The Challenge
A manufacturer specializing in pistons for conventional and alternative fuel applications faced a significant challenge. With seven different piston types, each requiring thorough cleaning to remove water-soluble coolants, chips, and light soils, they needed an efficient system that could handle variations in piston size (up to 8″ in diameter and height) and weight (up to approximately 25 lbs.). Additionally, the cleanliness requirement demanded that contaminants be reduced to a particle size of less than 100 x 100 microns while ensuring the parts were as dry as possible post-cleaning.
The Solution
A customized rotary indexing cleaning system was implemented, featuring a ten-position rotary table equipped with targeted spray and blowoff nozzles. The system incorporated:
- Variable spray and blowoff manifolds to clean both external and concealed surfaces efficiently.
- Quick-change part fixtures to accommodate different piston sizes.
- Regenerative blowoff and timed compressed air for effective drying.
With an annual production of over 200,000—equivalent to 2.9 pistons per minute—the RI-7200 rotary indexing provided consistent, high-quality cleaning while meeting the manufacturer’s rigorous production demands.
The Action
By integrating this tailored cleaning system, the manufacturer was able to:
- Attain cleanliness excellence.
- Decrease production constriction.
- Optimized operations with a single operator loading/unloading process.
This case study highlights how precision-engineered cleaning solutions can drive efficiency in high-volume manufacturing environments.
To learn more, visit www.alliancemfginc.com or contact us at (800) 969-7960