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