The hidden costs of poor cleaning practices in industrial settings

CLEANING AND hygiene play a fundamental role in industrial operations, yet they are often treated as secondary concerns. While most facilities prioritise production efficiency, equipment maintenance, and worker safety, cleaning strategies often remain an afterthought. 

But this oversight comes at a cost - not just in terms of hygiene but in productivity losses, unnecessary spending, and increased safety risks.

The global industrial cleaning market is expected to surpass £60bn by 2030, reflecting the increasing demand for efficiency, hygiene, and sustainability in industrial settings. However, despite this growing emphasis, many businesses still default to outdated cleaning habits, relying on low-quality materials, overconsumption of disposable products, and inefficient cleaning methods.

The impact of the bad cleaning in our factories

For factories and industrial environments, where even an hour of unplanned downtime can cost tens of thousands of pounds, the impact of improper cleaning practices is far greater than many realise. The choice of wiping products and cleaning tools may seem like a minor detail, but when the wrong solutions are used, the hidden costs quickly add up.

Industrial facilities face a range of cleaning challenges, from oil spills and chemical residues to dust accumulation and equipment maintenance. Each task requires a specific solution, yet many facilities continue to use generic blue rolls, rags, and laundered cloths, assuming they are fit for purpose. The reality is that these products often create more problems than they solve.

One of the most significant hidden costs of poor cleaning practices is waste and overconsumption. Many industrial wiping products, particularly traditional blue rolls, are prone to excessive use. Employees pull large amounts of material to clean a single spill, discarding most of it after minimal use. This drives up costs due to frequent restocking and disposal, while also increasing a facility’s environmental impact.

Then there is residue build-up and contamination, which can lead to unplanned downtime and equipment failure. Using low-absorbency materials for industrial cleaning often leaves behind moisture, grease, or dust, which, over time, affects machine performance. According to industry reports, unplanned downtime costs manufacturers up to £40.6bn a year, with a single hour of downtime now costing 50% more than it did just a few years ago. In today’s climate of rising inflation and increased production demands, businesses can no longer afford the risks associated with ineffective cleaning products.

The link between cleaning and maintenance

Effective maintenance and cleaning go hand in hand, yet many businesses fail to recognise this connection. Cleaning is often approached as an afterthought, separate from routine maintenance procedures. In reality, equipment longevity and performance are directly influenced by the cleaning tools used.

Residual oil, dust, and chemical build-up can lead to machine malfunctions, forcing businesses to increase spending on repairs and replacement parts. Cleaning products designed for industrial use, such as high-absorbency, lint-free wipes, prevent this accumulation, ensuring that machinery operates at peak performance for longer. Investing in task-specific wiping solutions reduces contamination risks, minimises wear and tear on equipment, and ultimately leads to lower maintenance costs.

Environmental responsibility is an increasing priority for industrial operations, with many facilities striving to meet corporate sustainability targets. However, traditional cleaning products such as rags and laundered cloths require high energy and water consumption for washing and processing. These processes contribute to increased CO2 emissions, contradicting broader sustainability goals.

Single-use wipes when used correctly can offer a more sustainable and cost-effective solution. 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 and the right wiper for each wiping task. This minimises overuse and waste, reducing consumption by up to 15%.

Many industrial settings still operate under the assumption that cheaper cleaning products lead to cost savings. However, these solutions often result in higher long-term costs due to inefficiency, excessive waste, and increased operational disruptions. Businesses that invest in smarter, more efficient cleaning solutions not only reduce expenses but also contribute to a cleaner, more sustainable industrial environment.

A smarter approach to industrial cleaning

To improve efficiency, reduce waste, and enhance workplace safety, industrial facilities should adopt a proactive cleaning strategy

Prioritising cleaning:

Cleaning may not always be the first priority in industrial settings, but its impact on efficiency, cost control, safety, and sustainability cannot be overlooked. Using inadequate cleaning materials leads to excessive waste, downtime, and health risks - problems that ultimately outweigh any initial cost savings.

Regular audits:

One of the most effective ways to do this is by conducting regular audits of cleaning practices and materials used across the site. Understanding where inefficiencies lie - whether in product overuse, poor storage, or ineffective cleaning tools - can help identify areas for improvement.

Task-specific wiping products:

Investing in task-specific wiping solutions is another key step. Different cleaning tasks require different materials, whether for grease removal, chemical spills, or delicate surface cleaning. Using a one-size-fits-all approach is ineffective and leads to excessive consumption.

Smart dispensing:

Optimising storage and dispensing systems is equally important. Many facilities still rely on open blue rolls, loose rags, or disorganised storage, leading to clutter, contamination risks, and unnecessary waste. Implementing smart dispensing systems can improve hygiene, reduce usage, and enhance overall site organisation.

By making small but strategic changes - such as investing in high-quality, task-specific wiping solutions - businesses can reduce waste, improve productivity, and enhance safety standards. In an environment where every minute and every penny counts, the right approach to cleaning can make all the difference.

For more information: 

www.kcprofessional.com

Tel: 0800 917 9908