Washer Case Study - Steel Industry

THE CHALLENGE:

This customer provides Roll Grinding, Polishing, and Finishing services for a number of large U.S. steel plants.  The services are provided on the end user site with the Customer managing and operating the plants' Roll Shop.

The Roll Shop services a large international steel plant located in the southeastern U.S.  This large facility has a 6-stand 4-high Hot Mill, Pickle Line, Galvinzing Line, 5-stand 4-high tandem Cold Roll Tempering Mill, and a Melt Shop with a 6-strand Continuous Strip Caster.

The JRI “steel-mill size” washer cleans all the roll bearings and chocks in the Roll Shop.

JRI'S SOLUTION:

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Printing Industry

THE CHALLENGE:

This customer is a large printing facility in the U.S., and they operate several printing lines in a 24/7 operation.

The requirements were to wash various printing press parts on a “roll-around” cart in a tunnel washer.  The parts included ink pans, transfer pumps, buckets, and doctor blades. The cart is at grade level for convenient loading and unloading of the washer.  This required putting the wash and rinse tank below grade.

JRI'S SOLUTION:

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Bearing Grease Case Study

THE CHALLENGE:

This customer is one of the largest wheel bearing remanufactures in the world. The current washing equipment was not only undersized but under powered to keep up with the production load required.

The customer needed to completely remove the heavy grease from heavy truck, railroad, and various heavy equipment bearings. A large share of the bearing contained up to 1 lb. of grease per bearing and the number of bearings being cleaned required a cycle time of four (minutes) max cleaning cycle.

Due to the large amount of grease being introduced into the wash sump we needed to completely drain the sump at the end of the day to allow the grease to separate for disposal. A batch tank and transfer pumping system were added to do the separation of cleaning solution and grease,and the clean solution was transferred back to the cleaning sump prior to the shifts start.

JRI'S SOLUTION:

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Contained Pressure Washing Booth for Natural Gas Drill Bits

THE CHALLENGE:

This customer is a high quality manufacturer and re-manufacturer of natural gas drilling bits. A major component for this customer is washing the drill bits prior to disassembly, and again after rebuilding. Cleanliness and inspection of the parts is critical as a down hole failure can be disastrous. Various other components are washed in the wash boot prior to the remanufacturing process.

Water is currently being hauled off by a licensed waste hauler. A wastewater recycling system is being considered.

JRI'S SOLUTION:

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Down Hole Pump/Motor Cleaning System

THE CHALLENGE: 

This company is a leading company in renting/leasing and rebuilding down hole oil field pump/motors. These parts are heavily soiled with oils and solids. Customer was cleaning rotors and stators separately with a hot water pressure washer and detergent.

JRI Cleaning Systems provided a safer more efficient alternative by automating the process.  This drastically reduced labor, water and detergent costs and reduced injuries due to a slick wet floor in wash area.

JRI'S SOLUTION:

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Aircraft Engine & Components Washer

THE CHALLENGE:

An FAA approved re-manufacturer of aircraft engines and components needed to replace and old cleaning system and needed to investigate new suppliers for the project.

They are required to adhere to the manufacturers' procedures and specifications (Pratt & Whitney, GE etc). One of their big concerns was the ability to maintain rinse-water quality.

Their old unit used a "flapper" diverter design and was not keeping the rinse water clean enough, causing them to clean out and refill the rinse water tank too often.

JRI'S SOLUTION:

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Turbine Component Manufacturing Center

THE CHALLENGE:

As a supplier for General Electric, a manufacturer of turbine engine components needed to replace an old cleaning system and needed to investigate new suppliers for the project. They are required to adhere to the General Electric's strict procedures for cleanliness.

One of their big concerns was the ability to wash, rinse, and dry the exterior and the interior of the part simultaneously to save time, and speed the washing process. Their previous unit used a design was only washing the exterior of the part.

JRI'S SOLUTION:

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Paint and Ink Tank Cleaner

THE CHALLENGE: 

A client that specialized in specialty paints and inks for the printing industry was interested in an efficient way to clean the residue paint and ink from the holding tanks.

From testing, they knew that a heated solution with an alkaline cleaner would do the job, if they could find a way to automate the cleaning..

JRI'S SOLUTION:

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