W3 Process Development
W3 Process Development involves several steps we call the Four "D"s to arrive at correct equipment selection for your application as defined below.
Step 1 – DEFINE
Step 2 – DEVELOP
the cleaning process.
Step 3 – DETERMINE
other machine and manufacturing site information.
Step 4 – DECIDE
on the correct equipment system.
An Easy Step
to quickly determine the type of equipment that might apply to your needs is to go directly to our Interactive Decision Tree
for Equipment Selection. Correct equipment selection still depends on following the above Four D steps which culminates with contacting W3
for the correct equipment proposal.
Use the following steps to Develop Your Application Process
W3 product philosophy is based in making the product fit the application rather than making the application fit the product. All selections of equipment are first preceded with a thorough analysis of your specific application and production needs with one of our experienced W3 Ultrasonic application personnel. Start the process development analysis yourself and/or contact W3 directly.
In order to arrive at the best process for your industrial cleaning need, some important information must be determined and that information can only come from one source - YOU. We need to know what you know.
Let's summarize what you know. The outline in the next section will help you gather the important information about your cleaning application. If you are missing much of this information, try to determine it before proceeding to the Interactive Decision Tree or contacting W3 directly.
Step 1: Define Your Application
What do you know about the dirty part or parts?
- general description of part & use
- materials of construction
- size and shape of part(s)
- weight per item and weight per load
What do you know about the "dirt"?
- composition of the dirt
- is the dirt soluble in any solution
- estimate of amount of dirt per part or load
- how is dirt adhered to the part(s)
What do you know about the manufacturing process?
- manufacturing process immediately prior to and following cleaning
- current cleaning how and why
- current cleaning process and problems
- current cleaning media and unacceptable media
- are part(s) to be "dry" at exit
- how do you measure "clean"
What do you know about the parts handling?
- do parts flow in a batch or continuously in line
- are parts piece parts or in existing baskets/carriers and type/size
- is part loading manual or automatic
- is part transfer manual or automatic
- desired production rate or line speed
- you can go to the Interactive Decision Tree
to see what type of system is likely for your application or Contact W3
directly to discuss. The important matter at this point is that a viable cleaning process with all process stages is set before determining a final equipment bill of material and proposal.
Step 2: Develop the Cleaning Process
We will discuss the information you have summarized above and determine if yours is a viable application for ultrasonics. If not ultrasonics, what other method should W3 consider to use? W3 can develop the process through testing where we strive to:
- apply the maximum power - mechanical cavitation intensity
- for the shortest time - high power allows short duration dwell times
- using the least aggressive chemistry and concentration - high power cavitation allows choices
- then select the likely chemical(s)
The resulting chemical solution may be vastly different when using high power ultrasonics than when chemicals only or other types of cleaning equipment are used. The mechanical action provides substantial cleaning force and when the chemical action is added, the combined effect of the two improves cleaning and lowers cleaning time. Again, experience is valuable here.
Step 3: Determine the other Machine and Manufacturing Site Information
Once we have the process established, we can finalize the proposal with some additional information gathered. What do you know about Site and Ancillary Equipment Needs?
- direction of product flow
- overall floor space allocation
- height limitations
- building entrance dimensions
- services available
- filtration requirements
- exhaust requirements
- waste minimization requirements
Now W3 will make the product fit the application.
Step 4: Decide on the Correct Equipment System
Visit the Interactive Decision Tree to get an idea of the type equipment for you or contact W3 directly for the correct equipment selection and proposal.
W3 product philosophy is based in making the product fit the application rather than making the application fit the product.
All selections of equipment are first preceded with a thorough analysis of your specific application and production needs with one of our experienced W3 Ultrasonic application personnel.
Start the Process Development analysis yourself or Contact W3 directly.