cost, and operational impact.