Posts Tagged ‘washer’

This residue clogs the machine, and makes it hard for the washer to produce a clean product.
It is common for a company to believe that “cleaning the washer” means replacing the water and solution in the machine that is used for the cleaning. Simply changing the water in the machine is not enough to clean the washer. To truly clean the machine, attention must be paid to the entire process.
Soil accumulates in every part of the washer. Nozzles, heating devices, inside pump housings, material-handling components, as well as the side walls of the fluid and blow off stages. There can also be a tremendous accumulation of soil inside the plumbing itself. The soil contamination prevents the washer from performing to its abilities, resulting in parts that are not clean, which means the washer becomes a waste of floor space.
Cleaning the washer to ensure high performance can take from 4 to 12 hours. Naturally many companies do not wish to lose this amount of production time, but making the time sacrifice when it is deemed necessary will ensure parts are clean to the specification of the customer and avoid future problems.
Cleaning the machine and restoring performance capability to affected areas can be broken down into a nine-step process.
1. Schedule 4 to 12 hours of production down time to clean the washer.
2. Add descaling solution, at a 10-15% concentration ratio, to attack hard water salts, sludge, and scale buildup. The surfactants in the solution loosen the buildup, making removal simpler.
3. Remove nozzles and filter media from the washer.
4. Turn up the heat and run the pumps with no nozzles or filters for up to an hour. (Running with no back pressure, which is made by the nozzles puts too much pressure on the pump motor. This will burn the pump motor out if allowed to run free for an extended period. )
5. Replace the nozzles only and run the heated descaling solution while the conveyor and blower are on. Run machine for 4-8 hours to dislodge caked soil.
6. Remove solution and dispose.
7. Power spray the inside of the entire unit. Spray the tank, conveyor, fluid stages, blow off stage, heating coils and anywhere soil can be seen.
8. Remove solution and dispose.
9. Inspect all gaskets, nozzles, and filters. Replace if necessary.
10. Fill wash tank with proper chemistry.
Cleaning the washer is a hard and long task. Performing this process will require a person or team willing to handle one of the dirtiest jobs in a plant. There are products and add-ons that can be bought that will stretch the length of time between total system clean outs.
Nothing can replace manual cleaning, but these products will help keep the washer cleaner for longer.
1. In-process fluid treatments.
a. Screen baskets to catch large particles before the cleaning fluid re-enters the tank.
b. Particulate removing filter bags or filter paper systems that hold tighter microns as water is pumped from the tank to the spray manifolds.
c. Magnetic collection units to attract metal dust.
d. Oil-water separation systems to remove free-floating oil from water, and thereby return clean water to the tank.
e. Cleaning chemistries that split oil instead of holding it in suspension, making oil-water separation simpler.
f. Making use of oil-based or semi-synthetic metal forming lubricant, allowing oil-water separators to do their jobs simpler.
2. Use quick fit nozzles. These nozzles can be removed easily with a quarter turn and pull, and then replaced within seconds.
3. Use quick-fit Victaulic or grooved piping instead of threaded piping for manifold connectors. These pipes can be cleaned quickly and easily with compressed air and a snake.
4. Install a Blow off section spray down manifold. This manifold is automatically fed from the rinse pump for 5 minutes each time the washer shuts down. This sprays away oils, dried chemicals and particles that have been carried over to the blow off stage. With the spray coming on with only the blower and the conveyor running, the fluid easily drains back to the rinse tank where it can be treated with the other soils.
Using a combination of these products will keep your washer running cleaner, longer. This is especially useful for companies that have a hard time finding employees to perform the manual maintenance necessary. While these products do not replace manual cleaning, when the time comes, the company can place a call to the washer vendor and start a maintenance contract to ensure the work is performed correctly.

Electric power washers are smaller and more light-weight than gas powered power washers.    They are available in many different styles and sizes.   The size of the unit usually indicates the spray power so if you have a smaller unit it can be used to clean your car or your porch.   If you have a larger unit it can be used for larger jobs like cleaning the walls of your home. The electric models are designed more for home use than for commercial use.   The larger more industrial models are too powerful to be used on cars or wooden decks at your home.   They can really hurt wood or paint so be careful not to use one that’s too powerful in the incorrect spot.   Always read the directions to avoid damaging your property. The components of an electric power washer is very similar to the components of the gas powered washer.    They both have available a decent variety of tips and nozzles as well as detergent mixing systems, varying wand lengths, different sizes of hose extensions, and different pumps.  The major difference overall though is their size.   The electric power washer is much more portable than the gas unit.    You can also use the electric models indoors.   The gas models are not designed to be used indoors.    The electric models also do not produce toxic fumes.   The gas models burn fuel so they release CO2 in the air.  All-in-all if you’re looking for a unit that you can take with you or a unit you can use inside or a unit that you can use for a small job then the right washer for you would be the electric power washer.   You can find these at nearly any online retailer like Amazon. com, Wal-mart, Target, Home Depot, etc. Learn more here: Excell Pressure Washer

Electric power washers are smaller and more light-weight than gas powered power washers.    They are available in many different styles and sizes.   The size of the unit usually indicates the spray power so if you have a smaller unit it can be used to clean your car or your porch.   If you have a larger unit it can be used for larger jobs like cleaning the walls of your home. The electric models are designed more for home use than for commercial use.   The larger more industrial models are too powerful to be used on cars or wooden decks at your home.   They can really hurt wood or paint so be careful not to use one that’s too powerful in the incorrect spot.   Always read the directions to avoid damaging your property. The components of an electric power washer is very similar to the components of the gas powered washer.    They both have available a decent variety of tips and nozzles as well as detergent mixing systems, varying wand lengths, different sizes of hose extensions, and different pumps.  The major difference overall though is their size.   The electric power washer is much more portable than the gas unit.    You can also use the electric models indoors.   The gas models are not designed to be used indoors.    The electric models also do not produce toxic fumes.   The gas models burn fuel so they release CO2 in the air.  All-in-all if you’re looking for a unit that you can take with you or a unit you can use inside or a unit that you can use for a small job then the right washer for you would be the electric power washer.   You can find these at nearly any online retailer like Amazon. com, Wal-mart, Target, Home Depot, etc. Learn more here: Excell Pressure Washer

Electric power washers are smaller and more light-weight than gas powered power washers.    They are available in many different styles and sizes.   The size of the unit usually indicates the spray power so if you have a smaller unit it can be used to clean your car or your porch.   If you have a larger unit it can be used for larger jobs like cleaning the walls of your home. The electric models are designed more for home use than for commercial use.   The larger more industrial models are too powerful to be used on cars or wooden decks at your home.   They can really hurt wood or paint so be careful not to use one that’s too powerful in the incorrect spot.   Always read the directions to avoid damaging your property. The components of an electric power washer is very similar to the components of the gas powered washer.    They both have available a decent variety of tips and nozzles as well as detergent mixing systems, varying wand lengths, different sizes of hose extensions, and different pumps.  The major difference overall though is their size.   The electric power washer is much more portable than the gas unit.    You can also use the electric models indoors.   The gas models are not designed to be used indoors.    The electric models also do not produce toxic fumes.   The gas models burn fuel so they release CO2 in the air.  All-in-all if you’re looking for a unit that you can take with you or a unit you can use inside or a unit that you can use for a small job then the right washer for you would be the electric power washer.   You can find these at nearly any online retailer like Amazon. com, Wal-mart, Target, Home Depot, etc. Learn more here: Excell Pressure Washer

A washer works hard to ensure that parts come out clean and ready for the next production process. To keep the machine working at a high level, it must be cleaned on a regular basis. The contamination removed from the parts does not magically disappear; it builds up in the tank and can greatly reduce performance. Performing a tank and system clean out is an vital part of the routine maintenance a washer requires.
To start the process, turn off the automatic water fill supply and remove the nozzles and filters for cleaning. Pay attention to the direction spray angles of the nozzles in relation to the flow of the parts through the washer. Most nozzles will have an indication, either a slit or indented line, which shows the angle. It will be vital to replace the nozzles in the right position.
After the nozzles and filters have been removed, add a washer cleaning chemistry to the current wash solution. Heat the new solution to 160F, or the highest level attainable. Turn on the pumps and let them run for 30 minutes.
Clean the sludge that has been removed during this process and replace the nozzles. NOTE: If you run the pump for an extended period without the nozzles, then the pump motor will not sense the appropriate back pressure and the pump will burn up. After replacing the nozzles, turn the pumps back on and let them run undisturbed for 4 to 8 hours and allow the solution to work on the tank. Once the time is up, pump or drain the solution from the tank.
Now that the solution is gone, remove the shed sheets. There are 1-2 of these flat metal sheets, and they are located below the conveyor that covers the tank in the majority of machines. The sheets normally will have a #-20 stainless steel bolt in one of the corners. Remove the bolt and allow the sheets to be went forward or backward to gain access to the inside of the tanks. Also remove the marine clean out door on the side of the machine. Be careful not to hurt the door during this procedure. If a seal is torn or hurt, replace it before the machine is refilled. Once these are went, clean out any sludge, debris, or sediment from the tank bottom and sides.
Use a power washer to completely clean the interior of the machine, beginning at the top and moving down. Make sure to clean the heater elements, auto-fill valve, wash headers, and blow-off headers. Check all corners or other areas that could catch dirt.
Completely clean any oil removal devices, and flush the tank of the remaining dirty solution. Then remove the clean pump inlet screen and chip basket for cleaning. Wipe down the outside of the machine. Take some time to inspect the interior and exterior components of the machine for hurt or missing parts. Make notes of any hurts or problems for repair.
Replace the shed sheets and the clean out doors, making sure that the doors are in excellent condition before doing so. Replace the doors in the reverse order from how they were removed, and then replace any other devices that were removed from the machine during cleaning. Place the nozzles back in their original position, making certain that they are at the right angle and aim.
Refill the tank with a new solution of cleaning chemistry, and turn on the heat. Observe this process to make sure everything is running smoothly. Run the pumps and observe the gauge readings, making sure there are no more than 10-15PSI differences before filter and after filter. If there is, replace the filter.
Once the solution has reached the right temperature, check the spray pattern on parts moving through to ensure the machine is running correctly. Remove the wash door, using a piece of Lexan the size of the door, and observe. If it is right, replace the door.
Performing this maintenance on your washer will help keep it running efficiently for a long time. Cleaning out the debris and inspecting the main parts of the washer allow you to head off major maintenance problems before they become too large of a problem to deal with. The shut down in production time that will take place during cleaning is more desirable than the extended shut down which will inevitably occur if cleaning is not performed and maintenance goes unchecked.