Automatic Cleaning System for Large Fixed Production Tanks

Case StudyBascaMobile Automatic Cleaning System for Large Fixed Production Tanks

Discover how a multinational manufacturer of paints and construction chemicals automated the cleaning of two large fixed production tanks, reducing water consumption, eliminating manual confined-space cleaning and improving production safety and process reliability.

Initial situation

The customer had recently built a new production facility equipped with two large fixed mixing tanks used for the manufacturing of paints and construction chemicals.

At the end of each production batch, the tanks needed to be thoroughly cleaned before starting the next cycle. An ineffective cleaning process could lead to cross-contamination between products and create conditions for bacterial growth inside the tanks, potentially compromising the quality of subsequent production.

The alternative was to perform the cleaning manually. This would have required an operator to enter the tank after every production cycle and clean the internal walls, agitators and dispersers using a high-pressure lance.

Besides requiring approximately 2 hours for every cleaning cycle, this solution would have introduced significant safety challenges related to confined-space entry, high-pressure cleaning operations and the management of personnel inside the tanks.

Case StudyThe solution

The applied solution

Basca designed and supplied a fully automated cleaning solution based on the BascaMobile high-pressure washing system.

The BascaMobile unit is connected through fixed high-pressure piping to motorized washing heads installed above the production tanks.

At the end of each production cycle, the washing heads automatically descend into the tanks and spray water at a pressure of 250 bar, thoroughly cleaning the internal surfaces as well as the agitators and dispersers.

The washing system is fully integrated with the factory’s centralized SCADA system through industrial communication protocols.

This integration allows the Basca washing system to automatically receive the production status and start the cleaning cycle at the correct moment.

During washing, the Basca PLC also exchanges information with the production control system to automatically modify the position of the dispersers, allowing the washing heads to reach and clean all critical areas inside the tanks.

The entire cleaning process therefore takes place automatically, without requiring an operator to enter the tanks.

Results obtained

By automating the cleaning of the fixed production tanks, the customer significantly improved both production efficiency and workplace safety.

The system eliminates the need for a dedicated operator to enter the tanks and perform manual high-pressure cleaning, removing one of the most complex and safety-critical activities from the production process.

Automation also reduces production downtime between batches, while ensuring a repeatable cleaning sequence after every production cycle.

Thanks to the optimized high-pressure cleaning process, the customer estimates a water saving of approximately 2,100 litres per cleaning cycle.

The automated and repeatable process also significantly reduces the risk of product cross-contamination and bacterial contamination, helping protect the quality of subsequent production batches.

Case StudyBenefit

Reduced water consumption: approximately 2,100 L saved per cleaning cycle

Reduced cleaning time: eliminating approximately 2 hours of manual cleaning per cycle

Improved operator safety: no operator entry required inside the tanks during cleaning

Lower labour requirement: no dedicated operator required for the washing activity

Reduced contamination risk: repeatable automatic cleaning between production batches

Full process automation: automatic communication between BascaMobile and the factory SCADA

Higher production efficiency: reduced downtime between production cycles

Case StudyResults

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Less Water Consumption

Reduce water consumption from 2,700 to 600 litres per cleaning cycle, saving approximately 2,100 litres of water every cycle.

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Faster Cleaning Process

Reduce the cleaning cycle from 120 minutes to just 20 minutes, minimizing downtime between production batches.

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Less Operator Time

Reduce operator involvement from 120 minutes to just 5 minutes, limited to process verification and cleaning validation.

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Manual Tank Entry Eliminated

Completely eliminate the need for operators to enter the tanks during cleaning, simplifying safety management and reducing exposure to high-risk activities.

Case Study

Cleaning Stainless Steel Mixing Tanks and Drums

Case StudyBascaLC Washing Machine to Clean Stainless Steel Mixing Tanks and IBCs

Discover how our client, one of the world’s leading producers of paints, has simplified the process of washing steel tanks and drum containers, reducing washing cost by 62%, washing time by 70% and increasing the quality of cleaning.

Initial situation

Our customer has the need to wash between 10 to 25 mixing tanks and about 5 to 10 drums per day, the initial situation involved 3 workers washing manually using solvents and brushes to clean the tanks. This meant a cost that exceeded € 500 per day between labor and the cost of the solvent (€ 110.000 per year).
In addition, the working conditions for the workers were not acceptable, which meant that many times the quality of the wash that was obtained was not what expected.