Return Conveyor Tote Washer – Case Study 23189

return conveyor tote washer
return conveyor tote washer load-unload ends
Return conveyor tote washer load-unload ends

Background:

This company is a warehouse supplier to a leading grocery store chain in the Mid-Atlantic and East North Central United States. Specifically, the warehouse facility operates a piece-pick area where individual products are picked, placed in plastic totes, loaded onto trucks, and shipped to the various store locations to keep shelves stocked.

Parts Cleaning Challenge:

The facility processes large quantities of grocery products for the distribution of both food and non-food items. These products are placed in various totes ranging in size from 19″ x 12″ x 7″ to 22″ x 16″ x 17″, many of which have attached flap lids. 

The totes can accumulate factory dirt, dust, or contain spilled contents from broken bottles such as jelly or shampoo. Consequently, this foreign matter needs to be cleaned to prevent contamination of the grocery items.

The FDA has regulations in place regarding the distribution of food. As a result, the facility needed an efficient way to clean the large volume of these various-sized containers to be in compliance. They also wanted an exit conveyor to return the totes back towards the infeed station.

Solution/System:

In this case, the solution was a model C-24 stainless steel conveyor washer with 24-inch wide flat-wire belting and a return conveyor belt. In addition, the belt has pushers every 24 inches to help move the totes through the system. Moreover, fixed side guide rails hold the lid flaps at a slight angle to promote water drainage. Furthermore, the system has three stages: wash, rinse, and heated dry with two air cannons in the dry module to blow standing water off the totes. The variable frequency drive (VFD) has a 1-10 FPM speed allowing the system to process one tote every 20 seconds (6 FPM). Also, the unit is fully insulated to conserve energy.

Other system features include:

  • steam exhaust system
  • electronic eye to sense parts
  • locking door switches
  • door safety switches
  • marine clean-out door
  • oil skimmer
  • automatic timers
  • multiple water level controls

Please contact us to learn more about cleaning applications and systems like this!

Tote Bin Washer for Food Distribution – Case Study 22570

c-24 tote bin washer
Guide Rails on Tote Bin Washer
Guide Rails on Tote Bin Washer

Background:

This family-owned company specializes in the manufacturing and distribution of food and food-related products. Significantly, the company is a leading national foodservice distributor to restaurants, casinos, resorts, healthcare facilities, educational facilities, and more. Because of this, they utilize a variety of totes and bins in the distribution of products.

Parts Cleaning Challenge:

The FDA has regulations in place for food distribution. In order to be in compliance, these plastic totes and bins need to be cleaned regularly to remove dirt, organic food matter, and other materials to prevent the contamination of the food in transport. Employees at the facility manually washed 400 plastic totes a day, 18″ x 26″ x 6″, with a power washer, the results of which did not meet cleaning requirements. Consequently, the process was inefficient and wasted water and human resources.  With this in mind, they needed an automated system to effectively clean a large volume of totes for reuse.

Solution/System:

The solution was a model C-24 tote bin washer with a 24-inch-wide belt, a 20-inch working height, and consisting of 3-stages: recirculated wash, recirculated rinse, and short blow-off with a 10 HP regenerative blower. Another key point is that the totes are loaded onto the conveyor on edge.

In addition, adjustable side guide rails support the totes and can accommodate new bins of other sizes. Furthermore, the throughput is 400 totes/day in a single 8-hour shift. Other system features include insulation, safety guards on the load and unload ends, automatic 24-hour/7-day timer, filtration rated for 200 GPM, and a steam exhaust system.

Results:

The results were that the automated tote washer provided consistent and thorough cleaning of all totes, ensuring that the company met regulatory cleaning guidelines. Likewise, they increased their productivity, utilized their human resources in other areas, and saved money on water.

Please contact us to learn more about cleaning applications and systems like this!

Cleaning and Sanitizing Medical Waste Containers – Case Study 23210

Cleaning and Sanitizing Medical Waste Containers
Ramp for Cleaning Medical Waste Containers
Ramp for Cleaning Medical Waste Containers

Background:

This company is a leading provider of environmental and industrial services for companies and government agencies and is an expert in hazardous waste management and removal. In particular, the company provides onsite pickup and replacement of Sharps® containers and medical waste bins from medical facilities. Effective cleaning and sanitizing of medical waste containers is crucial for FDA compliance. For this reason, container contents are properly disposed of, and then the containers are cleaned, sanitized, and placed back in the field for service.

Parts Cleaning Challenge:

Firstly, the customer needed to clean and sanitize a variety of Sharps® containers and medical waste bins ranging in sizes of 2-gallon and 3-gallon Sharps® containers and 10-gallon, 17-gallon, 31-gallon, and 43-gallon medical waste bins. Secondly, the bins also needed to be manually loaded directly from the freight dock to the washer.

Solution/System:

In this case, the solution was a stainless steel Cyberjet conveyor washer with a 36” inch wide belt. The belt is divided into two lanes by guide rails, one lane for the Sharps® containers and one for the medical waste bins. While Sharps® container lids are placed in a basket to be washed in the second lane.

This system is comprised of 3-stages: recirculated wash (sanitize to 180°+ F), recirculated rinse, and a short blow-off with a 15 HP regenerative blower. Additionally, the system throughput is 200 containers/hour. Furthermore, a conveyor ramp was attached to feed the bins directly from the freight door to the load end of the washer. The unit also features steam heat for the wash and rinse stages and a steam exhaust system.

Additional features include:

  • in-line micron filter
  • electronic eye sensors at the unload end of the conveyor
  • locking door switches
  • marine clean-out doors
  • valve to siphon detergent into a water fill line

Please contact us to learn about more cleaning applications like this!

Tower Garden Cleaning – Case Study 22902

vertical farming tower garden cleaning
Conveyor Washer for Tower Garden Cleaning
Conveyor Washer for Tower Garden Cleaning

Background:

Indoor vertical farming is a sustainable agricultural initiative that can produce more food from fewer land and water resources. Indoor food growers need to keep their environments clean and free of unwanted bacteria to prevent food contamination. Vertical farming uses food-growing towers that can be as tall as 15 ft. and weigh as much as 30 lbs. each. Tower garden cleaning is essential to food safety.

Parts Cleaning Challenge:

Organic plant material and soil need to be removed from the food growing towers after each cultivation and the towers need to be thoroughly cleaned. Consequently, manually cleaning the towers by hand is a tedious and cumbersome process.

Solution/System:

In this case, the solution was a C-14 conveyor washer that automatically cleans the tower garden sections after each cultivation. The food is cultivated, most of the growing soil is removed for re-use, and the metal growing sections are then sent through the conveyor washer where they are blasted with hot water to remove residual dirt. Compressed air at the end of the wash section blows water off of the parts. The sections are then ready to be re-packed with dirt and seeded. The single-stage, recirculated spray module has an increased length of 144” and processes parts at 33 FPM. A special belt was designed to hold the parts in place and special manifolds ensure that both the ID and the OD of the sections are cleaned.

The system also features:

  • 350-gallon heated tank
  • 10 HP pump
  • marine clean-out door
  • hinged canopy access lids for complete access
  • Allen Bradley PLC & 600 Panelview
  • multiple water level controls
  • electronic eye sensors at the load and unload ends
  • stainless steel construction.

Please contact us to learn about more cleaning applications like this!

Removing Hardened Resin from Ceramic Turbine Blade Castings- Case Study 22993

Parts Washer to Remove Hardened Resin
Containment Divider
Containment Divider

Background:

This company manufactures high-performance products for high-technology companies, government agencies, and academic institutions. One of the products they manufacture in particular is ceramic turbine blade castings for the aerospace industry. For this reason, lithographic etching and CNC machining are combined to produce master patterns and high-resolution lithographic inserts for these highly complex three-dimensional parts.

Parts Cleaning Challenge:

The process begins with 3D printing the model in a wax-like resin. This resin hardens on the molds and is difficult to remove. As a result, the challenge was to remove hardened resin from the ceramic turbine blade molds.

Solution/System:

In this case, the solution was a Cyberjet conveyor washer with a 14” wide belt with a recirculated spray wash and two recirculated spray rinse zones. A temperature of at least 165° F has to be maintained, the wash tanks and rinse tanks were increased to 225 gallons each, and the heater elements increased to 27 kW in order to remove the hardened resin. The throughput is one fixture of parts every 8 minutes, and pusher bars were affixed to the belt to help maintain a specific distance in the center of each module.

In addition, a wax removal basket and containment divider was designed for every stage. The system also included marine cleanout doors for both the wash and rinse stages for easy maintenance. A steam containment door was installed at the exit side of the machine instead of spray curtains to limit the amount of time steam can escape from the unit. Altogether, this type of system worked well as this was an indexing unit, loaded and unloaded robotically. The system also featured:

  • Allen Bradley CompactLogix PLC and Panelview
  • variable frequency drive controls
  • water level controls
  • locking lid safety switches
  • safety guarding on the load and unload ends to cover bearings and sprockets
  • electronic pressure switches
  • in-line bag filters
  • insulation for the entire system

Please contact us to learn about more cleaning applications like this!

Pallet Washer – Case Study 22570

Pallet Washer | Better Engineering
pallet washer cleaning system
Pallet Washer

Background:

This company is a leading national warehousing, distribution, and logistics firm. In particular, they offer a wide range of services including plastic pallet repair. Repairing damaged plastic pallets is a more sustainable solution as it keeps them out of landfills and the ecosystem. An aqueous-based pallet washer can be part of that solution.

Parts Cleaning Challenge:

Damaged pallets need to be cleaned when having repairs done. Thus, the company needed an automated pallet washer to help increase the efficiency and effectiveness of their pallet repair services.

Solution/System:

In this case, the solution was a model C-24 pallet washer. This cleaning system is specifically designed to wash plastic pallets that are as large as 48” x 48” x 6.5”. In addition, the pallets are cleaned on edge or vertically. Rails on both sides support the pallets in this orientation. The system shown is a single-stage, wash-only unit and is truly modular as additional rinse modules and dry modules can be added in the field.

The system also features:

  • water level controls
  • 5HP pump
  • easy-access filtration basket
  • insulation
  • steam exhaust system
  • end-of-cycle beacon light
  • door safety switch
  • main breaker disconnect

Please contact us to learn more about cleaning applications and systems like this!

Spline Shaft Washer – Case Study 21872

Mini Conveyor Washer C-6
Spline Shaft Washer C-6
Spline Shaft Washer C-6

Spline Shaft Cleaning
Background

This company is a leading American manufacturer of automotive electrical components, instrument clusters, power-train systems, and automotive electronic products. Their products are used by major U.S. automobile manufacturers. One of the components they make is spline shafts. They wanted a new spline shaft washer to integrate into their manufacturing process.

Parts Cleaning Challenge

They needed to remove chips and oils from the shafts after the milling process. They also needed a parts washer that that would fit into their existing work cell (between a knurling machine and an induction heating unit).

Solution/System

The solution was a custom, compact spline shaft washer with a 6″ wide conveyor belt. Side rails keep shafts aligned on the belt. The overall system length is only 70 inches. All wetted parts are grade 304 stainless steel with an insulation cladding covering. The system runs off of 110V power.

The customer’s pick and place unit automatically places the shafts onto the washer’s conveyor. The parts get washed, blown off, and then slide down a chute into the customer’s vibratory conveyor.

System features include a 75-gallon tank with automatic water level controls, a compressed air blow-off stage, a 2HP pump, a steam exhaust system, a NEMA-12 control panel, 7-day/24-hour timer, a digital thermostat for the heat tank, a variable speed controller for the conveyor belt, a lid interlock switch, and removable filter basket.

Please contact us to learn about more cleaning applications and systems like this!

Small Ammunition Cleaning – Case Study 21130

D-24 5-stage drum washer small ammunition cleaning
Drum Washer
Drum Washer

Background:

Small ammunition cleaning is imperative to remove chips and cutting oils in the manufacturing process in order to achieve optimal product safety and reliability. This company is a key ammunition manufacturer for the defense, aerospace, security, and outdoor sports industries and they needed to clean 7.62mm brass shell casings.

Parts Cleaning Problem:

They were using 70-year-old parts washers that no longer cleaned their parts efficiently or effectively.  They needed a new small ammunition cleaning system to clean the shell casings after heat treatment.

The System/Solution:

The solution was a 5-stage D-24 Drum Washer with a 24-inch diameter drum that cleans shell casings after heat treatment.

The system outputs 40,000 shells per hour. Shells are put through the following 5 stages: acid pickling to remove the heat treatment scale, rinse, rinse, lube, and dry. All wetted parts of the system are stainless steel. The drum has “scoops” to bring the fluid into the drum (there are no pumps). In the wet stages, the shells are fully immersed. The system processes 30-35 lbs. of shell casings per minute.

Features include gas heat for the dryers, marine cleanout doors for each tank, a steam exhaust system, and an Allen Bradley Micrologix PLC and Panelview.

Please visit our Drum Washers page or contact us to learn more about cleaning applications and systems like this!

Precision Cleaning Jet Engine Parts – Case Study 21805

turntable washer for aerospace cleaning
Jet Engine Parts Cleaning System RD-6000-PCS
Jet Engine Parts Cleaning System RD-6000-PCS

Background

This company is a leading American aerospace manufacturer with global service operations. Their aircraft engines are widely used in both civil aviation and military aviation. Jet engine parts cleaning is critical to ensure optimal product safety and performance.

Parts Cleaning Challenge

They needed an aqueous parts washer for final, precision cleaning of critical jet engine components.

Solution/System

The solution was twin, automated precision cleaning systems. Each unit has a 60-inch diameter turntable and a 60-inch working height with a roll-in door. The system also has two identical 300-gallon tanks for high volume wash and rinse stages, as well as fresh-rinse and dry stages.

The parts being cleaned can be as large as 55-inches in diameter and have internal cavities. A center-drop spray/dry manifold automatically lowers into the parts to clean the inner diameter.

Other features include a part collision sensor for the ID manifold, all stainless steel construction, steam heat for the tanks, a steam exhaust system and mist collector, a vacuum system, a viewing window, a mist collector, a 20HP regenerative blower with sound shield, a 10″ HMI screen, and more.

Please contact us to learn about more cleaning applications and systems like this!

Parts Cleaning System for Gas Cylinders – Case Study 21734

Gas Cylinder Cleaning System RTO-2000-PCS
Gas Cylinder Cleaning System
Gas Cylinder Cleaning System

Cleaning Gas Cylinders w/ Automated Passivation System
Background

This company is the world’s largest manufacturer of aluminum high-pressure gas cylinders. Their products are used in a wide variety of industries including SCBA, SCUBA, performance racing, medical, transportation, alternative fuel, beverage, life support, and more. Efficiently cleaning gas cylinders is critical.

Parts Cleaning Challenge

They needed a system for cleaning and passivating multiple gas cylinders in the final manufacturing process. They also required a system to integrate with their existing robotic work cell.

Solution/System

The solution was a return-to-operator system RTO-2000-PCS. This extraordinary machine cleans/passivates gas cylinders inside and out. The system has six individual cleaning chambers, each with a vertical, powered door and automatic valves to control flows from 3 tanks and air blow-off. The parts are loaded and unloaded with a robot. A top pneumatic device secures the part before the robot lets go. Another pneumatic device inserts a nozzle through the part orifice. In each chamber, the parts undergo a 5-step process:

  1. wash with fluid “A”
  2. rinse
  3. wash with fluid “B”
  4. rinse
  5. dry

Other system features include stainless steel construction, custom fixturing, ID spray nozzle, automatic water level controls, a steam exhaust system, safety sensors, sump pump/sump tank, and NEMA-12 control station with PLC.

Please contact us to learn about more cleaning applications and systems like this!