Challenge
Before installing an automated solution, the cleaning process for heat exchangers was partially manual and time-intensive. The customer needed an automatic parts washer to handle varying sizes of delicate aluminum heat exchangers while delivering repeatable, high-throughput cleaning and drying. The system had to be compatible with robotic loading and integrated with plant automation, all while maintaining precise chemical, temperature, and flow control to prevent fouling or material damage.
Approach
Better Engineering provided a fully custom PD-5000 aqueous parts washer, explicitly designed to flush, rinse, and dry heat exchanger coils in a safe and repeatable process. This industrial parts washer was engineered to ensure reliable washing of internal passageways and full drying with zero residual moisture in a 5-minute cycle time, critical for downstream packaging and storage.
Key Custom Specifications Included:
- Heavy-duty stainless steel cabinet construction, with reinforced floors, pitched tank bottoms for draining, and a fully enclosed structure to contain overspray and heat
- Wash Stage:
- Inline 100-micron filtration with bag filter housing
- Conductivity sensor and chemical dosing pump for precise aqueous chemical mixing
- Fresh Water Rinse:
- Spray manifold with flow-sensing capability for part presence verification
- Fresh water fill valve controlled via proximity switch
- Drip shields and air breaks for backflow protection
- Cycle Automation and Safety:
- Robot-optimized loading and unloading through front door design
- Allen-Bradley PLC touchscreen interface with full recipe management, diagnostics, and Ethernet IP integration
- Automatic water-level controls with shutoff alarms
- Safety features include locking disconnects, E-stops at each operator station, and NEMA 12 enclosures
- Efficiency Enhancements:
- All tanks are insulated to Level II energy standards
- Maintenance-friendly design with side panel access, forklift channels, and sloped internal plumbing
Results
The custom PD-5000 aqueous parts washer delivered measurable gains in throughput, consistency, and safety. By automating coil flushing and drying, the customer achieved zero-residue cleanliness standards while seamlessly integrating the system with robotic cells and plant automation. Key results include:
- Fully automated cycle enabled integration with robotic cells for loading/unloading, reducing labor demands and manual variability
- Effective internal flushing and drying of heat exchanger coils ensured zero residual moisture and no oil contamination
- Consistent cycle control via PLC-driven recipes with chemical dosing, temperature monitoring, and flow validation
- Improved safety and ergonomics, thanks to enclosed design, operator-free loading, and low-maintenance components
- Energy-efficient operation, with heated aqueous cleaning, filtration, and intelligent water and chemical management
Conclusion
The customer achieved repeatable, high-throughput cleaning of its heat exchanger coils with full integration into automated production by installing a customized aqueous parts washer system. The Better Engineering industrial parts washer delivered reliability, control, and energy efficiency, reinforcing its role as a trusted provider of advanced automatic parts washers for critical manufacturing environments.
Interested in finding your solution? Contact us for more information, a facility tour, or free part testing.