Reducing Water and Energy Consumption with an Automated Crate Washing System
The Challenge
A large dairy processing operation needed a high-capacity washing system capable of cleaning thousands of reusable plastic crates each hour while reducing water and energy consumption. The system also needed to deliver consistent sanitation performance and integrate multiple washing and drying stages into a single automated process.
The Solution
Sanicore Systems supplied a custom-engineered twin-track automated crate washing system designed specifically for high-volume food production environments.
The system combines multiple cleaning stages into one continuous process, allowing facilities to thoroughly wash, sanitize, and dry reusable crates while minimizing operating costs and water consumption.
System Highlights
- Twin-track automated crate washer
- Processes up to 5,000 crates per hour
- Pre-wash section
- Heated detergent wash
- Final rinse
- Sanitizing rinse
- Multi-pass air knife drying
- Hygienic stainless steel construction throughout
Washing Process
Pre-Wash
The process begins with a full 360-degree ambient water spray that removes loose debris. Water is filtered and recirculated to reduce overall consumption.
Heated Detergent Wash
Multiple spray manifolds deliver heated detergent solution at approximately 50-80°C using strategically positioned spray nozzles. The cleaning solution is continuously recirculated to maximize cleaning efficiency while minimizing water usage.
Final Rinse
A hot water rinse removes detergent residue before the crates move into the sanitizing stage.
Sanitizing Rinse
A dedicated sanitizing rinse applies a food-safe sanitizing solution immediately before drying. Water from this stage is recovered and reused as makeup water for the rinse system, helping reduce overall water consumption.
Air Knife Drying
Multiple high-efficiency air knives remove excess moisture before the crates leave the washer. The recirculated air naturally warms during operation, improving drying performance without requiring additional heating energy.
Engineering Features
The washer incorporates numerous design features intended for food processing environments, including:
- 304 stainless steel frame and tanks
- Stainless steel shafts and sprockets
- Hygienic machine construction
- Fully interlocked access doors
- Quick-release spray nozzles for simplified maintenance
- Adjustable leveling feet
- Heavy-duty chemical-resistant conveyor chain
Results
The completed washing system provides:
- Capacity of up to 5,000 crates per hour
- Reduced water consumption through multi-stage recirculation
- Lower energy usage
- Consistent cleaning and sanitization performance
- Improved operator safety
- Simplified maintenance
- Reliable operation in demanding food manufacturing environments
The project also demonstrated the value of a custom-engineered washing solution. During final inspection, design modifications were incorporated to accommodate new operational requirements before the equipment was shipped, ensuring the finished system met the end user’s evolving production needs.
Looking for a Custom Crate Washing Solution?
Every production facility has unique sanitation, throughput, and space requirements. Sanicore Systems provides engineered crate, tray, tote, pallet, and container washing systems designed around your specific application, helping food manufacturers improve sanitation while reducing labor, water usage, and operating costs.
Contact Sanicore Systems to discuss the right automated washing solution for your facility.
