How Do Industrial Washers Work?

An industrial washer is a machine that removes contaminants from the surfaces of a part or component before we send it on to the next step in the manufacturing process.

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Depending on how we made the part, these foreign materials can be machine oil, casting sand, metal shavings, parting compound, and even human skin oil.

To expedite the process and manage labor costs effectively, we often use an industrial washer to clean the parts rather than spend the time and money to clean each one by hand.

Industrial washers come in a variety of designs, and each has a different use depending on what contaminants we&#;re trying to remove and the degree to which the final part must be cleaned.

Spray washers operate much like a dishwasher, with revolving high-pressure water jets that spray the parts to remove foreign materials. This type of unit is used for general cleaning and removing large particles from smooth surfaces.

Immersion cleaners soak the parts in cleaning solutions to dissolve the contamination from the surface.

Solvent cleaners, a specific type of immersion industrial washer, bathe the parts in organic solvents like acetone, naphtha, or mineral spirits. This type of cleaner is very effective at removing oil and grease, but requires special enclosures to control the dangerous vapors and hazardous waste materials it generates.

Ultrasonic cleaners are used when a part is very complex,  need  to be super clean, or we want to save on energy costs.

Ultrasonic cleaners are effective because they decontaminate at a near-microscopic level and can clean hidden passageways and blind corners not reachable with other types of industrial washers. They work by sending ultra-high frequency sound waves (on the order of 40,000 pulses per second) through the cleaning detergent that impacts the part&#;s surfaces, dislodging and removing contaminants down to hundreds-of-thousandths of an inch in size.

Because these washers clean gently, they can be used in situations where other types of parts washers might damage the product, like the computer chip manufacturing industry. Ultrasonic cleaners also remove bacteria and molds effectively, which is why they are often used for cleaning parts that will be installed in food processing or medical equipment.

Industrial washers are an essential and cost-effective part of the manufacturing process. We find them in almost every business where parts are made, repaired, rebuilt, or cleaned for restoration.

Ultrasonic cleaners provide the best of all worlds because of their flexibility, gentle cleaning action, low energy usage, rapid cleaning time, and use of safe cleaning detergents. By knowing how each type of industrial washer works, and what it can and can&#;t do, we can be smart about getting the best parts cleaner available for the lowest cost of ownership.

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There is a fine balance in the use of the hydrofluoric acid (HF) in this stage. Too little HF results in the aluminum fines becoming a suspended solid versus being a dissolved solid. Keeping the aluminum dissolved is essential to keep these fines from making their way down the washer into the rinses.

Too much HF causes the can surface to go from a bright surface to a whitish surface. This &#;over etch&#; not only affects the reflectivity of the can, but it also makes the surface too rough to properly move through the line. Additionally, this white blush can be picked up on the decorator blankets, causing ink voids and any number of other problems.

Drag-out:  

The cans then enter a short so called &#;drag-out&#; (or chemical knock off) stage. The idea is to &#;drag-out&#; the bulk of the acidified water that remains on the can as it leaves the Wash stage. This stage does a good job of reducing the chemical load that ends up in the following rinse stage. The liquid from this stage is the source of the spray in the Pre-rinse.

Rinse #1:

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The can then enters a recirculating water rinse stage. The purpose here is very simple, that is to remove the remaining wash stage chemistry from the cans. This is done with low pressure ambient temperature water. Because this stage operates without the use of a &#;hold down&#; conveyer as used in the Pre-wash and Wash, can stability is an issue in this stage. Nozzle selection and nozzle alignment are an important consideration in this stage where there is a balance between rinsing power versus can stability.

Treatment:

The cans then enter a recirculating chemical stage. This stage is the treatment stage where the cans are given a conversion coating used to prevent brown staining of cans that go through a later retort process. The conversion coating also enhances the application of external decoration and internal spray coatings.

Rinse #2:

The cans then enter another recirculating water rinse stage. The purpose here again is to remove the remaining Treatment stage chemistry from the cans. This stage acts the same way as Rinse #1, except with a final spray of fresh water.

The fresh water that enters this stage is the source of water for the back flow system for the washer.  A properly designed backflow system, where fresh water moves through various stages and exits at the Pre-Rinse is used to minimize the overall water consumption of the washer.

De-ionized Rinse:

The cans then enter a recirculating de-ionized water rinse stage. The purpose of this stage to give the cans a spot free rinse. The stage is configured in (2) phases.

The cans are first exposed to a recirculated de-ionized rinse where the water is a mix of fresh DI and recirculated DI, a so called &#;dirty DI&#; rinse.

The exit sprays of this stage are fed from the plant&#;s de-ionized system such that the cans are exposed to very pure water with virtually no dissolved solids. When dried, this pure water will result in a water spot-free can, essential when a &#;see through&#; can decoration is applied.

With some newer installations, RO water is used to provide the spot free final rinse.

Mobility Enhancer (ME):

The cans then enter an optional mobility enhancer stage. This optional stage applies a very light chemical coating that allows the can to move more easily through the conveyors on the can line. It has been found that can lines that run over 2,000 cans per minute can benefit from an ME stage.

Vacuum Transfer:

The cans are then conveyed from the washer to the dryer. Although a few can makers still use dead plates to transfer cans from the washer to the dryer, a vacuum transfer is a more popular option. The vacuum transfer has the advantage that it allows the few downed cans that develop in the washer to drop out and not be pushed into the dryer.

Dryer:

The purpose of the dryer is to dry off any moisture prior to the transfer to the decorator.

Unlike an inside bake oven, cure times are of no concern. All that is needed is to have the cans become &#;just dry&#; as they leave the dryer. High operating temperatures can cause the ME that was applied in the washer to be burned off, and extreme temperatures, (or long stoppages in the dryer), can result in a semi-annealing of the aluminum, leading to dome reversals when the can is under pressure. From an energy saving point of view, the goal is to operate the dryer at the lowest possible temperature in order to minimize operating expenses and energy use.

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