LEGACY PARTS WASHER EQUIPMENT...parts washers have evolved to provide an effective solution for a wide range of ... Washing or Manual Pressure Washing New Innovations and Capabilities:

EXECUTIVE SUMMARYIn manufacturing operations, parts washers are an important step in the production process.

Cleanliness of parts and components relates directly to product quality and reliability.

Aging industrial equipment is designated “legacy” when it outlives efficient usefulness.

Beyond Breakeven: Factors that affect cost of operation include lower direct labor, improved reliability, improved component quality, environmental effectiveness, and safety.

Technical Overview: Automatic aqueous parts washers provide solvent-free cleaning for a wide variety of industrial applications.

General repair or production process cleaning industrial applications.

Aqueous parts washers to fit industrial categories.

Recent innovations in part washer operation, functionality and effectiveness.

Education is the key to selecting the right industrial parts washer system.

Chart: Parts Washers Configuration Spectrum of Increased Innovative Functionality and Effectiveness.

Service Line, Inc. | 2320 Zinga Drive Reedsburg, WI 53959 | Phone: 608-524-0204 | Toll Free: 800-774-7900 | FAX: 608-524-1446 | www.renegadepartswashers.com

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LEGACY PARTS WASHER EQUIPMENT: IMPORTANT FACTORS THAT AFFECT YOUR DECISION TO UPGRADE TODAY

by Steven Meyer

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Legacy Parts Washer Equipment: Important Factors That Affect Your Decision to Upgrade Today

http://www.renegadepartswashers.com


PARTS WASHERS ARE IMPORTANT IN MANUFACTURINGThis white paper outlines the main factors to consider when replacing or upgrading aging legacy parts washer equipment. Important innovations and advancements in the variety of parts washer systems and their automated components are explored. In manufacturing operations, parts washers have been an important step in the production process for many years. In order to accept surface treatment and finishing, parts require cleaning of grease and fabrication residue. In production process operations, cleanliness of parts and components is directly related to quality and reliability of the final product. However, parts washers, just like most industrial equipment, can outlive their efficient usefulness. At this point, the equipment can be designated as either outmoded or “Legacy” in its status.

A common misconception carried over from the days when solvents were the main option, that is, prior to the early 1990s, is that solvent-free aqueous cleaning was not up to the task. Numerous parts washer manufacturers in North America demonstrate that the technology is a now standard solution, and a clear alternative to solvent-based providers. In cabinet-based aqueous parts washers, solvent-free detergents undergo high heat and pressure to deliver superior cleaning efficiency. Aqueous Parts Washers also developed as a result of more regulations on the use of harsh chemicals and waste disposal, and alleviate concerns associated with spent solvents. Furthermore, technological innovations combined with solvent-free cleaning mean more types of parts washers have evolved to provide an effective solution for a wide range of industrial applications.

BEYOND BREAK EVEN: FACTORS THAT IMPACT REPLACEMENT OF LEGACY PARTS CLEANING EQUIPMENTThere are a host of factors that drive operation managers to consider the challenge of either replacing or updating outdated and legacy parts cleaning equipment to a more efficient and robust solution. Factors that have an impact on the cost of operation include lower direct labor, improved reliability, improved component quality, environmental effectiveness, and safety. Deciding to make a new equipment purchase when funds are allocated requires an analysis of the factors that justify the expenditure. Executive management or the operations team strives to improve the workflow and part quality output to achieve maximum value.

• Legacy parts washer equipment can cause inefficiency due to interrupted workflow and bottlenecks.

• Legacy parts washer equipment can cause quality and reliability issues in parts and components cleanliness.

• Legacy parts washer equipment can require increased maintenance costs.

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To achieve the results that benefit operational efficiency or affect related labor reduction, and therefore maximize return on investment in the parts washer purchase, the main factors to consider include:

Combine Wash, Rinse or Dry Cycles into One Process

Durability for Extended Production Life Cycle

Eliminate Hazardous Chemicals and Petroleum-Based Solvents from

Cleaning Process for Improved Compliance.

Eliminate Maintenance/Replacement Costs of Outdated Components

Enhanced Integration and Interface to Robotic Loading and Unloading

Greater Variety of Model Types Now Available from Single Manufacturer

(Front Load, Top Load, Pass-Through, Agitation Dip Tank, Carousel)

Greater Variety of Size and Load Capacities to Deal with Increasing Parts Variations Across Industrial Applications

(from Single Manufacturer)High Efficiency Pumps

Increased Automation and Ease of Operation with HMI/PLC

Labor Reduction by Replacing Hand Washing or Manual Pressure Washing

New Innovations and Capabilities: Closed Loop Wash/Rinse Cycle;

Gear Driven Turntable Operation; Sump Sweep Spray Manifolds

Ongoing Quality Improvement Goals such at TQM

Reduction in Production DelaysReduction in Waste Stream

Safety RequirementsSmaller Footprint

Updated Production Processes

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From the accounting perspective, industrial parts washer equipment has a life expectancy and its value is documented as depreciation (in its various forms) during its usefulness in production. The average age of manufacturing assets and equipment currently in operation in the United States, according to the Bureau of Economic Analysis, is close to 20 years. Incredibly, the parts washer manufacturer has the same challenges with the equipment they use to manufacture a quality parts washer (laser cutter for steel, brake press, powder coating ovens, design engineer, forklifts, for example).

Proceed with an analysis of cost savings compared to monthly maintenance cost of the old equipment. Understand the hurdles associated with the source of dollars to be allocated to the purchase (such as cash accruals vs. loans from various stakeholders). Situations are encountered where tracking maintenance and production budgets that were determined by various teams becomes difficult to pinpoint. Factor in the direct costs of equipment purchase, including price, training, maintenance, financing, and even down-time during installation and replacement.

The various industrial applications that utilize parts cleaning equipment require maximum efficiency and increased return on investment on a compa-ny’s capital expense. In engine or transmission re-manufacturing operations, produc-tion time spent on disassembly and cleaning of parts can be more than twenty percent.

TECHNICAL OVERVIEW: AUTOMATIC AQUEOUS PARTS WASHERS PROVIDE SOLVENT-FREE CLEANINGThe task is to scrutinize equipment attributes from a myriad of offerings in the market to arrive at two or three possible choices that address their concerns by priority. Purchasing a parts cleaning system requires research and a proactive approach toward assigning value to the various options and configurations available in today’s equipment choices. In cabinet-based aqueous parts washers, solvent-free detergents undergo high heat and pressure to deliver superior cleaning efficiency.

A review of the foundations of production process parts cleaning systems, along with design and engineering attributes, will demonstrate the scale and scope of choices available in the industry. Production process cleaning systems need to integrate stages, achieve the highest specified level of cleaning, and be constructed of highest quality materials to deliver results for the long term. The following information will address the industrial cleaning solutions that are available for a wide variety of industrial applications.

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General Repair or Production Process Cleaning Industrial Applications

Because of the wide range of industrial applications for aqueous parts washers, the purchasing team often requires a custom option that is unique to their cleaning requirement. An engineering consultation can assist in deciding cleaning stage configuration, throughput or batch process, cabinet type, or interface with automated loading and unloading of parts. Cabinet parts washers in either top load or front load design allows the operator full easy access to the wash zone.

One way to simplify identifying appropriate model choice is to determine whether your application is in either a general repair or production process cleaning operation. General repair parts washers typically are available in standard models with little variation while production process parts washers are highly automated and require custom design configurations to address greater cleaning challenges. It is important to note that adding components increases automation complexity, and typically requires larger cabinets to house more circuitry.

A standard general repair parts washer can be operated throughout the day, as required, or depending on demand, while high volume operations will require an industrial parts washer system that may operate around the clock. That’s because an industrial parts washer for production process cleaning may require multiple stages of wash, rinse or drying and then be loaded and off-loaded in a continuous operation.

Aqueous Parts Washers to Fit Industrial Categories

General Repair Parts Washers offer a variety of sizes and load capacities that fit for a wide variety of automotive and powersports applications, including: Automobile Repair Facilities, Boat Dealers, Bicycle Repair, Fabrication Parts Cleaning, Machine Shops, Production Engine Shops, Production Machining Facilities, Remanufacturing Facilities, Small Engine Repair, Transmission Machine Shops. For heavy-duty, large scale cleaning, the industrial applications include Truck, Transit, Rail, and Transportation Production Centers. Specialized General Repair Aqueous Cabinet Parts Washers are also designed for Fastener and Screw Machine Applications.

Production Process Industrial Parts Washers are highly automated and typically customized with options for applications that require meeting clean specifications and challenging or intricate parts configurations, including: Aviation & Aircraft Parts Cleaning, Contract Machining, Fabrication Parts Cleaning, Automotive Fleet, Metal Casting & Forming, Pattern & Machining, Precision Part Manufacturing, Production Engine Shops, Remanufacturing Facilities, Tool & Die Machining, Transit, and Transmission Machine Shops.

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Recent Innovations in Part Washer Operation, Functionality and Effectiveness

Recent innovations in part washer functionality include cabinet-based rotating fixture systems, pass-through or flow-through conveyor parts washers, and front load return-to-operator carousel parts washers that can accommodate robotic loading and unloading of parts and components.

The goal of a clean specification requirement is to achieve the determined quality level and eliminate any contamination. By their very nature, complex parts and intricate components contain blind spots and hard-to-reach areas that may need special fixtures and a custom array of nozzles aligned to challenge areas to thoroughly remove contaminants.

The Automatic Top Load Rotary Fixture Parts Washers operate like a rotisserie: as the part rotates from its balanced centerline, the spray manifold thoroughly flushes fine particulates from blind holes and other hard to clean cavities. Because every surface of the part is targeted with heated and pressurized water and solvent-free detergent, there’s no chance of the part remaining contaminated. During the dry cycle, rotation action dumps water from blind holes and hard to reach areas.

Cabinet Parts Washers or Pass-Through Conveyor Parts Washers: Advantages and Limitations for Batch Cleaning Processes

When considering an industrial parts washer for your application or production cell, it is important to compare functions that impact workflow. Cabinet parts washers are excellent choices for batch cleaning large size parts and components, whereas pass-through parts washers are well-suited to parts of uniform size, and production cells with continuous product flow.

Cabinet parts washers are loaded with parts, the door is closed, the wash cycle is initiated, and when completed, the parts are removed. For clean room situations, the closed-process nature of cabinet parts washers is well suited for environmental control. The turntable in front load cabinet parts washers can be designed with special fixtures and parts trees to accommodate multiple parts with odd shapes and sizes.

Cabinet parts washers tend to be of standard design, and therefore are less expensive to manufacture than pass-through conveyor parts washers. However, pass-through conveyor parts washers typically accommodate automated loading and unloading for lower labor costs, while cabinet parts washers require manual loading and unloading.

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EDUCATION IS THE KEY TO SELECTING THE RIGHT INDUSTRIAL PARTS WASHER

A best practice for ensuring a reliable and quality-driven manufacturer is to research the breadth of their product models, to include experience in the industry, number of machines in the field, and recent installations that demonstrate experience cleaning a variety of challenging parts and components. It is important that the parts washer manufacturer offer engineering consultation and a broad spectrum of value-added configurations that consider the operating costs of the entire cleaning production cycle, including advanced automation, product handling, worker safety, and environmental impact in order to be the appropriate solution for industrial applications.

Researching parts washer manufacturer information evolves to issuing request for quotes (RFQs), then to settling on final manufacturers. In addition to key requirements, additional questions that will complete the task of making the most informed decision include:

• Does the manufacturer provide technical support, service and supplies?

• Does the manufacturer also have experience in making their own detergents and additives?

• Can the manufacturer address issues such as excessive foaming or rust prevention?

• Can the manufacturer provide documentation in the form of printable Product Data Specifications?

• Can the manufacturer provide documentation in the form of Wastewater Approval Letters by State?

• Does the manufacturer provide turnkey installation and setup services that address labor for installation, general contracting of plumbers and electricians, facility modifications, and conveyors or robotics?

• Does the manufacturer provide product demonstration videos?

Increased quality begins with clean specification analysis and improvement of work processes. For clean specification requirements and special challenges, confirm that there is willingness and engineering ability to address your special need. It is recommended to provide sample parts for testing and evaluation.

It is now clear that one size no longer fits every industrial application. A wide variety of parts washer models has evolved to address the full spectrum of parts cleaning applications and functionality. However, not all industrial parts washers are constructed the same.

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Define the key requirements of the parts cleaning application by noting basic parameters, including:

Type of Part of ComponentSize of Part or Batch

Weight of Part or BatchPart Complexity

Environmental and Waste Disposal Concerns

Type of Operation (Top Load, Front Load, Pass-Through or Agitation Dip Tank)

Standard Base Model with Limited Op-tions, Or Custom Designed for

Specific Parts Cleaning ChallengesLocation in Facility

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TOP LOAD CABINET PARTS WASHERS:

STANDARD MODELS CUSTOM DESIGNED PARTS WASHERS

FRONT LOAD CABINET PARTS WASHERS:

Rotary Fixture Wash Rinse Dry

Manual Top Load Automatic Top Load

Automatic Top Load

Automatic Top Load

Automatic Top Load Wash Dry

Agitating Dip Tank Immersion

Automatic Front Load Wash Rinse Dry

Automatic Front Load





Automatic Front Load Wash Rinse Dry

Carousel Return to Operator

WASH, RINSE, DRY STAGES

RANGE OF CAPACITIES

RANGE OF CAPACITIES


PASS-THROUGH PARTS WASHERS:

Belt Conveyor Wash Dry

RANGE OF CAPACITIES


Chain Conveyor Belt Conveyor

Aqueous Parts Washers

Utilize Water and

Solvent-Free Detergent Under

High Heat and High Pressure

for Effective Cleaning of Parts

and Components

Examples of Parts and Components Aqueous Parts Washers Will Clean:Actuators, Extrusions, Barrels, Bearings, Brake Calipers, Bushings, Cam Shafts, Carbide Inserts, Carrier Plates, Channel Plates, Clutch Plates, Converter Housings, Cooling Bodies, Crankcases, Cutting Tools, Cylinders, Die Sets, Dunnage Trays, Exhaust Manifolds, Exhaust Tubes, Flanges, Flywheel Covers, Fuel Adapters, Fuel Manifolds, Fuel Filter Bases, Fuel Injector, Gears, Injector Bodies, Input Housings, Intake Manifolds, Lock Bodies, Nuts, Bolts, Screws, Piston Rings, Races, Reaction Plates, Rotors, Stampings, Transmission Components, Valve Bodies.

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AQUEOUS PARTS WASHERS SPECTRUM OF INCREASED FUNCTIONALITY



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Steven Meyer is Marketing Manager for Renegade Parts Washers and Detergents

About Renegade Parts Washers and Detergents:

The Renegade Product Lines of Parts Washer Equipment and Parts Washer Detergents is manufactured and sold by Service Line, Inc. in Reedsburg, Wisconsin. Founded in 1996, our extensive product lineup includes the standard Renegade automatic top load and front load parts washing systems, manual parts washers, and the Renegade Industrial Series of automatic top load and front load aqueous part washing systems with value-added customized configurations to meet or exceed clean specification.

Renegade Parts Washers Detergent and Additives are the solvent-free, high per-formance cleaning solution with additional health benefits.

The Renegade Team that engineers and manufactures each parts washer system is dedicated to quality, service and long-lasting value.

Made with pride in the USA.

Contact Renegade Parts Washers: [email protected] www.renegadepartswashers.com

Disclaimer:The contents of this document are for informational purposes only and are subject to change without notice. Service Line, Inc. and Renegade Parts Washers makes no guarantee, representations, or warranties regarding the enclosed information and specifically disclaims, to the full extent of the law, any applicable implied warranties, such as fitness for a particular purpose, merchantability, satisfactory quality, or reasonable skill and care. This document and its contents, including the viewpoints, dates, and functional content expressed herein are believed to be accurate as of its date of publication, May 2019.

Copyright © 2019 Service Line, Inc. All rights reserved.

LEGACY PARTS WASHER EQUIPMENT: IMPORTANT FACTORS THAT AFFECT YOUR DECISION TO UPGRADE TODAY

SUMMARYIn manufacturing operations, parts washers are an important step in the production process.

Cleanliness of parts and components relates directly to product quality and reliability.

Aging industrial equipment is designated “legacy” when it outlives efficient usefulness.

Beyond Breakeven: Factors that affect cost of operation include lower direct labor, improved reliability, improved component quality, environmental effectiveness, and safety.

Technical Overview: Automatic aqueous parts washers provide solvent-free cleaning for a wide variety of industrial applications.

General repair or production process cleaning industrial applications.

Aqueous parts washers to fit industrial categories.

Recent innovations in part washer operation, functionality and effectiveness.

Education is key in selecting the right industrial parts washer system.

Chart: Parts Washers Configuration Spectrum of Increased Innovative Functionality and Effectiveness.

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LEGACY PARTS WASHER EQUIPMENT...parts washers have evolved to provide an effective solution for a wide range of ... Washing or Manual Pressure Washing New Innovations and Capabilities: