Immersion washers are simply parts washers that employ some sort of immersion washing technique. They can be as straightforward as a tray or basket in which parts are placed and covered in water or a solvent, or they can be much more involved, featuring multiple stages and specialized processes.
Agitating washers are a type of highly efficient immersion washer. After the parts are immersed and covered in a cleaning solvent, the machine vibrates and mixes them, using either paddles or impellers, thus shaking off the contaminants.
Similarly, ultrasonic washers remove contaminants by scrubbing them off with tiny, ultrasonic bubbles, blasts, and solvents. These washers are growing in popularity because they offer environmentally friendly, safe, precision cleaning.
Spray washers have built-in conveyor belts that move parts along to be cleaned by water or solvent spray as they enter the machine.
Rotary washers clean parts by tumble washing, rinsing, and drying them. They’re often designed specifically for the application they serve. For example, some are made to wash large automotive components like engines and transmissions. Alternatively, some clean large volumes of small parts, such as bolts and fasteners.
Drum washers are specialty industrial washers that exist in their own category; they are manufactured exclusively to wash drums, pails, and barrels. Drums used for industrial processes store and carry materials and chemicals that need to be removed after every use, like inks, grease, and adhesives. To be effective, drum washers must be capable of cleaning both the drum interior and exterior. To accomplish this, drum washers can use spray or rotary washer equipment, like nozzles.
Manufacturers who are interested in reducing their carbon footprint can take things one step further than ultrasonic cleaning, by engaging in green parts washing. The newest green parts washers use biomatic technology, which places a microbe colony inside a heater washer that already contains a PH neutral solution. This combination enables the microbes to break down oil, grease, and other contaminants, effectively removing them. After this, leftover hydrocarbons are converted into carbon dioxide and water, which is then filtered and reused. To keep the microbes happy and thriving, oxygen is pumped into the solution. Not only is this process extremely environmentally friendly, but it is low-maintenance, has low power requirements, requires no chemical purchases, and since the solution can be reused almost an infinite number of times, it is extremely cost effective.
Beyond the washer itself, parts cleaning equipment includes a water heater, cabinet (sometimes called a housing or enclosure), pumps, scrubbers, nozzles, brushes, and a filtration system. Water heaters may be powered by gas, electricity or steam, and cabinets are usually made of stainless steel, sometimes with glass and plastic components as well. Pumps are added to the system to help remove contaminants by increasing the pressure of its scrubbers, sprayers, and brushes. Finally, the filtration system keeps the equipment running smoothly by collecting leftover debris and waste.
Parts cleaning is an essential part of many industrial processes. Whether your parts are brand-new or recycled, they must be cleaned well in order to be effective. Fortunately, given the vast variety of parts washers, it is virtually guaranteed that your perfect match is out there somewhere.
Understanding the Various Types of Parts Washers
Parts cleaning systems are one of the most important pieces of process equipment used by manufacturing businesses to clean and maintain their machines. Parts washers remove a number of contaminants and debris from the surface of machine parts. These specially designed cleaners are great at removing oily and greasy components from the parts, and ensure that the next production cycle is safe and cost effective.
There are many types of part cleaning systems based on which application and industry they are being used for. The following paragraphs discuss the different types of washers and offer suggestions in selecting the washer that best suits your needs.
Solvent cleaners are one of the most efficient parts cleaners. Also known as chlorinated solvent vapor degreasers, these cleaners have an unmatchable advantage of reducing the amount of vapor and grease during the cleaning process. Solvent cleaners mainly employ chlorinated solvents, for example trichloroethylene and methylene, to perform effective cleaning. However, when it comes to controlling the production of waste, the solvent-based cleaners lag behind other parts cleaning appliances. In addition to this, because they use highly inflammable solvents, solvent cleaner operators must be very careful and should be trained and certified for using these machines.
Aqueous cleaning systems, as the name suggests, are water-based parts washers, used for a large number for industrial cleaning activities. These devices use water, detergent, and acidic and alkaline compounds to wash industrial process equipment. Aqueous cleaners can be used as a substitute for solvent-based cleaners; however, they will need some technical adjustment in order to meet the objectives of solvent-based cleaning. Also, the wastewater discharged by aqueous cleaning systems needs thorough filtering. The contaminants, such as oil, grease, and toxins, released as a result of washing, may have a varying and negative impact on the environment.
There is also a range of semi-aqueous cleaners that become liquefied in water. They can also be used directly in concentrated form. Since they can be mixed with water and at the same time be used separately, they are called semi-aqueous cleaners. These thinners are highly toxic, and they could be lead to water pollution. Therefore, the waste generated after the semi-aqueous cleaning process should be methodically treated and filtered.
Ultrasonic cleaning appliances use extremely high frequency sound waves, which improve the cleaning efficiency of previously explained parts washing methods. Devices working on this technology are available standalone. You can also make adjustments to your existing aqueous or semi-aqueous cleaning systems to implement this technique. Apart from high frequency sound waves, ultrasonic cleaners also use very high pressure to increase the effectiveness of cleaning.
In addition to these types of cleaners, some other industrial parts washers are: electro cleaners, immersion parts washers, rotary drum parts washers, degreasing equipment, and spray washers.
To summarize, here are a factors to consider when selecting a parts washer:
Invest in a parts washer that has a lid, not an open bucket or pan. This design can help reduce the evaporation solvent; thus, will save money in the long-term.
Purchasing is more beneficial than renting parts washer. Frequently rented devices consume more energy and solvent or solution – adding to your cleaning expenditure.
Five Factors That Will Help to Evaluate Industrial Parts Washers
Parts washers are common sight from auto repair shops to large industries; they are essential for proper maintenance, remanufacturing, and repair operations.
People involved in the related industries understand that contaminants, such as dirt, grime, carbon, or oil, can affect the functionality of a piece of equipment, and in some cases can entirely destroy it. This makes parts washer essential for a wide range of industries.
Whether it is cleaning of bolts, nuts, fasteners, screws, diesel engine blocks and related parts, automotive assemblies, rail bearings, or wind turbine gears boxes, there are specific washers available on the market with a varying degree of abilities and advantages. Depending on the need, industrial parts washers can be simple as fancy jet-based washing machines to complex, multi-staged units, with pass-through part handling systems.
Given the multitudes of options available on the market, it gets difficult to select a parts washer that meets your needs. There are several factors and specifications that have to be considered; in this article, those specifications are discussed so your decision-making will be easier.
- Check the gallons per minute (GPM) of a pump, not the horse power
As you browse around, sales personnel or specifications will always emphasize the horsepower of a pump used in aqueous parts washers; however, for a good cleaning performance, the GPM is the most important factor. If you are confronted with the dilemma of choosing between two pumps of same horsepower, go for the one with better GMP.
- If the washer has efficient heating system
For a washer to work optimally, it needs to maintain 170-175 degrees of temperature all the time. There are many models that lack a potent heating system, making personnel involved wait for washer to get hot again; nothing is more annoying in the hustle bustle of a maintenance and repair facility.
- Capacity of the reservoir
Are larger metal parts washers better? They were at one time, when reaching a saturation point was an issue to pump oil back over the parts for them to be cleaned. However, after the arrival of the oil skimmer, oil saturation does matter, making large reservoirs a deterrent. Large reservoir operates at higher costs, as those beasts consume more power to get to optimum temperature.
- Spare and replacement parts availability
Maintenance plays an important part in optimal operation of parts-cleaning machinery, and the absence of replacement or spare parts can extend maintenance or repair time, making the operation expensive over time. Therefore, availability of spare parts is a very important factor that needs contemplation while selecting a washer. Buying local parts cleaners can save significant capital on the long run, but always go for machinery whose maintenance cost is not high.
- Simpler design
At first, a modern and sophisticated design may look promising and give the impression of making things automated, with promise of cutting labor cost; however, if proved ineffective, those complicated parts washers, can be a source of grief when things do not go as planned and you end up investing more money than saving. Simpler is better when it comes to parts cleaning equipment.
These five factors will help you to choose right machinery that will last long and meet your requirements efficiently.
Reducing Cost and Waste with Parts Washer Machines
Industrial machinery needs proper cleaning and upkeep in order to meet the production demands of a manufacturing facility. Industrial small parts washers are one of the key appliances that are used to ensure the smooth operation of production process equipment. These part cleaning systems include a cleaning basin, a solvent tank, and a solvent recirculation system. All these parts, along with the expertise of engineers, make sure that process machines are working well and seamlessly.
However, there is no denying the fact that parts cleaning results in the waste of materials and other resources, in addition to a frequent involvement of service engineers.
This article, in the following sections, attempts to highlight a few techniques that will enable you to reduce waste and cost associated with your production and parts cleaning cycles.
Increase the Span of Solvents
Taking measures to increase the life of solvents used in the cleaning process can greatly help in decreasing contaminant costs. A drop in waste production ultimately results in cost reduction. Following are steps involved in increasing the life of solvents:
Thoroughly check the condition of parts before scheduling cleaning.
Avoid cleaning parts when not necessary.
Remove the layer of dust and pollutants with brushes and scrapers before using any solvent.
Use Filtration Systems
Exhaust air and liquid filters can be of benefit if you are looking to regulate your production costs. Air and water filtration systems remove all contaminants from an outlet or inlet stream of a production process, and help ensure smooth operation. By implementing a filtration system, you can lessen the output of contaminants within your facilities. Alternatively, you can consider investing in part washers that come with built-in filtration systems. Some small part cleaners have an innate fluid or particle separator mechanism, which can double the life of the solvent.
Consider Alternatives for Ordinary Solvents
You can choose solvents that have a high flash point of more than 140 degrees Fahrenheit. High flash point solvents are those solutions that have a very low evaporation and odor emission rate. These thoroughly engineered chemicals dry at a slow pace, making the man ideal, cost-saving option.
Reduce Air Emission from the Solvent Tank
You can significantly control the cost associated with solvent consumption. For this, you need to make sure that the reservoir lid is kept tightly closed. It will decrease the feeding and leaking of solvents from each unit.
Keep Debris Away from the Cleaning Basin
Do not keep rugs and towels in the cleaning basin—especially near the drain outlet/inlet. Doing so will result in wastage of solvents and ultimately add to your overall production cost.
Cleaning Tips for Industrial Machine Parts
Improving the quality of products while keeping costs down is a great challenge for manufacturing businesses. Making sure that your pieces of process equipment are working properly one step toward achieving this goal. When it comes to machine maintenance, most manufacturers agree that routine cleaning is one of the essential steps. By keeping your industrial appliances free from dust and other pollutants, such as dried-out grease and oil, you can be sure that your machines are going to last within your manufacturing environments. Additionally, clean machines help to enhance the overall quality of the products you manufacture.
The following paragraphs discuss some valuable tips on cleaning industrial process machines. We will also talk about a few tools that will assist you during the cleaning routine.
After every production cycle, send the machine parts for cleaning, not to storage. Moving washable machines and parts to storage facilities will only allow greasy and oily components to collect on surface areas. The grease and oil will eventually solidify on parts, and create disturbance during the production cycle.
Don’t forget to scratch and clean the parts before using a cleaning appliance. Deburring is an important stage before washing. The process enables smooth and uncomplicated cleaning. Burrs that surface on machine parts during operation can cause cleaning issues. Therefore, removing rough edges from the parts is an essential pre-cleaning routine.
Don’t attempt to clean too many parts. Some aqueous parts washers may not be suitable for cleaning a large number of parts in one cleaning session. This is also true with basket-style conveyor part washers. To get the best use of these machines, consider decreasing the number of parts being washed.
Use the right appliance. Employing the wrong cleaning equipment consumes more electric power and labor than necessary and can greatly affect your cleansing results. For most parts, stainless steel baskets with round wires are suitable; still, you need to ensure that you are using the correct type of part washer for your specific cleaning process. Perforated metal baskets have a short opening, because of that they are suitable for certain parts only. Additionally, perforated baskets do not prove effective for parts that require ultrasonic cleaning. Therefore, choosing the right appliance is necessary if you want satisfactory washing and superior machine performance in your production sequences.
Test part cleanliness, before and after washing. Always test the cleanliness of parts before moving to a subsequent step in the cleaning process. In many cases, cleanliness can be evaluated by eyesight alone, and in other cases, it cannot be. Wet and dry parts can be seen and checked easily. Inner and unattainable parts can only be reviewed by testing and analyzing the appliances. You can contemplate using testing utilities to review the status and effectiveness of cleaning. Hydrocarbon cleaners can be used for this task. This device helps you in cleaning, as well as testing the condition of cleanliness. Alternatively, you can hire professional services to do this for you.