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zcleaner

Sistema automático de limpieza para inyectores de engomadoras de formato redondo

El sistema de limpieza ZCleaner es un complemento para engomadoras de formato redondo basado en un brazo servo controlado de alta precisión, que desplaza el inyector hacia la estación de limpieza de forma automática.

La estación de limpieza está equipada con:

alojamiento para purga del compuesto
cepillo de limpieza para eliminación de residuos
alojamiento para reposo estanco del inyector

El reposo estanco se consigue mediante el auto bombeo de un líquido de conservación (agua, vaselina alimentaria u otros fluidos compatibles), creando una inmersión controlada que mantiene el inyector protegido durante los tiempos de parada de la línea. Esta estanquidad evita la entrada de aire y previene la acumulación y secado del compuesto en la boquilla, garantizando condiciones óptimas de funcionamiento.

ZCLEANER

The ZCleaner system activates based on two configurable triggers from the control screen:

Scheduled cleaning frequency
After line stoppage, once the waiting time configured on screen has elapsed

In both cases, the objective is preventive maintenance to avoid compound build-up on the nozzle tip, which is necessary to prevent defective lining.

Scheduled cleaning process

When cleaning is triggered by schedule:

The injector automatically moves over the cleaning brush
Compound purging is performed
The injector passes through the brush again
It returns to the lining or working position

This preventive maintenance cycle removes compound residues and maintains process stability.

Cleaning process after line stoppage

When cleaning is triggered by a stoppage:

The injector is moved directly to the water housing (sealed resting position)
It remains submerged for the entire duration of tape absence

When tape presence is detected again and production resumes:

The injector exits the water
Passes through the cleaning brush
Compound purging is performed
Passes through the brush again
Returns to the working position

This procedure ensures optimal application conditions from the first cycle, preventing defective lining and maintaining process stability.

Practical Saving Cases

Case Study 1 – Reduction of Non-Productive Cleaning Time

In a traditional system with manual cleaning every 30 minutes, the time spent on cleaning can represent approximately 7% of the total daily production time when operating under a 3-shift regime.

With ZCleaner:

Cleaning time per cycle: 6 seconds
Actual impact on production: approx. 0.5% of total daily time
Fully automatic process with no operator intervention

In a dual-lane lining machine operating at:

200 ends/minute per lane
Total production: 400 ends/minute

A traditional system can result in approximately 40,000 ends not produced per day due to cleaning stops.

With ZCleaner, this figure is reduced to approximately 2,000 units not produced per day.

The difference represents a significant improvement in actual machine availability and overall production efficiency.

Case Study 2 – Reduction of Scrap After Unscheduled Stops

In traditional systems, after an unscheduled stop without manual injector cleaning, it is common for the first ends to have incorrect lining due to compound accumulation on the nozzle tip.

Considering:

20 improperly lined ends per stop
10 stops per shift
3 shifts per day

Scrap can reach approximately 600 defective ends per day.

ZCleaner eliminates this cause by:

Keeping the injector protected during stops
Automatically performing the brush–purge–brush cycle before production restarts

This ensures stable compound application from the very first production cycle, significantly reducing waste associated with line restarts.

Operational benefits

The ZCleaner system addresses one of the main issues in traditional lining machines: material waste caused by defective lining due to compound build-up or contamination on the nozzle tip. Such accumulation can produce incorrect application during normal operation and affect lining stability.

ZCleaner eliminates this cause by:
• keeping the injector clean and in optimal condition
• preventing compound build-up and drying on the nozzle
• ensuring correct and stable application throughout production
• reducing waste from defective lining
• minimizing adjustments and downtime

The system functions as preventive maintenance, ensuring application quality remains consistent and production is not affected by injector condition.

Compatibility

The ZCleaner system is designed for installation on any round-format lining machine with transfer movement, using the existing injector and lining position.

This enables integration into existing equipment without structural modifications, providing:
• automatic cleaning
• preventive maintenance
• waste reduction