Challenge
The manual cleaning process for production totes and lids was slow, labor-intensive, and inconsistent. It also introduced ergonomic risks for operators handling bulky containers and created a bottleneck in the sanitization cycle. Additionally, the client needed a cleaning solution that could integrate with existing systems, accommodate totes and lids of various sizes, and meet rigorous cleanliness standards typical in pharmaceutical manufacturing.
Approach
Better Engineering addressed these challenges by proposing a custom-built industrial parts washer, the RD-W-6000-P, configured explicitly as a tote washer. This heavy-duty cabinet featured a front-loading, roll-in door design to facilitate crane loading and optimize floor space. The system incorporated a custom fixture design with corner blocks to securely hold totes and vertical rods to stabilize lids. A segregated cleaning protocol was implemented to prevent cross-contamination, ensuring totes and lids could not be washed simultaneously. The washer included a powered door system with a gear motor and sensors for safe, ergonomic, and automated operation. Steam heat at 180°F (using a plate coil system) was used to sanitize the totes and lids effectively. An integrated drying stage, featuring a 20 HP centrifugal blower, custom plenum, steam coil, and filtration system, ensured parts were dry and ready for use. Additional features included automatic water level control and fill system for continuous operation, a steam exhaust system with three operational modes and condensate return to reduce moisture accumulation, an end-of-cycle beacon light for clear operator signaling, and a 200 GPM-rated in-line micron filtration system to prevent particle redeposition and extend solution life.
Results
The implementation of the RD-W-6000-P system led to a significant increase in throughput, as automated wash and dry cycles improved operational efficiency and eliminated the need for manual labor. Cleaning quality became consistent, with precision fixtures and programmable cycles delivering validated cleanliness every time. The roll-in design optimized the system’s footprint, minimizing space requirements without sacrificing capacity. Uptime was improved through features such as auto-fill, low-water shutoff, and advanced filtration, all of which reduced maintenance needs.
- Improved uptime: Features like auto-fill, low-water shutoff, and advanced filtration reduced maintenance needs
- Increased throughput: Automated wash and dry cycles improved operational efficiency and eliminated manual labor
- Consistent cleaning quality: Precision fixtures and programmable cycles deliver validated cleanliness every time
- Optimized footprint: Roll-in design minimized space requirements without sacrificing capacity
Conclusion
The customer’s investment in the RD-W-6000-P industrial parts washer modernized their cleaning process for production totes. The tailored tote washer configuration enhanced safety, consistency, and throughput while reducing downtime and manual labor. This project exemplifies how a customized parts washer cabinet from Better Engineering can align with strict pharmaceutical standards while delivering long-term value and reliability.
Interested in finding your solution? Contact us for more information, a facility tour, or free part testing.