Integrating better washing solutions allows you to speed up and therefore increase productivity, even when the size of the products can be a real challenge. In this case study we will see how we enhanced the production process of one of our customers on large pieces, integrating a parts washer into the process that speeds up and improves the processing system.
The Client
This is a client company of one of our distributors, based in France. They contacted us because they had a particular need for new equipment for cleaning and degreasing generously sized pipes. They therefore decided to turn to us to obtain a customized product.
The quality standard of the final product created by the customer is very high and requires very tight execution times between processing, cleaning and control of the pieces.
The Target
The main target was to be able to implement new washing and rinsing stations in the production process. To do this it was necessary to combine two systems: the first with soaking, the second with manual cleaning refinement and degreasing control. In short, the customer's need was:- Reduce the processing times of that specific production process;
- Increase productivity and quality.
The Solution
As a first step we analyzed the production system in order to fully understand how it works and to verify the dimensions and quantity of the pieces to be washed. The biggest challenge was the size of the items to be washed. In fact, they were tubes approximately 3 meters long and 40cm in diameter, not heavy but bulky. Furthermore, it was not possible to implement an automated process because the entire project involved manual control.
We determined that the best cleaner would be a water-based, heated scrubber. This type of detergent allows you to save significant sums of money in residue management and is also more environmentally sustainable than other cleaning products.
Having reached this point of the project, we identified the standard equipment model, the Top Cleaner 140, as the ideal starting point. From here we started with an initial test and determined the changes necessary for the customer's washing needs. Thanks to the tests, we understood that, to guarantee a better final result, we had to add an additional filtering system, in addition to the two already present. The additional system features 10 micron filtration to prevent some infinitesimal waste from entering the washing system.
The Results
The company has speeded up and improved the washing system of the production process examined, increasing daily productivity, eliminating further processing steps and also reducing quality waste.
For these reasons the customer was completely satisfied with the result. So much so that, after an initial period of checking the numbers, he decided to order a second machine and to plan the design of two other specific machines for another product they made.
To further improve, the inclusion of new options will be evaluated, such as programming of wash cycles and washing control, also for other customers.
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