Through feed / Inline Cleaning Systems ZD

The ZD Series is our innovative response to increasing quantities and diverse conveyor systems. Zippel throughfeed cleaning machines can be custom-fitted onto any production line. Depending on the machine length, the cycle time can thus be adjusted to the machines placed before and after the Zippel machine. In this way, the existing manufacturing process is neither interrupted nor delayed.

Technical Process

  • Multiple wash and rinse stations along the production line
  • Largely free of extracted air
  • Automatic loading
  • Noise insulation enclosure for low emission levels
  • Process duration invidually programmable
  • Reverse chain motion inside the cleaning tunnel
  • Variable conveyor speeds
  • Product carrier conveyor system adapted to equipment

Optional Components

  • In-line, hanging or O-shape conveyor
  • Vacuum, infrared or hot air drying process
  • Water treatment system
  • Oil separator /centrifuge /vaporizer
  • Cyclic operation
  • High pressure cleaning
  • Automation/conveyor technology
  • Oading and unloading solutions

Advantages

  • Easily accessible for maintenance
  • Energy-saving due to double wall insulation
  • 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 handed over to the throughfeed cleaning machine either manually or by an automated system. The goods to be washed pass through the consecutive treatment zones either continuously or in cycles, as needed. Even the integration into an existing conveyor system is possible. Also, special designs executed as so-called O or U type designs, where the loading and unloading positions do not have to be in line, are available upon customer request. Multiple-line designs for increasing throughput rates or cleaning different types of component shapes are likewise available.

Available treatment steps

  • Cleaning and rinsing
  • high-pressure cleaning
  • flake deburring
  • passivating
  • distributor-type injection water rinsing
  • cooling

During cleaning and rinsing, pressure is applied to the workpieces by spraying action. High-pressure cleaning is carried out by the high-pressure nozzles integrated in the high-pressure zone, where available. These nozzles are supplied by a high-pressure pump with just the right amount of pressure for each component. The high-pressure nozzles apply pressure to the workpiece in a precise manner and therefore ensure flake-free results after cleaning. Even purely mechanical treatments like brushing are possible (in the brushing zone). The cleaning media are heated to the required cleaning temperature, which is kept constant throughout the entire duration of the process, either by electrical heat (immersion heaters) or by technical heat using heat exchangers (hot water, thermal oil, gas heater, etc.).

Selection of the most suitable cleaning and drying method as well as of the most suitable handling system (suspended conveyor or chain conveyor system) depends on the types of workpieces processed, the cycle times, the workpiece volumes to be cleaned, and their required final condition. Intermediate zones serving as neutral zones or blasting zones for the reduction media carry-over are integrated in the system.

Additional treatment zones will be designed commensurate with customer requirements. All process media used in the machine are filtered and recycled into the system, with filtration fine-tuned to residual dirt requirements. After completion of the treatment, the workpieces are ready for pick-up and/or further transport. Unloading of the workpieces can be done either manually or by an automated system.

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. 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.

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.

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 the ZD-6.000-RAST Cleaning of Injection-Moulded Components Soiled with: Lubricants & Chippings

The ZD-6.000-RAST is a throughfeed cleaning machine designed for the cleaning and drying of injection-moulded parts made of aluminium. The workpieces are transported through the machine continuously and automatically by means of wire eye belts while being sprayed with cleaning media by flat-jet nozzles and finally blasted with air. At the end of the machine, the dry parts are ready for handover to further transporting.

Machine specifications – circa values
Length Breadth Height Weight Zones Cycle time
6.000 mm 2.900 mm 2.900 mm 5 t 8 15 sec/pcs
Temperatur of bath Agent Conveyor system Sound level Floor connections stainless steel § 19 I WHG
40 - 80°C neutral/alcaline Twin-track 80 db(A) 2 mm
Connections
Water intake Compressed air Electrical connections
4 - 6 bar, R 1" 3 - 6 bar, R 3/4" 3 phases, 400 V, 50 Hz

Cleaning areas

neutral | cleaning | blowing | rinsing | drying

Cleaning
Tank capacity Pump Filter
1.200 l 21 m³/h, 4 bar 50 – 200 μm
Rinsing
Tank capacity Pump Filter
1.200 l 16 m³/h, 3 bar 15 – 50 μm
Blowing
Blowers    
870 m³ 200 mbar 7 kW - 14 A