Fast and flexible - A Dürr Ecoclean Special 95W cleaning system for ThyssenKrupp

The Special 95W industrial cleaning system in
Bielefeld, Germany.

A Dürr Ecoclean Special 95W industrial cleaning machine has been in operation at ThyssenKrupp Umformtechnik at Bielefeld, Germany since August 2008. The machine fulfils three vital requirements: it is a high performance machine, flexible in adaptation to process variations and it incorporates a customized automation solution for parts logistics.

At its Bielefeld location ThyssenKrupp Umformtechnik produces a broad range of body and chassis parts for the international automotive industry. Prior to welding, all components pass through a cleaning process. To optimize this process both organizationally and commercially, the company chose a Dürr Special 95W multi-chamber immersion cleaning system, designed specifically to meet ThyssenKrupp’s high demands.

The Special 95W machine cleans pressed parts - of a wide variety of shapes and sizes - using a five stage, aqueous solution based degreasing, washing and rinsing process. The cleaning process combines the chemical effects generated by a neutral to weakly alkaline medium (pH value of 6-12) with the mechanical effects of movement to ensure intensive media application. Subsequently the parts pass through a drying stage that is equipped with two hot air dryers, each having a capacity of 300 kW. Integration of large volume containers and of two chambers arranged in parallel to double process capacity makes it possible to achieve a high throughput in a cycle time of 4 minutes. The containers have a maximum size of 2 m by 1 m, in which parts weighing up to 2 tons can be cleaned. The system is therefore able to reach a maximum capacity of up to 20 loads or 40 tons per hour.

The flexibility required by ThyssenKrupp is demonstrated by the Special 95W machine in relation to the size of the parts to be handled. Four container variants are available and up to two different containers can be used per cycle. In addition the containers can be turned or tilted whilst in the process bath. This leads to much better cleaning results in comparison to those obtained with other systems. If required, the Special 95W can be adjusted to tilt to one side only, to any chosen angle, to ensure a particularly gentle cleaning process.

To optimize parts transport Dürr Ecoclean supplied an automated logistics system, through which even feed in of the containers into the process is automated. Manual handling has been completely eliminated from the process. Chain conveyors, inclined conveyors as well as lifting tables and turntables transport goods of up to 60 tons at a variety of heights and over hinderances. The installation of a shuttle conveyor is a particular highlight here: the containers pass through a narrow tunnel beneath one of the internal factory roads as they deliver cleaned parts from the cleaning system direct to the pressed parts store.

Last but not least an evaporator for waste water disposal has been integrated by Dürr Ecoclean at the Bielefeld factory. Here, rinse bath treatment is carried out on a continuous and process bath treatment on a discontinuous basis

ThyssenKrupp Umformtechnik are extremely satisfied with the results of the project.

Your contact:

René Gums – rene.gums(at)ecoclean.durr.com