IBC Tote Washers - FAQ
Frequently Asked Questions & Answers that you need to know when selecting an IBC Tote Washing system.
The number of IBC's (Totes) to be cleaned in a given time period (per day, per week or per month) must be conveyed to the manufacturer of the IBC (Tote) washing system in addition to knowing what a day means in your company. Is a day considered 8 hours or do you operate your facility 24 hours. The answers to these questions are important for you as a user when selecting an IBC (Tote) washing system. Washing 30 IBC’s (Totes) per day versus washing 100 IBC's (Totes) per day or more will dictate the size of your system and how much automation is required to achieve your goals. Both factors have an impact on the total cost of the washing system. Drumbeaters’ sales application experts can assist you to find the right size system for your application.
The type or types of residues to be removed from your IBC’s (Totes) is very important for the manufacturer of the washing system to know because this has an impact on the design of the washing system and the cost of the system. Will you need an oil skimmer? Will you need a Multi-Media Filtration System? Will you need heat? Will you need a special water based cleaning solvent for the type of residue to be removed?
It is important to know if the IBC's (Totes) to be cleaned will be reused or recycled. Some of the IBC's (Totes) may only need to be washed and some the IBC's (Totes) may need both washing and rinsing. The answer to this question influences the design and cost of the washing system.
The GPM (gallons per minute) of the wash pump is a very important factor of the wash system. The horsepower of a motor is NOT indicative of the performance of an aqueous washing system. For example, a wash pump with a five horsepower motor may only be rated at 45 GPM whereas a one horsepower motor of another system may pump 100 GPM. This is not to say the one pump is superior to the other, but that pump designs are varied for specific uses. Since an aqueous washing system is more dependent on the volume of wash fluid that is pumped than the pressure (psi) for a good cleaning performance, the GPM can be the most important aspect of the wash pump. You need a large volume of fluid to carry the particles and solids to the drain.
Depending on the type of residue being washed out of the IBC's (Totes), heating the wash fluid contributes greatly to the speed and effectiveness of a washing system with the added benefit of the IBC (Tote) drying quickly after washing/rinsing due to the latent heat of vaporization which often eliminates the need for an expensive drying system. Further, the heating system must be able to maintain the desired temperature of the wash fluid. You do not want to have to wait for the wash fluid to heat back up again after only washing a few drums. Also, Drumbeaters wash & rinse recirculation tanks are fully insulated to reduce heat loss overnight when systems are not operating.
- Reduced Water Consumption. Drumbeaters Closed Loop IBC Tote washing systems recirculate the wash and rinse water. When Drumbeaters IBC Totes washing systems are used with Drumbeaters exclusive water based wash solvents, disposal of waste water is greatly reduced. Further, in systems that use a rinse recirculation tank system in conjunction with a wash recirculation tank system, the rinse water from the rinse recirculation tank is used as make-up water for the wash tank and fresh water is added to the rinse tank when the automatic fill option is selected. This means the rinse water is periodically being refreshed and therefore, the rinse water serves two purposes (rinsing & make-up water for wash tank). If you use Drumbeaters unique water based solvents, you will get full recovery of your solvent because the rinse water is used as make-up water for the wash recirculation tank system. Note: The necessity for make-up water is primarily the result of evaporation that occurs during the wash process.
- Less Energy Consumption. It takes less energy to heat recirculated wash and rinse water (145° F to 160° F) than to continuously raise the temperature of the wash and/or rinse water 85°-110° F or more. Also, Drumbeaters wash & rinse recirculation tanks are fully insulated to reduce heat loss overnight when systems are not operating.
- Reduced Consumption of Water Based Cleaning Solvent. Drumbeaters IBC Totes washing systems can all be closed loop systems. When Drumbeaters water based cleaning solvent is mixed with water, the wash fluid is recirculated through a recirculation tank system and not drained to the sewer (i.e. “closed loop”). Therefore, the water based cleaning solvent/water mixture is not continuously being lost down the drain. Instead, the user only periodically adds more water based cleaning solvent and water to the recirculation tank as result of evaporation over time making the wash fluid renewable. This results in a lower cost for the wash fluid (i.e. reduced consumable cost). Further, the wash fluid does not become a disposal cost. Drumbeaters unique water based cleaning solvents are not only recirculated and renewable but are cleanable by decantation by phase separation. Periodic decantation allows for the removal of solids at the recirculation tank bottom drain and the removal of any oils by using an oil skimmer. The water based solvent remains in the middle for reuse.
- Reduced or Elimination of Disposal Costs. Drumbeaters recirculation tanks are decant tanks. Any oils in the residues being washed out can be automatically removed with an oil skimmer which reduces labor and disposal costs and solids can be drained from the bottom of the tank. The oil skimmer used by Drumbeaters also has an oil/water separator that will yield higher quality waste oil that can be used in waste oil heaters, etc.
All Equipment Functions are PLC Controlled. This means that the standards to clean an IBC (Tote) are repeatable insuring the same quality standards desired are met each time. All machine functions (and make-up water if the auto fill option is selected) are automatic.
By using Drumbeaters Product Extraction System for removing residues as much as possible in the IBC Totes before washing the IBC Totes, the cleaning cycles are shorter, the frequency for decanting the wash fluid is reduced thus keeping the wash fluid cleaner longer and many products can be recovered for reuse. This opens the door for recovery of flowable residues such as paints, oil, fuels, solvents and many other residue materials that can then be reused or remanufactured and thus turning waste into sellable products. It is a “win win” situation.
Drumbeaters IBC Totes Washing Systems are engineered as a complete system to make installation easy and efficient. Our washing systems can be installed in hours not days. Each major system component and the connections between the major system components are pre-wired and pre-plumbed. All connecting plumbing between the system components are pre-cut and ready to connect to valves that are tagged. The electrical cables between the system components have multi-pin plugs that are easily plugged into the electrical control panels provided with the wash system. In the early stages of the project, the layout of the wash system is determined. The customer only has to bring the utilities to the washing system and then connect the utilities to the washing system based on the approved equipment layout.
Drumbeaters Drum and IBC (Tote) Washing Systems can achieve extremely high labor productivity per man hour through automation and using the latest technology in water based cleaning solvents. Therefore, fewer employees are necessary to clean the IBC's (Totes).
With automation, an employee is less likely to suffer injuries…pressing a "Start" button is less hazardous than using a power washer. Drumbeaters IBC Totes Washing Systems are sort of like an insurance policy to ward off the slip and fall problems with wet floors and leaky hoses and therefore has the potential to reduce your insurance costs.
Many parts used in Drumbeaters systems are manufactured by companies whose parts are available on a global basis and Drumbeaters ships replacement parts anywhere in the world. Also, Drumbeaters offers a remote diagnostic option that allows Drumbeaters to evaluate your system from Drumbeaters office in the USA if ever needed.
A well planned equipment layout will save you space in your facility plus increase efficiency when washing IBC Totes.
There is more to washing an IBC Totes than meets the eye. All washers are NOT created equal and washing IBC Totes may not be your company's area of expertise. The more information that you can provide to Drumbeaters about your project’s special requirements and the more you learn about features that you may never have considered will result in the selection of a washing system that will both meet your budget and requirements. All of Drumbeaters IBC Totes washing systems are custom configured for each customer. Let Drumbeaters sales application experts assist you to determine what features and system will achieve your goals.