Reciprocating Spray Manifold Parts Washer
Kemet are the UK representatives for PROCECO, a leading manufacturer of aqueous metal parts cleaning and surface treatment equipment used throughout the industrial manufacturing and remanufacturing industries worldwide.
The TYPHOON®-RCP is a batch-type, power-spray washer designed to clean large, heavy workpieces while minimizing floor space. Typical applications include cleaning of large diesel engine blocks, hydraulic components, and dies.The double sliding doors provide wide access for easy top loading with a hoist or front loading with a forklift.
The machine uses environmentally friendly, water-based cleaning solutions instead of harmful solvents. The cleaning process consists of a wash stage using a continuously recirculated, hot-water cleaning solution containing an alkali detergent. The cleaning solution is power-sprayed by a spray manifold that surrounds all four sides of the workpiece and travels back and forth across its entire length, ensuring complete coverage of all surfaces.The system effectively removes grease, carbon, and even paint (if so desired) prior to inspection and remanufacturing. The TYPHOON®-RCP is an ideal cleaning system for rebuild and remanufacturing applications. The system can incorporate a selection of options to remove oil and sludge from the solution, which substantially extends the solution life and reduces the need for manual tank clean-out.
- Recirculated, heated wash
- Fully welded tank and cabinet
- Double, hydraulically actuated, sliding cabinet doors
- Maintenance-free cabinet door with steel labyrinth seal
- Large tank access covers in spray cabinet floor and on pump bay
- Automatic solution level control
- Electric heating
- Low solution level heater protection
- Digital cycle timers
- Digital temperature controller
- 7-day programmable heating timer
- Easy-access stainless-steel screens protect pump and nozzles
- V-jet spray nozzles, mounted on elbows for easy adjustment
- Exhaust blower
- High-efficiency motors
- Finish: PROCECO gray
- 1-year warranty
- Recirculating 2nd stage
- Freshwater rinse
- Higher pressure wash pump
- Gas solution heating
- Steam solution heating
- Compressed air blow-off
- Full-flow bag filter
- Swing-down nozzle frame
- Stainless-steel construction
- Sound enclosure
- Manual spray wand
Highly Recommended Options for Remanufacturing Applications
These options substantially enhance cleaning results and extend solution life
- High-Pressure Pump - Increasing the wash pump capacity with a 600 USgal/min@ 200 psi pump enhances cleaning power and reduces cycle duration. Ideal for very dirty parts and paint stripping applications.
- Automatic Oil Skimmer - This device removes floating oil from wash solution tank.
- Automatic Sludge Removal Conveyor - The sludge conveyor scrapes the entire width of the wash solution tank bottom and drags out sludge to a container for disposal, reducing the need for manual tank clean-out.
Cleaning of Large Engines (Locomotive) - Case Study
Customer: Heavy machinery engine rebuilder
Workpiece: Engine block
Application: Cleaning and drying after teardown and prior to remanufacturing
Production: 1 block per hour
Cleanliness: Meets or exceeds typical remanufacturing requirements
- Four-stage process
- Stage 1 - Spray and immersion wash with hot (190°F), recirculated, caustic cleaning solution, followed by power flushing . Spray removes contamination of external engine blocksurfaces, while turbulation immersion cleans part holes and cavities. Power flushing removes contaminants from oil and coolant passages
- Stage 2 - Freshwater spray rinse, heated (140°F). Removes detergent residues by spraying heated fresh water to avoid contamination of the recirculated rust-inhibiting stage that follows
- Stage 3 - Spray rinse with hot (140°F) recirculated rust-inhibiting solution. Prevents oxidation of part surfaces
- Stage 4 - High-impact air blow-off, ambient temperature. Eliminates excess water and accelerates the drying process
- Rotating holding fixture exposes all engine block surfaces during cleaning and drying process
- Power flushing system forces the full flow of the pump through the oil and coolant passages
- High-pressure/flow pump. Effective removal of grease and dirt
- Sludge conveyor removes large quantities of sludge from the wash tank to extend solution life
Automatic Cleaning of Metal Forming Tooling - Case Study
Customer: Manufacturer of seamless tubes
Workpiece: Stretch Reducing / Sizing Block (SRB)
Applications: Cleaning prior to repair
Contaminants: Grease and baked rolling mill dirt
Part size and weight: Up to 48’’ long x 13’’ wide x 54’’ high; 4,200 lbs
System loading capacity: Two tooling blocks per batch; 10,000 lbs max.
Production: At least 20 tooling blocks/day
Cycle time: 10 to 20 minutes, depending on workpiece geometry
- Two -stage process:
- Stage 1: Power-spray wash with hot (160°F/71°C), recirculated alkaline cleaning solution. Removes grease and baked rolling mill dirt from tooling surfaces.
- Stage 2: Power-spray rinse with hot (160°F/71°C) recirculated rust-inhibiting solution. Removes detergent residue and prevents oxidation of part surfaces.
Reciprocating spray manifold surrounds the tooling block on all four sides, travels back and forth over the entire workpiece length for complete spray cleaning coverage. Water circuit flush-out system ensures the tooling water circuit drain hole is not plugged with debris. Sludge conveyor scrapes heavy soils from wash tank bottom extending solution life.
Problem: Long and costly cleaning process delivering poor results
Different models of metal forming tooling receive a spray booth cleaning using a high-pressure wand.
- The process is tedious and does not remove dirt completely.
- It takes 45-50 minutes to clean a part.
- Water splashing over the spray booth walls onto the surrounding floor creates a safety issue.
Solution: PROCECO RCP automatic parts washer
A Reciprocating Spray Manifold Washer washes and rinses all component surfaces and specific areas such as drive nozzles and recessed coupling wells in one process. The washer:
- Processes two tooling blocks per batch, in short cycle time of 10 to 20 minutes.
- The washer is completely enclosed preventing the solution from splashing and leaking.
Results: Parts are cleaned beyond expectations; higher production rate; reduced manpower
- Baked-on dirt and grease removed from tooling surfaces and cavities.
- Tooling housing water circuits flushed by a special device in the washer, ensuring that they are not plugged.
- Cleaning capacity has doubled and can support an increase in production demand.
Cleaning of Hydraulic Oil Tanks - Case Study
Customer: Heavy equipment manufacturers
Workpiece: Hydraulic oil tanks
Application: Washing after welding and prior to assembly
Production: Up to 8 tanks per hour
Cleanliness: Meets Caterpillar cleanliness specifications
- Reciprocating nozzle pipes spray clean the exterior of hydraulic oil tanks
- Rotating spray lances - Universally adjustable to clean the interior of all tank compartments
- Vacuum suction system creates a flow inside closed compartments and drains all washing fluids
- Large, open-top cabinet gives the operator full acces to all tank sides to connect all spray and vacuum lances
- Double sliding doors permits loading of the tanks using a lift truck or overhead crane
- Manual suction for the final suction touch-ups