Challenge
A leading Caterpillar engine rebuilder in the Western U.S. faced a significant operational challenge: efficiently cleaning heavy-duty Caterpillar engine components such as nuts and bolts, stacked in large steel racks as part of their high-volume fracking equipment rebuilds. Their existing washroom setup, which included cabinet-style washers, could not accommodate the size or weight of these racks, nor deliver the deep immersion cleaning required for complex engine assemblies. The client needed a robust, automated solution that could handle oversized, heavy loads while ensuring safety, efficiency, and thorough cleaning.
Approach
To address this challenge, the rebuilder partnered with Better Engineering to design and implement a custom industrial immersion washer. The selected solution, the S-32/28-HT/HT/DH, is a stainless-steel, four-stage automatic immersion parts washer purpose-built for deep-soak cleaning of large engine components using caustic detergents.
Key features of the approach included:
- Custom Rack Accommodation: Engineered to handle racks up to 29” L × 25” W × 47” H and 2,000 lbs, loaded via overhead crane onto a secure operator platform.
- Deep Immersion Cleaning: Immersion depth up to 54” to ensure full coverage of stacked parts.
- Four-Stage Automated Cycle: Two heated immersion wash stages, a heated rinse, and a heated dry, each with 450-gallon tanks, 84 kW heaters, and robust stainless steel construction for durability and thermal efficiency.
- Integrated Safety & Automation: Powered lids, pneumatic cylinders, safety sensors, and automated controls for safe, efficient operation.
- Energy Efficiency: Insulated tanks and recirculated airflow in the drying stage to minimize energy consumption.
Results
The implementation of the S-32/28-HT/HT/DH immersion washer dramatically improved the client’s washroom operations. The system delivered deep, consistent cleaning for large, complex Caterpillar engine assemblies, even when the parts were densely stacked in heavy steel racks. The fully automated four-stage cycle reduced the need for manual labor, enhancing both operator safety and workflow efficiency. Integration with the existing overhead crane system allowed for safe, ergonomic loading and unloading of the 2,000-pound racks.
Additionally, the washer provided reliable, repeatable cleaning results with aggressive caustic detergents, supporting the client’s demanding rebuild volumes. The robust, corrosion-resistant stainless steel construction ensured long-term durability and minimized maintenance requirements. Notably, the energy-efficient design—with insulated tanks and recirculated airflow during the drying stage—helped control operational costs.
- The client now benefits from a streamlined, high-performance cleaning process that supports their high-volume engine rebuild operations.
- The new system positions them for continued growth with a scalable and dependable solution.
Conclusion
By implementing the S-32/28-HT/HT/DH immersion washer, this major Caterpillar engine rebuilder overcame the limitations of traditional cabinet washers and achieved a new standard of cleanliness, efficiency, and safety in their fracking equipment rebuild operations. The custom-engineered solution not only met their immediate needs for heavy-duty, large-scale cleaning but also positioned them for future growth with a scalable, durable, and energy-efficient system.
Interested in finding your solution? Contact us for more information, a facility tour, or free part testing.
