19 August 2025

^{World first HydroPlasma®: Gentle, intensive and efficient removal of stubborn residues, like salt, oil, fingerprints, on glass, metal and plastic surfaces (Copyright:  Plasmatreat GmbH)}

 

In late July 2025, Plasmatreat GmbH, a global leader in atmospheric plasma technology, announced the launch of HydroPlasma®—an environmentally friendly solution for the ultra-precise cleaning of glass and metal surfaces. By combining its well-established Openair-Plasma® process with the reactive power of ionised water, the company has developed a breakthrough method for removing stubborn contaminants without resorting to chemicals or damaging surfaces.

HydroPlasma® represents a significant advance in sustainable industrial cleaning. It eliminates organic and inorganic soils such as fingerprints, grease, salts, and oils—all without the use of solvents. Instead, the system operates using only water, compressed air, and electricity. For manufacturers under pressure to reduce their environmental impact, this innovation offers a way to maintain uncompromising quality while aligning with stricter sustainability goals.

A Company Rooted in Plasma Innovation

Plasmatreat’s history is closely tied to its pioneering role in atmospheric pressure plasma technologies. The company was founded in the mid-1990s by Christian Buske, who patented the first Openair-Plasma® development in 1995. From its headquarters in Steinhagen, Germany, Plasmatreat has grown into a truly international enterprise, with more than 25 subsidiaries worldwide and a workforce of over 300 employees.

Today, the Plasmatreat Group operates technology centres in Germany, the USA, Canada, China, and Japan, and maintains a sales and service network spanning more than 30 countries. This global presence ensures close collaboration with manufacturers in diverse industries, ranging from automotive and electronics to medical technology and renewable energy.

As Corinna Hokamp, Public Relations at Plasmatreat, explains:

“We have always been at the forefront when it comes to new developments and applications. HydroPlasma® is a perfect example of how we continue to push the boundaries of plasma science.”

The Foundation: Openair-Plasma® and PlasmaPlus®

To understand HydroPlasma®, it helps to look at the company’s earlier breakthroughs. Openair-Plasma® is a dry, non-contact cleaning and activation process used in countless automated manufacturing settings. Plasma—an energised state of matter—transforms surface properties when applied to materials, turning hydrophobic (water-repelling) surfaces into hydrophilic (water-attracting) ones.

The process relies only on compressed air and electricity, making it both cost-effective and environmentally sustainable. It is capable of removing dust, release agents, additives, plasticisers, and hydrocarbons from surfaces, ensuring that subsequent steps such as bonding, printing, painting, or sealing are successful. For metals, Openair-Plasma® can even remove oxide layers inline during production.

Another milestone technology, PlasmaPlus®, builds on this by depositing nanocoatings that give surfaces tailored properties, such as enhanced adhesion. This functionalisation enables targeted performance improvements, often replacing less sustainable or more costly treatments.

With HydroPlasma®, Plasmatreat has taken plasma cleaning a step further—enabling the removal of even the most stubborn contaminants.

What Sets HydroPlasma® Apart

Whereas Openair-Plasma® reliably cleans and activates surfaces, there are certain contaminants—particularly oils, salts, and greasy residues—that require an extra push. HydroPlasma® provides that capability.

The innovation lies in feeding distilled water into a specially designed jet and nozzle head. Inside the plasma jet, the water is ionised using an electrical discharge, generating highly reactive species. These reactive molecules interact with contaminants on the surface, breaking them down and ensuring complete removal without chemicals.

“HydroPlasma® is an extended method to remove stubborn contaminants which are not possible to remove with Openair-Plasma® alone,” Hokamp explains. “Which technology is used depends on the customer’s process, products, and contaminants.”

Cleaning Without Compromise

HydroPlasma® can effectively remove a wide range of contaminants from glass and metal surfaces, including:

• Organic contaminants such as fingerprints, grease, and oil
• Inorganic residues such as salts and dust
• Release agents used in moulding processes

Because the treatment is inline, it integrates seamlessly into automated production lines—avoiding the need for manual handling or secondary processes. And crucially, it does this without generating volatile organic compounds (VOCs) or carbon dioxide emissions.

“If manufacturers are using green electricity, our plasma technology is completely CO2-free,” Hokamp notes. “Compared to traditional methods, it is environmentally friendly and avoids mechanical cleaning processes that can damage or reduce surface quality.”

Environmental Sustainability as a Core Driver

For industries under regulatory and consumer pressure to cut chemical use, HydroPlasma® represents a timely solution. Traditional surface cleaning often relies on solvents or abrasive methods, which bring risks to both workers and the environment. By contrast, HydroPlasma® requires nothing more than water, compressed air, and electricity.

This makes it not only safer but also more sustainable. There are no chemicals to purchase, handle, or dispose of, and no secondary emissions to manage. The process is compatible with renewable energy, helping manufacturers reduce their carbon footprint as they shift towards greener production models.

Industries That Stand to Benefit

Plasmatreat’s technologies are already widely used across industries that rely on precise surface treatment, from automotive to electronics and consumer goods. With HydroPlasma®, the company expects to unlock new opportunities in areas where contamination control is critical.

Industries such as:

• Automotive – for bonding, painting, and sealing components where even microscopic contamination can affect performance.
• Electronics – ensuring flawless adhesion and coating processes in increasingly miniaturised devices.
• Packaging – particularly for food and pharmaceuticals, where chemical-free cleaning is a regulatory and consumer requirement.
• Medical technology – guaranteeing sterile, residue-free surfaces without harmful solvents.
• Renewable energy – from solar panels to batteries, where surface preparation impacts efficiency and reliability.

“In all industries where manufacturers use bonding, printing, coating, gasketing, or lacquering, HydroPlasma® can deliver significant benefits,” Hokamp confirms.

The Challenge of Sharing Success

One obstacle to showcasing HydroPlasma®’s effectiveness lies in confidentiality. Many of Plasmatreat’s customers operate under strict non-disclosure agreements, making it difficult to share detailed case studies or application images. Nevertheless, Hokamp notes that early pilot programmes have demonstrated strong results, positioning HydroPlasma® as a game-changer in industrial cleaning.

Looking Ahead: A Greener Future with Plasma

Plasmatreat’s long-term vision is to expand the role of atmospheric pressure plasma as a replacement for harmful and unsustainable surface treatment methods. This ambition extends beyond HydroPlasma® to new developments that are still in the pipeline.

“Enabling and finding new applications to replace harmful and environmentally unfriendly processes is at the heart of our work,” says Hokamp. “Our goal is to make the future greener and reduce CO2 emissions through new plasma-based technologies.”

The company’s ongoing investment in technology centres around the world reflects this commitment. By collaborating with customers in different industries and regions, Plasmatreat continues to identify new use cases where plasma can provide cleaner, safer, and more efficient solutions.

Conclusion

With the launch of HydroPlasma®, Plasmatreat is once again setting new standards in surface treatment. By harnessing the power of ionised water within its proven plasma framework, the company has delivered a technology that is at once effective, sustainable, and industrially scalable.

For manufacturers, it offers a way to eliminate tough contaminants without the cost, complexity, or environmental burden of traditional cleaning methods. For industries under pressure to meet sustainability targets, it signals a practical path forward.

As industries move towards greener production models, innovations like HydroPlasma® highlight how advanced surface technologies can help balance performance with responsibility. True to its heritage, Plasmatreat is not only shaping cleaner surfaces—but also a cleaner future.