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