This is the most complete informational guide to parts washers on the internet.
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A parts washer is an engineered machine used to thoroughly clean components by effectively removing various contaminants like grit, grime, oil, debris, dirt, and paint. This critical cleaning step is necessary before parts are integrated into assembly lines, packaged, or subjected to coating applications. There are multiple types of parts washers available, including high-pressure washers, cabinet washers, rotary basket washers, and deburring machines, each specialized to meet unique industrial requirements.
Freshly manufactured components, whether they are machined, forged, or fabricated, frequently have leftover residues, such as oils, chemicals, burrs, abrasive particles, debris, and paint from the manufacturing process. These parts need to be meticulously cleaned and decontaminated before they can advance to subsequent stages of operation. This is where parts washers play a crucial role, ensuring that the components are thoroughly cleaned and prepared for the next phases of processing.
When designing a parts washer, the primary considerations include the size, shape, and configuration of the parts to be cleaned. Additional factors such as weight, surface area, angles, closed sections, and blind holes must also be taken into account. Addressing these aspects is crucial for ensuring efficient and thorough cleaning of parts during the selection and purchasing process.
Manufacturers have various options to consider when developing parts washers, including CNC programming, back or front loading, baskets, trays, rack systems, rotary tables, and conveyor belts. Most parts washers use aqueous solutions with water-based solvents or cleaners to boil, blast, or soak dirty parts. Customization is often required to meet the specific needs of each customer, as part designs and requirements can vary widely.
The fundamental components of a parts washer include a water heater, a filtration system, one or more pumps, scrubbers, brushes or a power nozzle, and a cabinet or enclosure.
The heating unit, which can be powered by gas, electricity, or steam, is designed to rapidly increase the temperature of the cleaning solution. This not only accelerates the cleaning process but also enhances the effectiveness of solvents, detergents, and chemicals by speeding up the chemical reactions involved.
When a parts washer is in operation, the cleaning solution or water circulates from the cleaning tank to the storage tank. During this process, it passes through two filters. The first filter is a coarse grid that captures larger particles, while the second, finer filter traps smaller particles that the coarse filter may have missed.
Parts washer pumps are engineered to operate while submerged in solvents, water, and detergents. Their primary function is to transfer cleaning solutions from the storage tank to the cleaning tank. Designed for continuous operation, these pumps typically run at 185° F, moving 115 gallons per minute (GPM) with a pressure of 65 psi. Both GPM and PSI are crucial for effective cleaning; inadequate levels can result in incomplete removal of contaminants.
The scrubber in a parts washer can be either a sprayer or a set of brushes. The pump circulates the cleaning solution from the storage tank to the scrubber, which performs the cleaning of the parts. In a heated parts washer, spray nozzles are generally positioned at the back and sides of the cabinet to ensure thorough cleaning.
Parts washer cabinets come in a range of sizes and capabilities. They are designed to handle the high-pressure application of cleaning solutions, which can occur either in a cabinet or on a conveyor belt. The water pressure used must be sufficient to effectively remove contaminants. Consequently, the cabinet must be built to endure this force and resist damage from continuous exposure to water or solvents. The cabinet pictured below is a spray wash cabinet from BendPak.
Maintaining the correct water level in the cleaner storage tank is crucial to prevent damage to the heater, which can occur if the water level becomes too low. To address this, an automatic low-water shutoff valve is employed. This valve shuts off the parts washer when the water level drops below a certain threshold and prevents the machine from restarting until the storage tank is refilled to the proper level.
The purpose of a parts washer is to help maintain parts in excellent condition for other processing. Though there are a variety of parts cleaning systems, the majority of systems divide into two types – aqueous or water cleaners and solvent cleaners.
Aqueous cleaners have the cleaning power of solvents using cleaning solutions that are biodegradable and water based.
Solvent cleaners work by dissolving dirt through a chemical process. Examples of solvent cleaners include mineral spirits, petroleum naphtha, benzene, trichloroethane, and xylenes.
Parts washers can also be categorized based on their level of automation: manual, semi-automated, or fully automated.
A sink-on-a-drum is one of the most basic and common types of parts washers, ideal for cleaning individual or a small number of parts. It features a drum with a sink mounted on top, equipped with a solvent or water supply line. These models typically include a pump and brushes for efficient cleaning.
Immersion parts washers clean components by immersing them in a bath of cleaning solvent. The system uses agitation or oscillation to enhance the cleaning process. Once the parts are coated with the solvent, a vibrating action generates turbulence in the solution, effectively removing contaminants from the parts.
Sprayers are a crucial component of parts washers, and maintaining their cleanliness is essential for effective operation and overall maintenance of the equipment.
Cabinet parts washers utilize a high-pressure, heated aqueous spray within a cabinet to clean parts of any size, including large and heavy ones. Parts are loaded into a basket through a door at the front of the cabinet. Inside, the basket rotates while being exposed to a powerful spray that mixes water with cleaning chemicals or detergent.
The multi-purpose spray cabinet parts washer is an effective and convenient tool for cleaning small batches of diverse parts.
Conveyor parts washing systems feature an enclosed, automated transport mechanism that moves baskets or fixtures of parts through each stage of the cleaning process. The design of these systems varies based on the functions required at each cleaning stage. In an immersion conveyor system, parts are transported to the washing station, rinsed, and then subjected to a series of drying cycles.
Conveyor parts washers include several features that enhance the efficiency of the cleaning process. Similar to robotic-fed washers, these systems often incorporate stages with variable speed stainless steel belts, filtration units, moisture blow-off mechanisms, heaters, and exhaust ducts. They offer continuous inline processing with dedicated heated wash zones, rinse zones, and air-dry finishing zones, tailored to the specific requirements of the parts being cleaned.
The primary advantage of conveyorized continuous flow systems is their ability to process parts efficiently with minimal handling. The systems can differ based on whether they use fixed or variable speeds and the types of products they can handle. Overall, continuous inline parts washing is valued for its high efficiency and rapid processing capabilities.
Rotary drum parts washers are designed for high-volume cleaning of small parts. Similar to conveyor parts washers, they automate the processes of cleaning, rinsing, and drying. The system employs a high-pressure sprayer for cleaning, and incorporates immersion agitation to effectively reach into tubes and hollow sections.
In part manufacturing, most burrs are removed during the finishing process, but tiny burrs often remain and need further attention. Thermal deburring addresses these small burrs by placing parts in a chamber filled with flammable gas, such as methane or hydrogen. The gas is pressurized and ignited briefly once the chamber reaches the optimal temperature and pressure. The intense heat of the ignition burns away the burrs without damaging the parts.
Complex parts with contaminants and oxidation may not be effectively cleaned using standard high-pressure sprays or immersion methods. Ultrasonic cleaning systems offer a solution by using ultrasound at frequencies ranging from 20 to 400 kHz, combined with a cleaning solution. This process creates cavitation bubbles through high-frequency sound, which agitates the liquid and generates heat. The intense agitation reaches deep into holes, cracks, and crevices to thoroughly remove contaminants. Ultrasonic parts washers are available in both bench-top and large-capacity models to suit different cleaning requirements.
Green parts washers, also known as biomatic parts washers, offer an environmentally friendly method for cleaning parts. In these systems, parts are placed in a heated washer containing a pH-neutral solution with a colony of microorganisms. These microbes break down grime on the parts, converting hydrocarbons into carbon dioxide and water.
The cleaning process is enhanced by aeration and filtration. The aeration system adds oxygen to boost microbial activity, while the filtration system maintains the cleanliness of the solution. Thanks to the biomimetic process, the cleaning solution rarely needs replacement, reducing the overall cost of the system.
Tunnel parts washers are designed for linear, continuous parts washing. Parts are placed on a conveyor system that moves them through various treatment phases. The design of tunnel washers is tailored to the dimensions and shapes of the parts, as well as factors like hourly productivity and the specific washing processes required, such as degreasing, phosphating, rinsing, rust prevention, drying, or cooling.
The carousel parts washer, similar in design to conveyor models, is optimized for high-volume operations. Its compact footprint and ability to integrate with automated loading and unloading systems make it highly efficient. Parts are loaded and unloaded at the same location, allowing for streamlined, single-operator control.
Certain parts washers may need to be classified as explosion-proof, depending on the solvents used. To be deemed explosion-proof by the National Fire Protection Association (NFPA), a machine must be engineered to withstand explosions from vapors or gases and prevent igniting the surrounding environment.
Acid parts washers are built with materials and components specifically engineered to endure the corrosive effects of caustic substances. Their design is tailored to handle the cleaning of aggressive corrosive agents, including acids and alkalis, while maintaining durability and effectiveness.
Maintenance is crucial for the longevity of industrial equipment, including parts washers, and regular cleaning is often required. Alliance Manufacturing offers a solution for top-load parts washers with a removable canopy design. This feature provides full access to the interior of the parts washer without the need for disassembly. The lightweight fiberglass canopy can be easily lifted, allowing convenient access for maintenance and cleaning.
Vibratory parts washers are a type of immersion washer designed for batch processing. Parts are placed in a cleaning container filled with a solution. A motor at the bottom of the container generates vibrations that agitate the solution, effectively scrubbing and cleaning the parts. The continuous motion of the vibrations removes surface residue and particulate material. Vibratory washers can be configured for automated flow-through operation, continuous use, or basic batch processing.
Robot-fed parts washers integrate multiple washing functions into a single machine, enabling prewashing, high-pressure washing, and drying, along with deburring. High-pressure nozzles clean deep into cross holes, tap holes, bore holes, tapers, and cavities. Parts are moved robotically between different stages of the process, which can include pick-and-place operations with grippers for part handling.
Parts washers represent a crucial investment and require regular maintenance to ensure optimal performance. For parts washers that are used frequently, weekly checks may be necessary to maintain their efficiency and proper operation. Below are some key steps to follow when assessing the condition of a parts washer.
The first step in effective maintenance is to familiarize yourself with the parts washer's components. Understanding how each part functions helps in identifying potential problem areas that may require closer inspection. Components such as tanks, heaters, pumps, nozzles, filters, and turntables can experience malfunctions or may not perform as expected.
The filter is a crucial component of the parts washer and should be checked regularly for buildup that can lead to clogging. It is generally recommended to replace the filter monthly, or more frequently based on the frequency of use. To prolong the life of the filtration system, consider pre-cleaning parts before placing them in the washer.
In spray-type parts washers, spraying is the most straightforward and cost-effective method for cleaning parts. It is important to regularly check the spray patterns to ensure they provide complete coverage and verify that the water pressure is adequate.
The pump generates the necessary pressure for the system and should be inspected for proper alignment and any required adjustments. Regular maintenance should include checking the pump’s bearings, depending on their location, and ensuring they are properly lubricated.
Certain cabinet parts washers feature a turntable that rotates parts for thorough cleaning. The turntable is driven by a set of gears, so it's crucial to ensure it operates correctly. Regularly check the bearings for proper lubrication and ensure the gears are aligned to prevent slippage. Additionally, monitor the turntable's weight capacity to avoid overloading. While washing more parts at once can reduce the overall cleaning time, the pump must have a high gallons-per-minute capacity to adequately cover all surfaces.
The turntable cleaning method can also incorporate indexing, where parts are washed individually. In an indexing system, parts are loaded onto a rotating fixture either manually or robotically. The fixture then indexes through timed cycles, typically ranging from three seconds or longer, moving the parts into high-pressure spray zones to effectively remove chips and oils.
Proper leveling of a parts washer is crucial for its optimal performance. Leveling is typically part of the installation process. Although rare, it is advisable to check the washer’s level if a malfunction occurs. For small, portable parts washers, ensuring the device is level during setup is essential and usually outlined in the manufacturer’s instructions.
Parts washers produce waste during the cleaning process, and proper disposal is essential. This waste should not be disposed of in onsite septic systems, as it can cause contamination. Waste may be managed by evaporation in some systems, but local regulations vary. Some municipalities allow waste to be discharged into the sewer system, so it is important to check with local regulatory agencies to ensure compliance with disposal guidelines.
When preparing parts for cleaning, avoid overfilling or tightly packing the cleaning basket, as this can result in inadequate cleaning and may require re-cleaning. To ensure parts are thoroughly cleaned, use methods such as visual inspection, particle counting, and other testing techniques.
Parts with burrs, cleaned using solvent or aqueous methods, can present challenges during the cleaning process. Thermal deburring is the most effective method for ensuring complete removal of these burrs.
Choosing the right solvent or cleaner is crucial for effective parts cleaning. Parts that are coated with oil-based coolants from machining processes require solvents specifically designed for hydrocarbon removal. For parts cleaned from grinding or lapping operations, an aqueous cleaning method is typically more suitable. Selecting the correct cleaner and cleaning process can significantly improve efficiency and reduce the time needed for parts washing.
When the cleaning solution becomes saturated with grime, dirt, and other contaminants, its ability to effectively clean diminishes, as the solution can no longer handle the volume of grease and oil. While using a skimmer or sludge scraper can help manage this issue, they do not completely eliminate the need for periodic cleaning of the parts washer tank.
A key component of a parts washer is the type of chemical or detergent used for cleaning. The choice depends on the type of parts being cleaned and the cleaning method. Chemicals and detergents for immersion cleaners differ from those used in ultrasonic or spray parts washers.
Parts cleaning often involves detergents and solvents that can be hazardous, dangerous, and toxic. Effective parts washer management includes monitoring the workplace environment to ensure proper control of these materials, thereby preventing potential injury and illness.
Washing parts is a complex process that requires specialized materials to effectively remove grease, grime, oil, chemicals, and soil from high-volume parts production. In response to growing environmental concerns, manufacturers are increasingly using biodegradable ingredients. For example, the detergent shown in the image below from TEMCO highlights this shift towards more eco-friendly cleaning solutions.
Oil eater detergents are an effective solution for cleaning industrial parts. They serve as degreasers without containing any acids.
Water-based detergents are high-quality parts cleaners that are pH-neutral, non-toxic, non-irritating, and non-flammable. They can also be used with bioremediating systems.
Detergents for aqueous parts washers are specifically formulated for use in jet sprayers and power washers. To enhance their effectiveness, these detergent solvents often include a defoamer, which floats on the surface of the washing solution to prevent foaming.
There are several different types of cleaning solutions designed to be used with ultrasonic parts cleaners. The different types include acidic solutions, alkaline solutions, high caustic solutions, deionized water, enzymatic solution, neutral solution, and mildly alkaline solutions.
Ultrasonic cleaning solutions can be either demulsifying or emulsifying. Demulsifying solutions are used to remove oily contaminants but must be drained from the tank after use. Emulsifying solutions suspend contaminants within the tank, which can lead to residues clinging to parts if the solution is used over multiple cleaning cycles.
Powerful and aggressive chemicals are essential for ensuring thorough cleaning and optimal performance of a parts washer. Regardless of the cleaning method employed, strong cleaning agents are necessary. Examples include Trichloroethylene, Butyl Cellosolve, bacteria-based cleaners, Sodium Hydroxide, Toluene, Benzene, and Acetone, among others.
Trichloroethylene: Trichloroethylene is a colorless chemical commonly used in cleaners and solvents.
Butyl Cellosolve: Butyl Cellosolve is present in a variety of cleaners, ranging from industrial to household products.
Bacteria: Bacteria and enzymes used in parts washers offer a natural method for removing soil and stains through a process known as bioremediation.
Sodium Hydroxide: Sodium Hydroxide is a caustic agent that effectively dissolves grease, oils, fats, and protein deposits.
Toluene: Toluene, which is less potent than acetone and butanone, is primarily used in paint thinners and dissolves adhesives, rubber, and sealants.
Benzene: Benzene is extensively used in manufacturing but must be handled with caution due to its harmful effects.
Acetone: Acetone serves multiple purposes, including cleaning and preparing metals for painting.
The chemicals listed above are among many used for parts cleaning. Due to their toxicity, they must be handled with great care. Proper storage and management are essential to ensure the safety of workers and the integrity of materials.
There are a variety of methods used to assess the cleanliness of parts. These methods range from simple visual inspections, such as wiping a part with a cloth, to more sophisticated tests involving chemical reactions. Because there are no universal cleanliness standards, the evaluation of cleanliness can be somewhat subjective. Below are some commonly used tests for determining part cleanliness.
The cotton swab test is a straightforward method where the surface of a part is wiped with a white glove or cotton swab. The glove or swab is then inspected for any residual contaminants. This visual inspection determines whether the part meets cleanliness standards based on the presence or absence of residues.
The dyne test measures the surface wetness or tension of a part. This simple test involves marking a flat area of the part with a pen, marker, or ink. If the ink beads up instead of spreading out, it indicates that the part's surface is contaminated.
The gravimetric test quantifies particulate matter on a part by measuring different levels of microns (μm), from as low as 2 μm to several microns. Initially, the part is washed with a solvent to determine its level of contamination. After cleaning with a chemical like acetone, the solvent is filtered to separate non-soluble contaminants. These contaminants are then analyzed for amount, weight, size, and type.
FTIR is used to assess organic cleanliness by scanning the infrared spectrum absorption rate of a part. The part is first rinsed in a solvent and then scanned to evaluate the organic residues before and after cleaning.
The TOC test measures the total, organic, and inorganic carbon content in dissolved carbon dioxide and carbonic acid salts. This test is performed before and after cleaning to gauge the efficiency of the cleaning process and to check for any remaining alkaline content.
This test checks for the presence of oil and hydrophobic films on freshly cleaned metals such as stainless steel, titanium, steel, aluminum, and brass. The part is immersed in clean water at an angle. The formation of water droplets that do not spread evenly indicates the presence of residues or oils.
The conductivity rinse test is conducted before, during, and after the rinsing process. Changes in the conductivity of the rinse water are used to evaluate the effectiveness of the rinsing process.
The ROSE test detects ionic contamination by using solvent solutions to extract ions from the part's substrate. The resistivity of the solution is analyzed before and after cleaning to determine the level of ionic contamination in units per square inch.
Similar to the ROSE test, ion chromatography uses thermal extraction to collect ionic species into a solution, which is then analyzed using an ion chromatograph. The test measures the level and type of ionic species and the conductivity of the extracted solution.
Precision cleaning is crucial for removing contaminants, meeting cleanliness parameters, and adhering to industry standards. While the concept of cleanliness might seem straightforward, each industry has its own interpretation, parameters, and requirements for cleanliness. Additionally, companies set their own cleanliness goals that must be met before a part is approved for use or shipment.
Parts washer manufacturers produce equipment that cleans parts to precise micron (µ) or micrometer levels, which are significantly smaller than inches or millimeters. This precision is critical due to the specific nature and use of the parts. Some parts washers clean to as low as 2 µm, while others may clean to 50 µm.
Accurate and precise cleaning is essential for ensuring the proper functioning of parts and preventing damage to equipment and components.
Precision cleaning is increasingly essential for enhancing the usability, safety, and longevity of parts. Modern manufacturing processes introduce various contaminants and unnecessary materials that must be removed through multiple cleaning methods. Effective precision cleaning ensures adherence to required cleanliness standards.
Contaminants are typically categorized into solid and residual types. Solid contaminants include fibers, particles, and fragments that attach to the part's surface, while residues are substances like oil or grease left behind after manufacturing.
Ensuring part cleanliness involves proper inspection following the cleaning process, using various testing methods to detect any remaining substances or materials.
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