By David Barney, President
Manufacturers facing sudden surges in demand know the pressure is real. Cleanliness, dryness, and consistency that worked at lower volumes can quickly become bottlenecks when throughput multiplies.
After more than 30 years of designing and manufacturing industrial parts washers, we have learned that early planning matters when increasing throughput. Cleaning should be evaluated before it becomes the process that limits production. The earlier manufacturers review part presentation, cycle times, loading, filtration, and drying requirements, the easier it is to build a cleaning process that supports future growth.
Recently, our team had the opportunity to visit a major HVAC manufacturer, producing massive chillers and walk the production floor with their engineering group. The conversation centered on a clear and aggressive ramp: increasing output from four components per day to twenty-four by year-end to meet strong market demand.
Producing six times as many components each day requires more than additional machine capacity. It requires a repeatable industrial aqueous parts-washing process that can handle the increased volume without introducing new quality or production concerns.
Understanding the Application
The parts in question are delicate aluminum HVAC coils and related components. These parts demand strict cleanliness requirements and very low residual moisture after cleaning. Any remaining water pockets or film can affect downstream processes and final product quality.
In addition, the components are typically presented in carts, which means the cleaning system must accommodate larger, heavier loads while still providing thorough coverage. The washer must clean the components consistently without requiring operators to remove each part from the cart or handle the parts individually.
The Proposed Solution: Pit-Mounted Turntable Aqueous Washer
After reviewing the process flow, part geometry, and target cycle times, we recommended a pit-mounted turntable-style aqueous parts washer with an approximately 7–8 foot diameter table.
Mounting the turntable in a pit places the loading surface closer to floor level. This allows operators to roll loaded carts directly into the washer instead of lifting the carts or transferring the components onto an elevated platform.
The larger turntable is intended to accommodate the customer’s existing carts and allow larger or multiple components to be cleaned during each cycle. This helps increase the amount of production completed per load while keeping the customer’s current material-handling process largely intact.
This configuration allows operators to roll loaded part carts directly onto the turntable, close the door, and start the cycle.
The preliminary target sequence includes:
- Load carts onto the turntable
- Close the door and initiate the cycle
- Approximately five-minute wash cycle , with the final dwell time adjustable based on testing and cleanliness requirements
- Approximately fifteen-minute dry cycle , subject to final testing and part orientation
- Open the door and roll carts out
Because of the way parts are oriented in the carts, some residual water pockets may remain. This does not necessarily indicate that the overall drying system is ineffective. Complex coil geometry, enclosed areas, and upward-facing pockets can physically trap water even when the cabinet environment is thoroughly dried.
For those isolated areas, a short compressed-air blow-off or vacuum step after the primary cycle may provide a practical and efficient final drying solution. The exact need for this step should be confirmed through test washing and drying evaluation.
Key Technical Features That Matter at Higher Volumes
Two system features are especially important when daily volume increases:Continuous Sump Sweep and Filtration
While the wash pump is operating, the sump-sweep system helps move chips and fine contaminants toward the filtration system instead of allowing them to settle in the tank or continuously recirculate onto the components.
Removing these contaminants from the wash solution helps support longer bath life, more consistent cleaning results, and fewer interruptions for tank maintenance as production volume increases.
EVA Steam Evacuation During the Dry Cycle
During drying, the system actively evacuates steam from the cabinet. Removing moisture-laden air helps create a drier cabinet environment and supports improved final part dryness. This is especially important when residual moisture must be kept to a minimum.
For high-volume aluminum component cleaning, aqueous cleaning provides a water-based process that can reduce reliance on harsh solvent-based cleaning methods. When paired with chemistry selected for the aluminum parts and the contaminants being removed, the process can provide repeatable cleaning while supporting operator safety and environmental goals.
Looking Ahead
A major production increase requires manufacturers to look beyond the washer’s basic capacity. The entire cleaning process must be reviewed to determine whether it can consistently support the new production goal.
When planning for higher-volume parts cleaning, manufacturers should evaluate:
- How the parts will be loaded and unloaded
- How many components can be processed during each cycle
- Whether spray coverage will reach all required surfaces
- Whether the filtration system can keep up with the additional contaminants
- Where water may become trapped within the parts
- How dry the components must be before the next operation
- Whether the cleaning process can operate consistently throughout the required shifts
The proposed pit-mounted turntable washer, continuous sump sweep, filtration, and steam-evacuation system provide a promising direction for supporting the manufacturer’s production goals. Final spray placement, wash times, drying performance, and operating parameters will be refined through continued engineering review and testing.
We left the plant encouraged by the open technical discussion and by the next steps identified during the visit. Supporting customers through growth—especially growth driven by strong demand—is exactly the kind of work we enjoy.
If your operation is preparing for a similar production increase, Renegade can help evaluate your part geometry, current workflow, cleanliness requirements, and target throughput. Contact our team to discuss your application or arrange a test wash using your actual components.