Chamber Cleaning Systems ZK

The well-established cleaning technique in our ZK-Series provides a cost-effective, technically mature solution for small quantities. This single chamber system with several cleaning tanks and integrated spray cleaning system offers a wide range of cleaning processes for a relatively low quantity of pieces.
A multi-chamber system can be used instead of a single chamber system in order to reduce the design related problems with throughput times.

Technical Process

  • Different cleaning and drying processes possible in a single chamber
  • Integrated spray cleaning system
  • Manual or Automatic loading
  • Separate cleaning agent container
  • Process duration individually programmable
  • Largely free of extracted air
  • Throughput system possible

Optional Components

  • Air circulation drying
  • Infrared drying
  • Water treatment system
  • Multi-chamber design possible to reduce throughput
  • Loading equipment / travelling carriage
  • Automation technology

Advantages

  • Low servicing costs due to anti-twist snap closure on
system example
system example
system example

This system is comprised of cleaning chambers and media containers installed underneath. The workpieces are placed in baskets or boxes or on workpiece carriers and pushed into the chambers by a loading unit (e.g. loading table) for easier handling. Loading can be done manually or by an automated system. After loading, the shutter is closed for cleaning.

Available treatment steps

  • Cleaning
  • Rinsing
  • Dryling

The workpieces to be cleaned are sprayed with the required spraying pressure either by rotating crosses installed in the chamber (i.e. force-actuated, rotating spraying crosses equipped with nozzles), or splash lances, or movable registers.

It is also possible to integrate water-bearing workpiece carriers which are automatically coupled to a plug-in type main extension inside the cleaning chamber. That way, even hard-to-reach areas of the goods will be reached by the washing media. To keep carry-over of the media to a minimum, the lines are blasted with air after each process. The cleaning medium is heated to the required cleaning temperature, which is kept constant throughout the entire duration of the process, either by electrical heat (immersion heater) or technical heat using heat exchangers (hot water, thermal oil, gas heater, etc.).

Selection of the most suitable drying method depends on the workpiece and the desired final condition thereof. Loading and unloading can be done manually or by an automated system. All process media present in the machine are filtered for recycling and remain within the circuit.

Containers

The water necessary for machine operation is normally supplied directly from the customer’s water supply mains and is controlled via filling level sensors. Replenishment of the water and cleaning agent is automatic. If several containers are used simultaneously, water supply is available via cascade pumps at customer request. The media are returned from the process zones via a return line with integrated screen. During this process, our specially developed sliding unit ensures that the various media will be returned to the correct tank if several cleaning and/or rinsing processes are used. All media containers are made of stainless steel and heat-insulated.

Nozzle system

A variety of different nozzle systems are used for application of the cleaning media. A variety of rotating or firmly installed spraying registers, water-bearing carrying systems, or movable spraying registers are used. It is also possible to use differing pressure intensities for cleaning. The nozzle type and volume flow rate are configured and calculated during the design phase.

Closed circuits

All media present in the machine are filtered and reintroduced into the circuit for an effluent-free machine operation.

Floor trough

An integrated floor trough is used to ensure collection of the fluids in case of a container leakage. In larger-sized machines, the floor trough is integrated in the machine’s supporting frame. The floor trough is made of rust-free stainless steel and equipped with a leakage warning probe. The collecting volume is at least identical to the volume of the largest container. That way, the provisions of Article 19 I of the Federal Water Act will be met.

Enclosure

The entire machine can be enclosed to reduce noise emissions. Large-surface doors will be integrated to ensure adequate accessibility for maintenance and inspection works.

Drying

There are a number of different systems available for workpiece drying. Normally, side channel blowers or high-pressure fans are used for this purpose. These fans are designed specifically for the required volume flow rates and pressure rates and are adapted to the specified requirements. The air is applied to the workpieces either by a specially developed blasting pipe system (capillary system with air heating) and/or blasting fan. Air heaters may be used to increase the temperature. A vapour exhaust ensures the shortest-possible drying times. This unit is used to extract and actively recondense vapours during the cleaning process while ejecting dried air into the environment. It is also possible to design a virtually exhaust-free system upon request. Another available drying method involves the use of infrared rays to heat the workpieces and evaporate the residual moisture.

Bath care

You can download futher information for this at Periphery.

To achieve maximum service life for washing liquids, the washing media are filtered in many different ways. Coarse dirt is separated during a first phase while the medium is returned to the tank. Further residue is separated during full flow by an adequately designed fine-mesh filter. This process involves double filter systems which can be switched over manually to allow filter changes during ongoing operation. This equipment is standard in every Zippel cleaning system. For special needs, additional bath care systems are available as full-flow or bypass systems, including e.g. screen inserts, band filters, swarf conveyors, solenoid separators, three-phase centrifuges, evaporators, osmosis systems, etc. For oil separation, we recommend our proprietary, highly-effective ECOSEP gravity oil separator which works through coalescing action. It separates the oil, passes it into a separate tank, and returns the cleaned water into the container. Even physical water treatment is possible with this system.

The increase in environmental protection requirements for industrial enterprises is the reason behind our search for environmentally-friendly methods for preventing air and water pollution. Over the last 48 years many of Zippel‘s innovations have been awarded prizes and have redefined standards for water and air treatment. Such inventions combine ecology with economy in an exemplary way since they minimise current costs for energy, waste and recycling.

Our systems usually operate within closed loop systems in all medium-conducting sectors. The closed loop does not channel wastewater out of the machine, rather it feeds it back in after it has been filtered. In order to lower the costs for disposal of solid waste and reduce its quantities, there is an option to filter the discharged waste further and discharge it as a concentrate. Zippel has been developing such optimised systems for filtering, exhaust air treatment and water treatment with its suppliers for years. Closed, segregated loop systems are the decisive factor with
regard to operating costs (chemicals consumption, water consumption, energy consumption, heating). In order to increase the efficiency of our machines, we attach great importance to energy-efficient planning and design of components used. As a matter of principle, our cleaning systems are equipped with an integrated base trough (in acc. with para.19 of the German Water Resources Act), including a leakage warning sensor, and therefore do not require a licence from the water authorities.

Environmentally friendly components

  • BioJet: Hydrophysical water and fluid treatment to prevent and reduce the biological contamination of industrial water and process water
  • AquaCorrect: Reduces the surface tension of process water and improves oxygen enrichment
  • EcoSep gravity oil separator: Reduced costs and longer service life thanks to permanent oil separation
  • Water treatment plant
  • ZUT vapour exhaust: Extraction and filtering of water vapours. Recycled fluids are returned to the plant
  • Three-phase centrifuge
  • Filtration and separation technology: A concept custom-designed for the plant in compliance with the most stringent environment requirements, for improved production results
  • Osmosis systems: Compact systems for the desalination of softened potable water
  • Closed fluid and exhaust-air circuits

Technical Data for the K1-200-3-LB Cleaning of Burner Parts – Soiled with: Combustion Residue

The K1-200-3-LB is a chamber cleaning machine designed for the cleaning and drying of burner parts made of different alloy steels. It is comprised of a cleaning chamber and three containers installed underneath for cleaning 1, cleaning 2, and rinsing. The workpieces are loaded into the cleaning chamber by a movable loading table. After closing the shutter, the cleaning agent is applied to the workpieces by spraying crosses equipped with nozzles which rotate above the goods to be cleaned. The cleaning agent are transported to the annular orifice of the goods to be cleaned via a water-bearing frame with plug-in type main extension. The workpieces are dried with hot air and can be picked up by the loading unit after the shutter is opened.

Machine specifications – circa values
Length Breadth Height Weight Process sections Gravity oil separator
3.000 mm 3.000 mm 3.000 mm 3,5 t 4 ECOSEP
Temperature of bath Agent Sound level
60 – 65° C Acid/alcaline < 80 db(A)
Connections
Water intake Compressed air Electrical
4 – 6 bar, R ½ “ 4 – 6 bar, R ¾ “ 3 phases, 400 V, 50 Hz

Cleaning areas

cleaning I | cleaning II | rinsing | drying

Cleaning
Tank capacity Pump Filter
1.000 l 16 m³/h, 4 bar 100 μm
Rinsing
Tank capacity Pump
1.200 l 12 m³/h, 3 bar
Hot air drying
2 blowers    
580 m³/h 6,5 kW,13 A 200 mbar