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A Comprehensive Tank Cleaning Optimisation Guide

Home / A Comprehensive Tank Cleaning Optimisation Guide
03/12/2019 10:00:00 AM

Industrial tanks get extensive use in pharmaceutical, food, beverage and petrochemical processing applications. Companies commonly use process tanks, reactors, blenders, mixers, kettles, shipping containers or fermenters to complete these tasks.

Cleaning this equipment has been a long-standing challenge because a lot of the powders, granules and liquids are prone to clogging and clogging due to their viscous nature. Certain chemicals and residues can linger longer than others, and improper cleaning can negatively impact a company's bottom line.

Fortunately, there are several viable solutions available with modern tank cleaning services and equipment. You get an increased safety level, it's better for the environment, and it can significantly lower your cleaning costs. Today's cleaning solutions can: 

  •         Achieve 100% cleaning effectiveness
  •         Decrease cleaning times by 75% to 85%
  •         Eliminate or reduce confined space entry by 100%
  •         Increase productivity by 20%
  •         Reduce chemical and water usage by 70% to 80%

Taking On the Five Business Challenges Associated with Tank Cleaning

Having dirty tanks, totes or chemical processing vessels bring businesses five main challenges, including:

Consistency

A clean container is a hallmark of product quality and consistency. Without proper cleaning, cross-contamination can happen between product batches. Businesses must pick tank washing nozzles that they can adapt to different operating conditions and residue types.

Unsafe Working Environments

Going into an industrial vessel carries risks. However, many companies don't realise they have other options besides manual cleaning. New technological advances eliminate the need to enter the containers and are safer for the employees.

Less Healthy for the Environment

Manual tank cleaning wastes a lot of water and resources. This makes it bad for the environment as a whole. Using a tank cleaning service drastically cuts down on the energy, water, chemicals and materials used to complete the cleaning process.

Profitability

Manual cleaning is time-consuming, and it can lower a business's profitability. Rotating tank cleaning gives you faster and more efficient cleaning times. This improves a business's profitability and capacity.

Regulatory Effect

WH&S (Work Health & Safety) regulates the use of safety precautions and manual tank cleaning. Utilising industrial tank cleaning services in Australia ensures your business stays in compliance and avoids penalties or fines

Industrial Tank Cleaning in Australia Method Consideration

The overall goal when you choose tank cleaning solutions is to limit the waste products and time while optimising the cleaning process itself. Every situation has unique variables, but the primary factors that you have to take into consideration include: 

  •         Available temperature, pressure and flow rate of the facility's wash fluid
  •         Drain size, so the tank does not fill up while being cleaned
  •         Number and size of available tank openings to insert a tank cleaning device
  •         Outlets aided by suction or gravity
  •         Scope of the tank
  •         Substance being cleaned
  •         Tank obstructions like as agitators, mixers, baffles or impellers
  •         Use of cleaning chemicals

Understanding Conventional Tank Cleaning Methods

For decades, static spray ball methods and manual cleaning have been the go-to methods. Boiling or fill-and-drain cleaning are also popular.

Manual cleaning with a hose and tank cleaning nozzles require suiting up in personal protective equipment (PPE) and entering the tank. These workers are at a higher risk for eye and skin irritants, falls and inhaling fumes. Additionally, these workers have to undergo training, and human error is high.

Static spray balls gently cascade cleaning solution that will eventually erode the reside away from the tank walls. It's useful for cleaning water-soluble liquids, but it's not effective on stubborn residue because it lacks the necessary force.

Understanding Modern Tank Cleaning Methods

More advanced industrial rotary tank spray nozzles deliver more reliable, faster and more effective cleaning. They take the safety risks associated with manual cleaning away, and they ensure consistent quality for every clean.

A rotating tank washing nozzle creates a sheeting action with a pre-defined coverage pattern that hits the entire tank wall. They're easy to change and economical, but they're time-consuming for more difficult applications.

Tank cleaning nozzles with rotary jets and impingement technology optimise the water flow and pressure for high-impact cleaning. They work in a 360-degree pattern on a 4 to 25-minute cycle. This method uses the fewest chemicals, water and time. Key advantages of these rotating tank washing nozzles include:

  •         Avoiding confined space entry
  •         Decreasing water, energy and cleaning chemicals consumption
  •         Eliminating cross-contamination
  •         Improving productivity, profitability and sustainability
  •         Preventing blockages and clogging
  •         Reducing tank cleaning downtime

Spray tank manufacturers rely on tank cleaning head's rapid return on investment and thoroughly cleans to support tank sales to businesses.

Tank Cleaning Spray Equipment Application Advantages

The most significant application advantage of a tanker cleaning nozzle is its durability. They can withstand harsh environments and tough substances. Mixing two tank cleaning sprays maximises each jet's impact.

 

Another advantage lies in the industrial rotary tank spray nozzles' ability to reduce waste and improve efficiency. There are no large chunks of downtime, and there isn't a lot of waster resources due to the higher efficiency rating over manual cleaning. 

Trials Showcasing Automated Bulk Container Cleaning Pays Off

Intermediate bulk containers (IBCs) and totes are standard for passive use in manufacturing and processing applications. They're cost-effective, convenient and reusable. However, reused totes must be completely clean to avoid cross-contamination complications.

Tote Cleaning Challenges

One of the biggest challenges with tote cleaning is deciding to send them away for cleaning and refurbishing or having staff clean them manually. In response, several tote cleaning trials got underway to see which tank cleaning head and nozzle produced the best results. For the trial to succeed, this equipment had to cut down tote cleaning time while increasing in-house cleaning effectiveness.

During the trial, the system surpassed all expectations. The rotating tank washing nozzle used impingement technology to give high-impact, full-coverage cleaning. In turn, they wasted less water and chemicals. The 360-degree pattern ensured every inch of the tote was debris and residue-free.

As a result of these findings, the entire tote-cleaning process moved in-house. Cleaning times were 25% to 50% faster with a whole tote getting cleaned in under eight minutes. Since cross-contamination is a thing of the past, the company can deliver consistent product quality again and again.

Learn how much time and water you can save with Gamajet tank cleaning nozzles

Tank Cleaning - Rotating CIP

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