Basca washing machine to clean mixing tanks for masterbatch production
Discover how our client, a manufacturer of masterbatch, has simplified the process of washing its mixing tanks, reducing washing cost by 83%, washing time by 75% increasing cleaning quality and operator safety.
The customer has the need to wash about 15 mixing tanks per day, the initial situation involved 1 operator full time washing manually using high pressure washer. This meant a cost that was exceeding € 300 per day considering labor and wastewater disposal cost (€ 72,000 per year).
In addition, the working conditions for the worker were not acceptable, which meant that many times the final tank quality was not as expected and the washbay quite untidy and slippery.
The applied solution
Basca supported the client to analyze facts and figures of the present situation, suggesting possible solutions to wash the containers in automatic way. Then a washing test at Basca facilities has been done to find the most suitable machine configuration. One the desired machine configuration has been finalized we have supplied a Basca Washing Machine equipped with a 200-bar pump to spray the water on the tank surface granting a perfect cleaning in about 5 to 8 min/tank.
Together with Basca Washing Machine, we installed a small wastewater recovery system that allowed to recycle and reuse the washing water again and again for further washing cycles, reducing the related costs.
The whole system is managed by a single operator less than 2 hours/day, which allowed the company to let him perform other tasks thanks to time savings, generating great value for the company itself.
How it works
The operator brings the dirty tank to the machine, selects the program in the control panel, brings down the cover to seal the tank and starts the cycle.
The washing head starts its rotation and contemporary spray of the washing water in re-circulation. The washing machine has 3 different programs, Eco Wash, Normal Wash, Intensive Wash, that can be chosen according to the tank size and dirt.
At the end of the washing cycle, the machine automatically switches to the rinsing mode and injects clean water into the system. Rinsing water is sucked from the waste water treatment stocking tank.
The machine handles automatically the transfer of the generated waste water to the treatment unit.
The operation of water regeneration is automatic and does not require a constant supervision of the operator.
Applying this technology, a single operator manages all the operation of the system, it has the possibility of washing a greater number of mixing tanks and in less time, the risk of health problems is reduced by eliminating the exposure of workers to toxic products and simplifies the management of dangerous products.
· Increase in production - a greater number of tanks that can be washed.
· Increase in efficiency - less dispersion of resources and controllable processes.
· Labor cost reduction - the reduction of low added value activities.
· Increased safety - no more jobs at high risk to health and elimination of the transport of hazardous substances.
· Greater flexibility - the ability to wash different types of containers.