Improving productivity is always a challenge in manufacturing and is key to staying competitive. One solution now drawing attention is inline systems that integrate cleaning and drying into a single process. Such integration can streamline workflows, cut costs, and reduce environmental impact. At the same time, adopting this approach requires careful planning and evaluation.
This article looks at the benefits of inline cleaning–drying integration and the key points to consider when designing such systems.
Benefits of Introducing Inline Integrated Cleaning and Drying Design
Boosting Productivity
By integrating cleaning and drying into a single line, inline systems can greatly reduce processing time. For example, in Asahi Kasei’s case, the flexographic plate-making process was reduced from 12 steps to just 1, cutting work time by 90%. This leads to higher throughput, shorter lead times, and increased production output. Automation of cleaning and drying also reduces human error and contributes to more consistent product quality.
Cost Reduction
Fewer steps mean savings in labor, materials, and energy consumption. In Asahi Kasei’s example, ink usage was cut by 20%, and overall ownership costs were significantly reduced. Wastewater treatment costs also dropped. The AWP-LOOP™ system reduced wastewater to about 3 liters and enabled roughly 70% water reuse, contributing to both cost savings and water conservation.
Labor Savings
Automation and integration reduce the need for manual labor. With labor shortages becoming a serious issue, labor savings are critical for maintaining and improving productivity. Freed-up workers can be reassigned to higher value-added tasks.
Lower Environmental Impact
Inline systems also help reduce environmental burden by saving water, reducing waste, and lowering energy use. As seen in Asahi Kasei’s case, water-wash plate-making systems enable environmentally friendly production and contribute to a “Solvent ZERO” plate-making environment.
Key Points for Selecting Inline Integrated Cleaning and Drying Systems
Cleaning and Drying Performance
Performance is the most important factor, as it directly affects product quality. Important considerations include the material of the object to be cleaned, the type of contamination, and the acceptable residue level. Equipment should be selected with the right cleaning and drying capability. Specific details such as the cleaning method, drying method, cleaning time, and drying time also need to be confirmed.
Initial Investment Cost
Initial costs include the price of the equipment itself, installation costs, and costs for peripheral devices. It is important to evaluate both the upfront cost and future running costs, and select equipment that is optimal in terms of total cost.
Ease of Maintenance
Ease of maintenance has a major impact on production line uptime. Factors such as maintenance frequency, time, and cost should be considered, and equipment that is easy to maintain should be selected. The availability of spare parts and the simplicity of replacement are also important.
Future Expandability
Future expandability needs to be considered to prepare for increased production volume or product changes. Equipment with high expandability can reduce future investment risks.
After-Sales Support
The quality of after-sales support is also a key point. It is important to confirm the availability of maintenance services, technical support, and parts supply, and to ensure that any problems can be resolved quickly.
Summary
Inline integrated cleaning and drying design offers many benefits, including higher productivity, cost reduction, labor savings, and lower environmental impact. However, to maximize these benefits, it is essential to take a comprehensive view of factors such as cleaning and drying performance, initial cost, ease of maintenance, expandability, and after-sales support, and to select equipment best suited to your company’s needs.
From equipment design to rental and contract coating, we offer safe and practical dip coating solutions tailored to your needs. Feel free to contact us to discuss your coating projects in detail.