THE APPROPRIATE PROCESS PARAMETER SELECTION
Time of exposure
Standard wash cycles typically range from 1 to 2 minutes for newly manufactured parts, while heavily soiled parts may necessitate more extended cycles lasting 15 to 20 minutes. The duration of the cycle is contingent upon the nature of the contaminants, and in cases involving particularly stubborn soils, extended cycle times may be essential to facilitate effective chemical interaction with the soiled surfaces.
Temperature during function
Elevated operational temperatures serve to unlock the cleaner’s complete efficacy, facilitating the melting of greases and the softening of resilient contaminants. While higher temperatures can lead to shorter cycle times, it’s imperative to note that they can also escalate operating expenses.
Furthermore, increased operational temperatures play a pivotal role in expediting the parts’ drying process. This is achieved through the transfer of heat to the components during the wash cycle, heightening the flash-drying effect and thus reducing drying time.
Used a cleaner
A variety of cleaners cater to diverse substrates and soils. Amines suit new parts, while robust alkaline cleaners are ideal for heavy soiling. Inhibitors counter oxidation concerns during cleaning.
THE IMPORTANCE OF PROPERLY POSITIONING COMPONENTS
Parts orientation for proper drainage
To achieve consistent spray-jet coverage on all surfaces, position parts with hollow spaces to prevent solution pooling, ensuring efficient cleaning and minimizing solution transfer to the rinse stage.
Shadowing between parts
Avoid overloading the washer and ensure parts don’t touch. Overlapping and overloading diminish cleaning efficiency. Meeting production demands should not compromise cleanliness.
The right way to position and expose spray nozzles
To ensure effective cleaning, place parts in close proximity to high-impact cleaning nozzles, aligning them precisely with the spray direction. The preferred choice is the flat V-jet nozzle, delivering uniform, high-impact spray for improved cleaning. Correct nozzle slot alignment is essential; spray patterns should not intersect, as this adversely impacts the spray’s effectiveness. A typical 15-degree angle nozzle arrangement is depicted below.
Maintaining chip filters
Filters play a vital role in trapping solid particles and preventing their recontamination of cleaned components. Daily filter maintenance is crucial, as clogs can impede the wash pump, compromising spray nozzle efficiency. These filters also safeguard the wash pump and nozzles by capturing larger contaminants, contributing to trouble-free washer operation.
inspecting nozzles for wear and obstruction
Perform regular visual inspections of nozzles to detect blockages and clean clogged ones properly. Merely pushing dirt back won’t suffice, as it can re-enter the nozzle upon pump activation. Over time, nozzle wear leads to enlarged orifices, affecting spray patterns, reducing pressure and impact, thus diminishing cleaning effectiveness. A larger orifice also raises flow, increasing amperage draw, potentially tripping the pump breaker.
cleaning the heating system and tanks to get rid of accumulated dirt
Accumulated scale on heated surfaces impairs heating efficiency and poses a risk to the heating system. Hard water, rich in minerals, contributes to scale deposits on hot surfaces. This issue can be mitigated through reverse osmosis or using cleaners with chelating agents to soften water.
Moreover, sediment build-up on the tank bottom can lead to corrosion on steel surfaces. The extent of sludge accumulation hinges on the contaminants removed from parts. It’s essential to promptly clear sludge if it exceeds one inch in thickness to maintain optimal performance.
KEEPING AN EYE ON WASH SOLUTION
Employ titration for precise cleaner concentration measurement and maintain a logbook to monitor pH shifts, signalling the need for solution replacement.
Changing the solution once it becomes saturated
Cleaning solutions have a saturation point for soils, beyond which adding more soap won’t enhance cleaning. It’s crucial to change the solution, using a chemical dosing system for the correct cleaner-to-water ratio.
Oils that float are eliminated
To prolong the cleaning chemical’s life and prevent oil contamination, skim floating oils, particularly during off hours when they rise to the solution’s surface. A programmed seven-day timer aids in consistent oil skimming.