Combined Spray-Immersion Cleaning Systems

The Zippel APOLLO combines the advantages of a chamber system with that of an immersion system. The cylindrical shape enables the charge to be rotated and swivelled, thereby optimising both spraying as well as injection flooding. The cleaning process can be further enhanced by integrating ultrasound, which also benefits from the cylinder shape. APOLLO‘s design also enables different drying modules to be installed, thus allowing it to be adapted to different requirements.

Technical Process

  • Combined spray and immersion cleaning
  • Various cleaning and rinsing processes in a single chamber
  • Several cleaning agent containers for different mediums
  • Automatic loading
  • Can be rotated and swivelled in all directions
  • Process duration invidually programmable

Optional Components

  • Ultrasound
  • Robotics
  • Customised programming for different system suppliers
  • Vacuum, infrared or hot air drying processes
  • Oil separator
  • Centrifuge system
  • Swarf removal belt
  • Water treatment system

Advantages

  • Effective Cleaning of both the outside and hard accessible boreholes inside of the part
  • Easily accessible for maintenance
  • Low servicing costs due to anti-twist snap closure on the nozzle line
system example
system example
system example

This plant type comprises one or several cleaning chambers and the related media containers situated underneath. The workpieces are placed in a basket or a box or a product carrier designed for the goods to be cleaned. For easier handling, the containers are loaded into the chamber by means of a feeding unit (e.g. loading table). Loading is available as a manual or automated process. After completed loading, the chamber is closed for the cleaning and drying process.

Available treatment steps

  • (Ultrasound) cleaning
  • rinsing
  • flooding
  • (vacuum) drying

Cleaning and rinsing is possible either by spraying the goods or by flooding the chamber. The plant is also capable of rotating or swivelling the goods past the spray cords for cleaning.

That way, even hard-to-reach areas of the goods to be cleaned will be perfectly coated by the cleaning medium. The cleaning medium is heated to the required heating temperature either by electrical heat (immersion heater) or by technical heat, using heat exchangers (hot water, thermal oil, gas heater, etc.). The heating temperature is maintained at a constant level for the entire duration of the process. To reduce any carry-over of media to a minimum, the lines are air-blasted after every process.

The main advantage of this cleaning system is its hermetic sealing – that way, the entire cleaning chamber can be flooded with media for ultrasound cleaning and vacuum drying. The most suitable drying process or filtration method can be selected to meet the requirements of the various workpieces and their desired final condition.

Loading & unloading is available as a manual or automated process. All process media present in the plant 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. A specially developed control system guarantees that the respective medium is led back into the correct tank in case of several cleaning-and/or rinsing processes. 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. The system supports pressures ranging from low pressure to high pressure (up to 1,000 bar). 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.High-pressure nozzles can also be used for flake deburring, if needed.

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.

Closed circuits

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

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.

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 40 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 e.g. K1-100-2-LB-V Cleaning of Spur Gears – Soiled with: Blasting Dust + Blasting Media

The APOLLO cleaning machine K1-100-2-LB-V is a single-chamber system comprising a spraying, flooding & drying system for cleaning spur gears which are loaded onto the conveyor system by a roller conveyor cart. The baskets containing the goods can be cleaned either stacked on top of each other or in a row, i.e. one after the other. While inside the chamber, the baskets containing the goods can be swivelled and rotated for optimised spraying and injection flooding. The cleaning media are heated to the required temperature by means of a pipe heat exchanger. Filtering of the cleaning media is done by manually operated fine-mesh filters.

Machine specification – circa values
Length Breadth Height Weight Process sections Cycle time
6.500 mm 4.700 mm 3.000 mm 5 t 4 150 pcs/h
Temperatur of bath Agent Sound level
60 – 65° C Acid/alcaline < 80 db(A)
Connections
Water intake Compressed air Electrical
3 – 6 bar, R 1 “ 3 – 6 bar R ¾ “ 3 phases, 500 V, 50 Hz

Cleaning areas

spray-flooding | driping | rinsing | vacuum drying

Cleaning
Tank capacity Pump Filter
2.000 l 35 m³/h, 4 bar 100 µm
Rinsing
Tank capacity Pump
1.000 l 24 m³/h, 4 bar
Vacuum drying
2 blowers    
300 m³/h 6,5 kW, 13 A 10 mbar