Immersion Cleaning Systems ZT

The ZT Series offers an ideal solution for both bulk goods and individual components. The complete wetting through immersion of the parts being cleaned enables intricate designs and strong impurities to be thoroughly cleaned. The cleaning itself can take place using aqueous-based solutions with or without ultrasound. Several immersion tanks can be placed one after the other to reduce the throughput time.

Technical Process

  • Thorough cleaning as a result of immersion cleaning process
  • Several cleaning agent containers for different agents
  • Automatic loading
  • Can be rotated and swivelled in all directions
  • Process duration individually programmable
  • Plastic-coated tanks when using aggressive mediums

Optional Components

  • Ultrasound cleaning
  • Vacuum drying
  • Cold or hot air drying
  • Integrated conveyor system
  • Water treatment system
  • Unlimited number of immersion tanks due to grid design

Advantages

  • High positioning accuracy
  • Low water consumption
  • Small space requirement cause of compact design
  • Suitable for all component sizes
  • Compatible for bulk goods and individual components
  • Low servicing costs due to anti-twist snap closure on the nozzle line
system example
system example
system example

The parts to be cleaned are unloaded from the infeed conveyor by a loading unit either individually or in bulk (in containers or baskets) and placed in the consecutive dip tanks together with the required media.

The following treatment steps are available as part of the dipping method

  • Cleaning
  • (distributor-type water injection) rinsing
  • treatment with liquids or ultrasound
  • spraying,
  • high-pressure deburring
  • passivating
  • drying
  • cooling

The workpieces or workpiece carriers are placed on an unloading station either manually or by an automated system (e.g. within an interlinked system). From here, a loading unit takes over the loading of the individual containers/zones and the further handling between the zones. In smaller machines, manual handling can be used between the zones to reduce costs.

The number of containers/zones depends on the number of treatments administered. The handling system places the workpieces or workpiece carriers into the respective basins. Here, the goods to be washed can be optionally placed into a rotatory device to create rotary and/or swivelling movements during the process. Inside the basin, the medium is set into motion by pressure flooding and special nozzles under the liquid level to optimize the cleaning effect. After completion of the treatment, the loading system picks up the goods to be washed, forwards them to the next station, and sets them down. For goods requiring scooping, the grippers of the loading system are available in a motorized design to allow bucketing of the washing medium above the appropriate zone and minimizing media carry-over. To prevent resoiling of the workpieces during unloading by floating impurities, the cleaning baths are equipped with a surface flooding mechanism.

In a dipping system, the zones can also be designed as spraying or high-pressure stations, similar to chamber systems. It is also possible to integrate an ultrasound in the various dip tanks. It is possible to precede the unloading process, which like the loading process can be done manually or by an automated system, with an upstream drying and/or cooling phase. Selection of the most suitable drying method depends on the workpiece and the desired final condition thereof. All process media used in the machine are filtered and reintroduced into the circuit, with filtration fine-tuned to residual-dirt requirements.

Containers

The water necessary for machine operation is normally supplied directly from the customer’s water supply mains and iscontrolled 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. 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. In dipping systems, special nozzles are installed underneath the liquid level for pressure-flooding the goods to be washed. If a treatment zone also involves spraying, it is possible to work with different spraying pressures. The nozzle type and volume flow rate are configured and calculated during the design phase. To ensure optimum maintenance and manageable repair, we generally use nozzle clip systems and the nozzle fittings which are equipped with quick-release fasteners.

Closed circuits

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

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.

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.

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. Another available drying method involves the use of infrared rays to heat the workpieces and evaporate the residual moisture. Even vacuum drying is possible. In that case, however, the components to be washed have to possess an adequate mass for storing the energy introduced during washing and releasing it as vaporization enthalpy during vacuum drying.

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 of the T9 Cleaning of Cylinder Heads – Soiled with: Metal Chippings + Oil

The T9 is comprised of several consecutive immersion tanks, a drying chamber, and a separate vacuum chamber for cleaning and drying cylinder heads made of steel. The parts are handed over automatically to the individual chambers in bogies via a portal axis system. After set-down of the bogies, the baskets containing the parts are put into rotation. The system is equipped with ultrasound plates for removing clinging dirt. In the drying zone, the cylinder heads are pre-dried by a high-pressure fan and forwarded into the vacuum zone by a chain conveyor. Ultrasonic Cold- or hot air drying Integrated transport

Machine specifications – circa values
Length Breadth Height Weight Zones Cycle time
14.000 mm 4.600 mm 3.500 mm 45 t 7 24 pcs/h
Temperature of bath Agent Sound level
60 – 65° C Alkaline < 80 db(A)
Connections
Water intake Compressed air Electrical connections
4 – 6 bar, R 1 “ 4 – 6 б bar, R ¾ “ 3 phases, 400 V, 50 Hz

Cleaning areas

spray cleaning| immersion cleaning with ultrasonic | immersion-spraying| pre- and vacuumdrying

Cleaning
Tank capacity Pump Filter
2.000 l 50 m³/h, 8 - 10 bar 100 μm
Rinsing
Tank capacity Pump
2.000 l 50 m³/h, 8 - 10 bar
Vacuum drying
Reinforced vacuum pump  
700 m³/h 7,5 kW, 15 A