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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 important part of the routine maintenance a washer requires.

To begin 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 important to replace the nozzles in the correct 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 moved 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 damage the door during this procedure. If a seal is torn or damaged, replace it before the machine is refilled. Once these are moved, 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 damaged or missing parts. Make notes of any damages or problems for repair.

Replace the shed sheets and the clean out doors, making sure that the doors are in good 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 correct 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 correct 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 correct, 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.

Midbrook Cleaning Systems is a minority owned provider of parts washer and parts cleaner systems, custom metal fabrications, CapSnap water bottling systems, and production cleaning services.

Metal Cleaning: Washing Long Aluminum Skin Panels

Large, aluminum door panels can be difficult pieces to clean. Used in many applications, including the construction of the United States Army's Hummer vehicle as a skin to be placed over the armor plate frame, these panels need to be cleaned quickly and efficiently. This article will serve as an example of how one manufacturer was able to replace an outdated and inefficient washing system with one that cleans more effectively and the steps that went along with the transformation.

The original washer had a load/unload stage of 5', a wash stage of 16', and a spray length of 12'. The overall dimensions of the machine measured out to 7' W x 8'H x 76'L. The machine had a 600-gallon washer tank, a 5,000,000 BTU/hr heater size and design, and a pump size of 481GPM running at 15 PSI. By decreasing some of these measurements and using a more efficient design, the overall design of the washer will be reduced and operating costs will be lowered, along with an increase in production and quality.

First, the loading and unloading stages of the machine will be increased from the original 5' to 8'. By adding three to these stages the operators will have the benefit of increased safety while maneuvering the larger panels. The wash stage will be reduced, from 16' to 12'. The smaller length will make it easier to clean the tanks, as well as keeping the gas burner immersion tube to a minimal dimension. Still, the 12' length will allow a 10' panel to drain before moving on to the next stage in the process. Once loaded, the parts will move through the system in one of two separate lanes, which are both driven by a single, common drive motor. The lanes will consist of flat wire belts on a roller bed, driven by the motor at approximately 8 feet per minute. Adjustable guide rails in the tall lane will allow the machine to handle 3 different widths of the panels.

Spray length will be reduced from 12' to 8'. By decreasing the pump size, from 500 gallons per minute to 300 gpm, but running at a higher PSI, 40 instead of 15, the spray length can be reduced without a drop in wash quality. Since the washer tank has been increased from 600 to 1000, the pump must be size appropriately. Tank volume cannot be less than 3 times the total pump volume or else you can possibly run the pump dry. In the previous configuration, the tank was 600 gallons and the pump was running at 481 GPM, which is not the correct ratio. A 1000-gallon tank and 300GPM pump is more appropriate. The increase in PSI makes up for the decrease in gallon per minute flow and spray bar impingement time. Also, by installing a larger tank, the time before the tank becomes saturated with soil and stamping lubricant is increased, thereby decreasing the amount of time that production must be stalled in order to clean the machine.

In terms of maintenance, the spray stages will also be easier. The pump will be a vertical barrel mount pump, which can be removed without draining the tank. The spray nozzles are quick change, for easy maintenance. The nozzles and headers are customized to optimize the coverage of parts as well.

After the wash stage but before the rinse stage, a blow off feature is installed that was not present on the previous machine. Using a stripping air knife system running at 25 horsepower and delivering up to 600 cfm of air, the parts will be stripped of excess or puddles of water before being sent to rinsing. This stage helps to prevent the cleaner from being carried over to the rinse tank from the wash tank, thereby making the rinsing stage more effective. There will always be wash water rinsed off into the rinse tank, but carrying the water on the part and dumping it into the rinse tank makes the rinse tank just another part of the wash tank and diminishes efficiency and efficacy.

After a rinse stage that removes any left over contaminant or cleaner, the parts will move along into the final blow off stage. High velocity regenerative blowers will be used to strip the excess water from the parts. The air manifolds, which utilize air knives with directional nozzles that create a curtain of air, will be mounted parallel to the spray headers. The blow off stage is further enhanced by the addition of a heated blow-off for 2 of the blowers. These heated blowers will be adjustable up to 200 degrees and enhance flash drying. With the increased PSI and more efficient air knives used in the blow off stage, the length will be decreased from 24' down to just 12'. By increasing the power of the blow off stage and effectively concentrating it, length is reduced in half and keeps the footprint of the machine small.

Additional monetary savings will be made when the heater used in the machine is replaced. In the old machine, a 5,000,000 BTU/hour heater was used. This was necessary in order to maintain a steady temperature using a 500 gallon per minute pump flow. In the new design, a 3,000,000 BTU/hour system is installed. This results in 2 million less BTUs expended per hour of use and decreases monthly energy costs.

Finally, by using two lanes for washing and speeding up the conveyor, the washer and therefore the heater only need to operate 8 hours per day. This is 2 times less than the 20 hours the old machine was operating. Using the newest technology available, the burner operates at a higher efficiency rate as well, further reducing costs.

The overhaul of this particular wash process illustrates how new technology and an experienced vendor can help a manufacturer save money and increase productivity. With the advances made in washing technology and design, it is worthwhile for any company to investigate whether they could benefit from a change in process. In this example, the footprint of the machine was significantly reduced while efficiency was increased and operating costs were decreased.

About the Author

Midbrook is a minority owned provider of parts washer and parts cleaner systems, custom metal fabrications, CapSnap water bottling systems, and production cleaning services.

shorty headers or long tube headers?

i have a 1990 sierra with a 305 5.0 engine.....if i lower the truck not slamm it but lower it which one should i get.....would it matter......the truck had a 350 block but it got messed up..... if i buy headers for which motor do i buy it for 305 or 350.......
the 305 i got it at a junkyard in good conditin but i don't no what vehicle is it from....its at STD.....the heads are from a 93 caprices.... so how would i order or buy the headers....to what vehicle do i buy it fo...for my 90 sierra or the 93 caprice

Long tube headers help produce more power by letting the motor breath better and removing heat from the cylinder heads. You will want to get headers for the 305 but it really does not matter to tell you the truth. They are the same motor just have a different bore. It is important to get them for the correct year motor though because there are options for square bore and round bore exhaust ports. Hope I have been helpful.

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