Parts Washing System for Filling Equipment

Parts Cleaning Filling Equipment in Chocolate Manufacturing

Background

With locations worldwide, this customer is the leading manufacturer of high quality cocoa, chocolate and confectionery products.

Parts Cleaning Challenge

In the production process of chocolate candy, heated chocolate is poured onto 4’ nozzle outlet plates, which deposits very accurate measured amounts of chocolate into molds. These plates were being cleaned by hand - a very time consuming process. Due to cleaning standards issued by the FDA for food processing, the plates need to be thoroughly sanitized.

Solution/System

A stainless steel F-4000-LX-P parts washer with custom fixture to hold the plate at a 45 degree angle. A special spray manifold was designed for this unit to flood and wash the entire surface of the nozzle plate.  The automatic parts cleaning system sanitizes the plates to be used for making subsequent batches of chocolate.

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Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Tube Washer for Cleaning Extruded Tubing

Conveyor Washer for Cleaning Tubes/Tubing

This in-line conveyor washer cleans tubing immediately after it is extruded (the platform elevates the washer so it is at the same height as the customer's production line.)  The C-14 parts washing system has seven (7) stages... wash, blow-off, rinse, rinse, fresh rinse, blow-off and dry.  All wetted parts are stainless steel.

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Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Drum Washer Cleans Brass Shell Casings

Rotary Drum Washer for Small Ammunition

A key corporation in the defense, aerospace, security and outdoor sport industries needed to clean 7.62mm brass shell casings in the manufacturing process. The system designed for this application was a rotary drum washer with a 24" diameter drum specifically for cleaning small parts in volume.

Parts come to the 3-stage drum washer from an annealing oven and are washed, rinsed and dried at a rate of 30-35 lbs. per minute.  The system outputs 26,000 shells per hour sending them to final machining. The drum has "scoops" to bring the fluids into the drum (there are no pumps). In the wet stages, the shells are fully immersed. The drum washer is all stainless steel.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Mini Conveyor Washer

Automotive Parts Cleaning

Compact conveyor washer designed to fit in customer’s existing work cell (between a knurling machine and a induction heating unit). 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.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Cleaning Transmission Gears and Shafts

Automotive Parts Cleaning

A leading manufacturer of heavy-duty vehicles had wheeled racks of transmission gears and shafts that they needed to clean.  They required an automatic parts washer that would fit into a pit in the floor so that the turntable is flush with the floor.  They could then wheel these racks of parts, the largest being 41” deep x 42” wide x 75” height, with a 39” wheel base, into the washer and directly onto the turntable.  The system has wash, fresh rinse and dry stages.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Replacing Solvent Cleaning with a Water Based System

Aircraft Parts Cleaning System

In the middle of a jet engine there are parts called a “Rotor”, a “Stator” and a “Stage 2 Nozzle Assembly.” The “Stator”  is around 5 ft. high and the “Rotor” is close to 7 ft. high.

The customer needed to replace vapor degreasers with an environmentally clean aqueous system. The system had to handle all three parts (each very different from the other) and still meet the stringent cleanliness specifications.

A special fixture was designed for each part and mounted on the turntable such that one did not interfere with the use of the others. The wash, rinse, dry and deburring manifolds could all be removed or pivoted out of the way when not in use.

A stainless F-5000-P parts washer with an ARC-22 rinse tank, a compressed air drying system, and a 3,000 PSI pump for deburring met the rigorous requirements needed to precisely clean jet engine parts.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Automatically Wash Parts With Open Load/Unload Area

Parts Cleaning for Work Cells

A manufacturer of automotive disc brakes produces parts in work cells, where one operator is constantly rotating from machine to machine. They needed to clean the parts in the cells without burdening the operator with constantly opening and closing a door and then waiting for the cycle to end.

A "Carousel" system which has the front of the turntable exposed for loading and unloading was the solution to their application.

The operator, at his convenience, loads and/or unloads the parts. The turntable rotates very slowly - about 5 minutes per rotation in this case - moving the parts through a "wash" zone and then a "dry" zone. By the time the parts come back around, they are clean and dry.

It doesn't matter if the parts go around once or several times.  The operator knows that any parts coming through the exit curtain are clean and can be removed.

A C-5000-P (50" diameter turntable) with wash and dry zones was designed. For drying, the machine has a 10HP regenerative blower and a 21 kW air heating system.  The large "box" on top is a "Mist-Pac" which pulls out the steam and condenses it, avoiding the hassle of running a vent line. The system runs 24 hours a day, six days a week, and processes up to 6,000 parts per week.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Automatic Parts Washers

Transit Rail Car Parts Cleaning

T-7000-P Spray Washer

Around the country daily, metropolitan mass transit authorities transport commuters via rail.  Dirt, grease and grime need to be routinely removed from the large parts on the transit rail cars to ensure the efficiency and reliability of the mass transit system.

The T-7000-P heavy-duty, top-loading spray washer blasts large, rail car parts clean.  The powered lid opens so that parts can be hoist-loaded onto the 70" diameter turntable which has a 2,500 lb. load capacity. This parts washer has wash and dry stages (the wash solution is re-circulated from a heated tank), oil and particle filters and a steam exhaust system.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Pharmaceutical Washer to Clean Pill Slats

Pill Slat Washer for Pharmaceutical Industry

In the packaging section of a pharmaceutical plant, there are pill counting machines that automatically insert pills into the bottles. During a changeover, from one type of a pill to another, everything in the line gets torn down and cleaned. The "pill slats" from the counting machine are the parts getting cleaned in this application.

The challenge is to automatically wash, rinse, and dry two (2) full sets of pill slats in a 30 minute cycle; there are 72 slats per set.

This CE-3000-SAN sanitization spray washer is specifically designed for the food and drug industry.  The washer automatically sequences through a wash stage, one or more rinse stages, and a dry stage.  The fixture holds 144 slats and is adjustable for different slat lengths. The tank can be automatically dumped after a given stage. CIP nozzles clean-out the tank before it is refilled.

 

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Automatic Parts Washers

Turntable Washer for Large Castings

Industrial Parts Washer with Roll-in Door Cabinet

An 80 year old, family owned/operated company manufacturers components for industrial hot and cold water circulation systems... pumps, valves, heat exchanges, air removal devices, etc.

Imported castings need to have Cosmoline removed. Machined parts are also washed to remove chips and oils. Much of their parts cleaning was done by hand, which they found to be inefficient.

Better Engineering's F-RD-7000 turntable parts washer handled the application efficiently and effectively. This automatic parts washer has a roll-in door, a 70” diameter turntable with 2,500 lb. holding capacity, and 60” working height.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Custom Spray Washer for Turbine Blades and Vanes

Jet Parts Washer for Aircraft Engines

Clean turbine blades on jet engines is an integral part of the aerospace industry.

A manufacturer of turbine blades and vanes required a parts washer capable of handling 4 different applications: 1) To clean a water soluble zirconium oxide slurry off ceramic coated blades post laser drill. 2) To rinse FPI fluid off uncoated parts. 3) To wash water based coolant off post CNC mill parts. 4) To wash oil based coolant off post CNC grinder parts. They also required internal cavities to be flushed.

In this F-3000-P jet washer, up to four (4) blades are fixtured on the turntable such that the "root holes" of the parts are facing up. In this orientation, water and air are blasted into the parts to thoroughly flush and dry the internal passageways. At the same time, the turntable is rotating and the exterior of the parts ware washed and dried. This stainless steel machine has wash ,rinse and dry stages.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Remove Slag, Machining Fluid From HPT Blades More Efficiently

Parts Washing System for HPT Blades

Hundreds of "fins" surround the center "rotor" section of jet engines.  These fins are actually high pressure turbine (HPT) blades which are very complex.  The surface of the part is peppered with tiny EDM holes which lead to a central cavity and larger "root holes" in the rectangular end.

These blades eventually wear down from air friction and have to be rebuilt.  Metal is added, the ends are re-contoured, and EDM holes are re-cut.  After being rebuilt, the parts have to be cleaned - EDM slag removed, dielectric fluid removed, etc.

Cleaning these parts can slow and cumbersome.  The solution is to flush, don’t spray.  Put the parts inside a sealed box which is divided into upper and lower chambers.  Solution from the wash tank is forced into the upper chamber of the box.  Under pressure, the water is forced into the EDM holes, through the central cavity and out the root holes.

The process is reversed in the rinse stage.  Rinse water is pumped into the lower half of the box under pressure.  The water is forced into the root holes of the blades, up through the central cavity, and out the EDM holes at the top.

This method of parts cleaning is more efficient and effective than traditional spray washing.  BE's two tank "PCS" Precision Cleaning System parts washer with a vertical pneumatic doorway meets the stringent cleaning requirements for these aerospace parts.  All wetted parts of the washer are stainless steel.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Automatic Parts Washers

Monorail Parts Washer for Protective Sports Eyewear

Monorail Style Conveyor Washer

This company is renowned for their high quality sports goggles and sunglasses.  They needed a monorail style conveyor washer to clean the frames prior to paint.  The frames had to be clean and dry in order for the paint to adhere properly.  This was not an easy challenge when you consider that each piece had to be clipped to a rack and water gets trapped in the lens groove.

The solution... first, design monorail racks to meet 3 criteria: 1) firmly hold the parts; 2) orient the parts for best drying, and 3) minimize interference with the paint guns.  Then design a monorail system to wash, rinse, and dry these racks at speed.  The custom monorail cleaning system pictured met all design requirements and the customer's application.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Automatic Parts Washers

 

RTO Carousel Washer for Train Cylinders/Robotic Cell

Carousel Parts Washer C-6000-P-SS

Cylinders built for locomotive engines need to have chips and oils removed and then be dried after the manufacturing process.  The cylinders are 12.5" D x 20" H and weigh 150 lbs. each.

This parts washer is robotically loaded and unloaded. The system has a large turntable for indexing and 4 mini-turntables to spin the parts at the wash and dry stations. Every five (5) minutes the turntable indexes 90 degrees. The robot removes a clean part and loads a dirty part. The C-6000-P-SS parts washer also has a mist collector and a chip drag-out conveyor.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Parts Washer for Helicopter Gear Boxes

Industrial Parts Washer, Return-to-Operator Style

A leading manufacturer of civil and military helicopters needed to clean gear boxes to the highest level.

This RTO-R-6000-PCS washer rotates the parts around a horizontal axis as they are being sprayed to flush out complex passages. A dolly transports the parts in and out of the spray chamber. This system has four tanks and a five stage cleaning cycle… a wash stage followed by three rinse stages and a dry stage. The company has reported to us that before this machine was implemented into their cleaning program they only had a 20% parts approval rating.  After only 6 months, they are up to a 65% approval rating and are on track to reach an 85% approval rating in the coming months.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Industrial Parts Washers

Replace Hand Washing With An Automatic Parts Washer

Automatic Parts Washer Capabilities

A particular mid-west based company produces precision machined high-performance powertrain parts and prototype components for all the major automotive manufacturers.

This particular part is an aluminum bed plate. Its dimensions are 19”L x 14” W x 4” T with many blind holes. Previously manufactured as a prototype and individually cleaned, this bed plate is now in full production and a more cost effective and less time consuming cleaning method was needed. Several criteria had to be met: 1) the system had to be totally automatic with safeguards in place in case of production line back-up; 2) it had to be integrated into a fully automatic production line with the ability to communicate with several other machines; 3) the part temperature could not exceed ambient +/-5°F after the wash, rinse and dry cycles; 4) the system also had to produce at least 150 clean parts per hour / 1,200/shift; 5) upon completion of the cleaning cycle the part had to be 100% dry to pass a QC inspection of the machined surfaces (a surface indicator test).

A customized automatic, aqueous-based conveyor system capable of washing, rinsing, and drying these bed plates was designed. Unlike other conveyors, this machine was specifically designed to be loaded and unloaded by a “pick- and-place” robot. In case of any production line difficulty, special PLC programming was incorporated to purge any parts remaining in the conveyor to avoid unnecessary heating of the parts. The conveyor was also equipped with three (3) electronic eyes that would: a) first, index each part to begin the cycle after being placed onto the conveyor belt; b) secondly, would sense the part entering the dry zone and position the part to be blasted with 80 psi of compressed air using specifically placed nozzles located directly above the blind holes. The part then passed through a heated dry section to assure 100% dryness; c) lastly, would sense a completed part and allow the “pick-and-place” robot to remove it from the conveyor. Finally, wash, rinse and dry temperatures are carefully monitored to ensure compliance with part temperature requirements as the part exited the machine.

The output requirements have been met; this cleaning system is now producing a clean, dry part every 23 seconds (1,253/shift). The automatic conveyor washer cleans and dries their parts more efficiently and effectively than hand washing previously did.

Better Engineering Mfg., Inc. • T: 800-229-3380  F: 410-931-0053 • info@betterengineering.com • www.betterengineering.com Automatic Parts Washers