Challenge
The operator’s equipment had become a drag on operations. Throughput fell short of demand, label and adhesive residue persisted after washing, and maintenance access was poor, all of which increased manual rework, caused avoidable rejects, and lengthened downtime. The company required a single, durable system that could: run many different SKUs without manual rework or frequent changeovers; remove labels and adhesives reliably; deliver repeatable cleanliness at high throughput; and be easy to service to minimize production interruptions.
Approach
Better Engineering delivered a purpose-built multi-lane conveyorized washer configured S7-S7-S5-DH to meet the brief. Key design and engineering elements included:
Maintenance-forward, modular engineering. Large vertical access doors and a bolt-together stainless-steel module design simplify inspection, routine service, and future expansion, minimizing downtime and easing field maintenance.
Multi-lane configuration for high-mix operations. A four-lane guide-rail layout keeps product types organized: two adjustable lanes for multiple tote styles, a dedicated lane for dividers and slip sheets, and a lane for larger pallets and trays. This preserves conveyor capacity while enabling mixed SKU runs.
Integrated de-label capability. The S7 de-label stage is engineered specifically to remove labels and adhesive residue that previously required manual labor or caused rejects.
Robust wash, rinse, and dry stages. Two S7 recirculated wash modules deliver heated detergent through high-pressure spray manifolds; an S5 recirculated rinse removes detergent and contaminants; the DH heated dry module uses high-velocity air knives and a 20-hp centrifugal blower to dry parts quickly at temperatures up to 250 °F.
Power and repeatability. Each wet module uses high-capacity vertical seal-less pumps (~200 gpm) for comprehensive spray coverage; natural gas heating delivers efficient, consistent wash temperatures for demanding industrial loads.
Results
The C-60 dunnage cleaning conveyor parts washer addressed the failures of the old washer and delivered measurable operational benefits.
Operational performance and highlights
- High-mix capability: The washer reliably processes 53 different SKUs, from small totes to large pallets and trays, without frequent changeovers.
- Throughput: Continuous operation at speeds up to 20 feet per minute, supporting high-volume cleaning throughput.
- Part accommodation: 60-inch belt width and up to 48 inches of internal vertical clearance handle a broad range of reusable packaging without special handling.
- Cleaning quality: The S7 wash → S7 de-label → S5 rinse → DH dry sequence removes soils, labels, and adhesive while delivering repeatable wash-to-wash consistency.
- Power & drying: ~200 gpm vertical seal-less pumps per wet module and natural gas heating ensure consistent wash energy; the DH dry module’s 20-hp blower and heated air knives reach airflow temperatures up to 250 °F for fast drying.
- Serviceability & uptime: Large access doors and modular construction simplified routine maintenance and reduced mean downtime for service events, preserving continuous operation and reducing lost production time.
- Flexibility & future proofing: The bolt-together modular design makes it straightforward to expand or reconfigure the line as SKU mix or throughput requirements change.
Business impact
Replacing the outdated washer with the C-60 conveyor washer restored reliable throughput, eliminated a major source of manual rework and label-related rejects, and shortened service windows. Repeatable cleaning performance and improved serviceability translated into smoother operations and a lower total cost of ownership versus continuing to patch aging equipment.
Conclusion
The company chose Better Engineering because it needed more than a like-for-like replacement; it required a modern, flexible, serviceable system that would eliminate the inefficiencies of an outdated washer and scale with operations. The C-60 multi-lane dunnage washer met the brief: reliably cleaning a broad SKU mix at continuous high throughput, removing persistent labels and adhesives, and making maintenance predictable and fast. Built with stainless steel modularity, robust pumping and heating, and thoughtful service access, the system returns reusable packaging to service clean, dry, and ready for the next cycle, keeping the supply chain moving.
Interested in finding your solution? Contact us for more information, a facility tour, or free part testing.