IBC container washing system type KWA-IBC

Subject to errors and technical changes. Supplied without IBC container, holding rack for customised wash ware, etc.

Material

Manufactured from stainless steel 18/10 material no. 1.4301.
The externally visible stainless steel sheet surfaces have a polished finish with 320 grit.
The externally visible stainless steel profile surfaces, such as the feet, have a uniform brushed finish.

Possible wash items

• Standard IBC (stainless steel, 1,000 litres)
• Electrically heated IBCs (stainless steel, 1,000 litres)
• Aseptic IBC containers (stainless steel, 1,000 litres)
• Aseptic IBC containers for highly viscous products (stainless steel, 800 litres)
• Plastic pallets with optional support racks

Customised solutions and user-specific extensions

In addition to the standard configuration described below, customised special solutions can be implemented to optimally adapt the system to existing processes and special requirements. These include, for example

• Versions for cleaning other, special IBC container types with different geometries or connection situations.
• The addition of an external cleaning function for IBC containers, for example via additional spray frames or nozzle levels, in order to incorporate external container surfaces into the process.
• System variants with two large-volume wash tanks in a two-stage tank cascade, in which one tank is designed as a fresh water tank and the other as a process water tank for more heavily loaded wash medium. Both tank zones are continuously "refreshed" via the rinse water: the rinse water flows back into the upstream process water stage in stages, while excess, heavily soiled water is fed to the drain in a controlled manner via an overflow system. This results in a permanent exchange of media with significantly reduced fresh water consumption.
• A shaft installation version for ground-level feeding, in which the cleaning cabin is integrated into a floor or technical shaft and a separate, large-volume water tank (or a two-stage tank cascade system) provides the media supply in the background.
• An IBC quick coupling system for the outlet nozzle (incl. nozzle system), which significantly simplifies handling and speeds up the connection process considerably.

This means that the IBC cabin washing system can be integrated into both new projects and existing production environments as a customised solution.

Product description

The cabin washer for reliable internal cleaning of IBC containers is designed for continuous industrial operation and is made entirely of 1.4301 stainless steel. One IBC container is cleaned per batch, with a typical hourly output of approx. 5-6 containers. In the closed cabin system, the IBC interior and drain opening are cleaned in one batch - without cleaning the outside of the container (optional). The system is designed in particular for hygiene-critical applications in the food and beverage sector and for liquid, sensitive products.

The machine is set up as an elevated cabin solution directly on the hall floor and loaded via a high-lift truck ("ant"). A shaft installation version for ground-level loading, in which the cleaning cabin is integrated into a floor or technical shaft and a separate, large-volume water tank (or a two-stage tank cascade system) in the background provides the media supply, is available as an option.

The washroom is closed via sturdy, double-leaf, double-walled stainless steel doors with thermal insulation; each door is equipped with triple locking per door leaf and safety switch monitoring, thus ensuring safe operation and good tightness of the washroom.

A mechanically adjustable stop device for the IBC containers is integrated in the interior of the machine in the rear area of the two loading rail guides. This means that IBC containers of different designs or volumes can always be reproducibly positioned in the centre of the wash cabinet by simply moving a lever. This ensures that the 360° FURY interior cleaning nozzle, which is inserted into the interior of the container via the upper filling opening (dome) of the IBC container, reliably reaches the interior and optimally loads it.

In addition, the dome passage is fitted with a tight-fitting plastic lid on the internal cleaning system. This sealing lid closes the filling opening around the 360° FURY nozzle during the washing process so that washing water and detached product residues remain inside the container. This effectively protects the interior of the cleaning cabin from contamination and at the same time prevents the outer surface of the IBC container in the dome or lid area from becoming unnecessarily contaminated. The cleaning process remains clearly focussed on the inside of the container, while downstream handling and transport processes benefit from a clean container exterior and a hygienically separated cabin interior.

The inner container cleaning system is designed as a pipe-in-pipe system: The main wash is fed via the internal pipe to the FURY cleaning head, which covers the container interior with a powerful 360° spray pattern. The rinse cycle then takes place via an integrated ball nozzle system, which is supplied with fresh water via the outer pipe. In this way, the washing and rinsing processes are combined in a compact unit to save space and the media flows are clearly separated from each other.

Automatic lowering and raising of the internal cleaning system

The inner tank cleaning system is automatically lowered via a hose reel installed on the machine roof with an integrated lifting and positioning unit and raised again after the washing process. The system is conveniently operated via the touch control panel display.

If the operator selects "Lower spray head" in the HMI (Human Machine Interface) menu , the interior cleaning system is lowered until the tight-fitting plastic lid of the interior cleaning system (spray head) rests on the dome of the IBC container. The lowering process takes place via a brake gear motor, which moves the hose and guide unit downwards in a controlled manner.

Once the washing programme is complete, the spray head is automatically raised again: The brake gear motor moves the unit upwards until the lifting movement is safely completed. Additional safety sensors monitor the area above the end position and prevent uncontrolled overturning or overrunning of the mechanical stops. This means that the entire lifting and lowering process of the spray head (internal cleaning system)is permanently monitored and safely integrated into the control system.

The centrepiece of the interior cleaning system is a compact FURY high-pressure cleaning head. The cleaning device is driven solely by the cleaning fluid: A slowly rotating piston sets the spray head in rotation and simultaneously causes the nozzles to oscillate at an angle of around 90°. While the head rotates continuously around its own axis, the specially designed nozzles generate high-energy, far-reaching jets that cover the inside of the container with a full 360° spray pattern.

Only a small proportion of the medium is used for the drive; around 95 % of the flow rate is available for the actual cleaning effect. This ensures a pronounced mechanical effect with efficient use of resources. Thanks to the robust mechanical design without high-speed turbines, the slow rotation speed and the open, easily accessible design, the system is very maintenance-friendly and designed for a long service life. The spray principle has proven itself many times over in applications with high demands on hygiene and product purity - for example in beverage and milk processing, in breweries, pharmaceutical, chemical, nuclear and transport industries.

Parallel to internal cleaning, the drain opening area in the standard version is intensively cleaned via a manually screw-on 90° drain nozzle with integrated nozzle system and separate pump circuit (11 kW / 500 l/min at approx. 7 bar). This allows product residues and deposits in the bottom valve area to be specifically removed and discharged. As an option, an IBC quick coupling system for the drain nozzle (incl. nozzle system) can be used to significantly simplify handling and considerably speed up the connection process.

The double-walled insulated wash tank (approx. 1,200 litres) is heated by three electric tubular heaters with 11 kW each. This allows typical wash water temperatures in the range of around 55-65 °C to be realised. Two stainless steel centrifugal pumps from EDUR are used to circulate and supply the consumers. The 7.5 kW pump (approx. 500 l/min at 6 bar) supplies either the internal cleaning system with FURY cleaning head or the spray frame system for optional pallet cleaning, depending on the items to be washed and the programme selected. Switching between the two consumer circuits takes place via a pneumatically actuated angle seat valve, which automatically opens the active line and reliably shuts off the other.

A specially designed spray frame system with 20 nozzles is available for pallet cleaning, which covers the pallets with a homogeneous spray pattern all round. The system is also equipped with a separate water lance for the pallet rack drive. The water pressure causes the special pallet rack to rotate so that all surfaces are sprayed evenly and the pallets are cleaned all round without spray shadows.

Fresh water is used for rinsing via the ball nozzle system in the outer pipe of the pipe-in-pipe system; the consumption per batch can be set in a range of approx. 30-60 litres - depending on the desired rinsing result and hygiene standard.

Vapour extraction

The cabin washer is equipped with an effective vapour extraction system to capture and remove steam/vapours. A stainless steel radial fan is located on the machine roof, which extracts the exhaust air via a DN 250 exhaust air connection with a flow rate of approx. 1,500 m³/h. The extraction system is automatically time-controlled.

The extraction system is switched on automatically at the beginning and end of each batch, i.e. precisely in the phases in which most of the vapours escape when the cabin doors are opened. In this way, the moisture-laden air is directly captured and extracted, condensation on ceilings and walls is effectively reduced and the risk of mould forming in the surrounding rooms is significantly minimised. At the same time, the indoor climate in the area where the system is installed is improved - a plus for hygiene, building fabric and employee comfort.

The cabin washing system is controlled by a modern SIEMENS S7-1500 with freely programmable washing programmes. Depending on the installation situation, the technical compartment and control cabinet can be positioned on the left, right or at the rear - for practical integration into existing production environments. The machine is fully welded, double-walled, sound and heat insulated and designed for a long service life with low maintenance requirements. High-quality brand components (including EDUR, SEW, SIEMENS, KARL KLEIN, EATON, SCHMERSAL) support reliable and service-friendly operation.

A specially designed pallet rack is available as an option, which is designed to hold and clean up to four pallets. The frame is not mobile, but stands firmly on four stable stainless steel feet and is optimised for rotating operation in the spray frame system.

Highlights of the IBC cabin washer

• Combined cleaning of the interior and drain opening
  In the closed cabin system, the IBC interior and drain opening are cleaned in one batch - without cleaning the outside of the container.
• Sturdy, double-leaf stainless steel doors
  Double-walled, insulated cabin doors with triple locking per door leaf and safety switch monitoring ensure safe operation and a good seal of the washroom.
• Precise positioning of different IBC types
  Mechanically adjustable stop device in the loading rail guides enables reproducible, centred positioning of different IBC designs and volumes by simply moving a lever.
• Pipe-in-pipe internal cleaning system
  Inner pipe for main washing via the FURY cleaning head, outer pipe for rinsing via a ball nozzle system - compact unit with clearly separated media flows.
• Automatic lifting and lowering system for the spray head
  The internal cleaning system is lowered to the exact position on the tank dome via a roof hose reel with brake gear motor using the HMI function "lower/lift spray head" and raised again at the end of the programme; monitored by several end position sensors and an additional safety sensor.
• Efficient 360° interior cleaning with FURY cleaning head
  High-pressure cleaning head with rotating and oscillating spray pattern, driven solely by the cleaning liquid; around 95 % of the medium acts directly as a mechanical cleaning force in the container interior.
• Two wash pumps with automatic line switching
  EDUR stainless steel centrifugal pumps, one of which is a 7.5 kW pump (approx. 500 l/min at 6 bar), optionally for IBC interior cleaning or pallet spray frames; line switching via a pneumatically actuated angle seat valve.
• Spray frame system for pallets without spray shadows
  Spray frame with 20 nozzles and separate water lance; the ball-bearing pallet frame is set in rotation via the water pressure - for all-round uniform pallet cleaning without spray shadows.
• Targeted cleaning of the drain opening
  Manually screw-on 90° drain nozzle with integrated nozzle system and separate pump circuit (11 kW / 500 l/min at approx. 7 bar) for intensive cleaning of the base valve area.
• Powerful heating with electric tubular heaters
  Double-walled insulated wash tank (approx. 1,200 litres), heated via three electric tubular heaters with 11 kW each - for stable wash water temperatures in the range of approx. 55-65 °C.
• Vapour extraction with time-controlled exhaust air routing
  Vapour extraction with stainless steel radial fan (approx. 1,500 m³/h) via DN 250 exhaust air connection; time-controlled operation at the start and end of the batch for targeted capture and removal of steam/vapours.
• Robust stainless steel design
  Completely made of stainless steel 1.4301, material thickness approx. 2-8 mm, firmly welded, double-walled housing with integrated sound and heat insulation.
• Large-volume wash tank with adjustable rinse volume
  Tank volume approx. 1,200 litres, rinse volume adjustable per batch (approx. 30-60 litres) to adapt to product, hygiene requirements and use of resources.
• Modern control and drive technology
  SIEMENS S7-1500 with two freely programmable programmes, high-quality control cabinet components (including SIEMENS, EATON, SCHMERSAL), EDUR stainless steel centrifugal pumps and SEW drive technology for reliable, service-friendly operation.
• Optional: stationary pallet rack for up to four pallets
  Pallet rack permanently mounted on four stainless steel feet, designed for water-pressurised, rotating operation via the spray frame system - for reproducible, all-round effective pallet cleaning.

Options

• Tank heating via steam direct Art. no. 11.10.02.75
• Tank heating via steam indirect Art. no. 11.10.02.76
• Hot water or thermal oil heat exchanger for wash tank Art. No. 11.10.02.81
• Support racks for a wide variety of wash items (e.g. for plastic pallets) on request