Challenge
A leading tier 1 automotive supplier faced significant inefficiencies in its cleaning process for aluminum castings. Parts were being washed manually, a labor-intensive and time-consuming method that not only slowed production but also used excessive amounts of water and detergent. This method contradicted the company’s sustainability objectives and contributed to inconsistent cleaning results. Additionally, stagnant water pooling in the castings’ blind holes led to corrosion concerns and rework.
Approach
A new cleaning line was designed and installed at the North Carolina facility to address the customer’s needs. The system featured a wash and dry monorail part washer that differed from traditional conveyor washers by utilizing a continuous loop, allowing for uninterrupted operation and consistent throughput. Recognizing the customer’s requirement for parts to remain cool after drying, the system incorporated ambient air drying instead of heated drying. An oil coalescer was added to the system, enabling continuous filtration of oils and supporting 24/7 operation. Additionally, plastic touch points were integrated into the hooks to prevent metal-to-metal contact, safeguarding the car panels from scratches and other damage during processing.
Results
To resolve these challenges, Better Engineering implemented an industrial parts washer—specifically, the M-24-S4/DA Monorail Washer. This custom-designed automotive parts washer uses a monorail conveyor system to automatically wash and dry aluminum castings after CNC machining, removing oil, metal chips, and contaminants with consistent, high-pressure spray technology.
The monorail system is designed to clean one part every eight seconds, delivering a throughput of 450 parts per hour. By suspending parts vertically, the washer allows for thorough drainage, eliminating water retention in blind holes. This design ensures higher-quality cleaning results while extending the longevity of the parts.
Key Features
- Automated Tunnel Washer configuration with modular wash and dry zones
- In-line oil/water coalescer, chip baskets, and bag filtration for cleaner operation
- Energy-efficient electric heating with digital controls
- Auto-fill and water level sensors to optimize water usage
Results
- Increased throughput: Reduced cycle time to just 8 seconds per part
- Labor savings: Eliminated manual cleaning, allowing redeployment of labor
- Sustainability: Reduced water and detergent consumption significantly
- Quality improvement: Prevented water pooling in blind holes and ensured dry, chip-free castings
- Consistency: Automated system delivers uniform, repeatable results every cycle
Conclusion
Integrating Better Engineering’s industrial tunnel washer transformed Bharat Forge’s post-machining cleaning process. The automated monorail washer not only met production demands but also aligned perfectly with the company’s sustainability and quality goals, solidifying its position as a forward-thinking leader in the automotive parts sector.
Interested in finding your solution? Contact us for more information, a facility tour, or free part testing.
