How Automatic Tank Cleaning Can Elevate Facilities Performance

Introduction:

Industrial tank cleaning is a task that, despite its routine nature, poses significant challenges to efficiency and consistency. Whether dealing with chemicals, food processing remnants, or other industrial by-products, ensuring tanks are thoroughly cleaned is crucial for operational success. Traditional manual cleaning methods often fall short due to variability and inefficiency and can also pose safety risks for workers if they need to enter tanks to clean them. We’ll look at the benefits of automated tank cleaning systems, showcasing how they can address common pain points. From reducing labor costs to enhancing sustainability, automated systems offer a compelling alternative for the future of tank cleaning.

Green Cleaning: How Tank Cleaning Choices Affect the Environment

Sustainability is not just an option but a necessity and tank cleaning is a key component in achieving this goal. Tank cleaning is a water intensive process and overusing what seems at the time like a small amount, can accumulate into thousands of gallons wasted annually. With an automatic tank cleaner, such as a rotating spray ball, your company can get total coverage of your tank with minimal water use. The method chosen for tank cleaning – manual or automatic – has large environmental implications. This section will discuss how these methods align with sustainability goals, focusing on water and energy usage, chemical use, and waste management.

Water and Energy Usage

A crucial aspect of sustainable tank cleaning is water and energy conservation. Automatic tank cleaning systems are significantly more efficient in this regard. In a recent case study, a chemical manufacturer implemented TankJet® nozzles in their cleaning process. This switch led to a 65% reduction in water usage and halved their cleaning time.

Similarly, food processing plants implementing automated tank cleaning equipment have seen substantial savings in water and energy, thereby enhancing their sustainability efforts. Key benefits include more efficient use of cleaning fluids, consistent and safer cleaning processes, and a notable decrease in maintenance and downtime. Automated systems offer reliability and repeatability, crucial for maintaining high hygiene standards in the food industry. To read more about this topic, click here to read our white paper on sustainability in food. 

Chemical Use and Waste Management

Another key aspect of sustainability in tank cleaning is the management of chemicals and waste. Manual cleaning often requires large amounts of chemicals, which can lead to increased production of hazardous waste. This poses environmental risks and raises concerns about worker safety. Automated systems, on the other hand, can be precisely calibrated to use the exact amount of chemicals needed for effective cleaning. This precision reduces the volume of chemicals used and the amount of hazardous waste generated.

Moreover, the wastewater from tank cleaning processes, which may contain residues of the cleaned substances and chemicals, must be treated before disposal. Automated systems result in less contaminated wastewater, simplifying the treatment process, and reducing the impact on wastewater treatment facilities. This is crucial in minimizing the environmental impact of industrial operations and in complying with increasingly stringent environmental regulations. 

Why You Should Automate Your Tank Cleaning Operations

Better and more consistent cleaning results

Automatic tank cleaning equipment allows for better and more consistent washes than manual methods. This is because of the ability to configure flow, pressure, and positioning of the tank cleaners in the systems. Manual methods of cleaning such as pressure wash guns and brushes may result in inconsistent cleaning due to distractions of daily life, or interruptions. Additionally, it's easy for a worker to miss an area or not fully clean a tank which leads to cross-contamination. In a recent case study, a chemical manufacturer halved their tank cleaning time by switching to TankJet products, ensuring thorough and uniform cleaning without the variability of human performance. To read more about this case study, click here.

Increased production time

One of the most tangible benefits of automated tank cleaning is increased production time. By significantly reducing the downtime associated with cleaning, these systems allow for more frequent use of tanks and equipment. This is particularly crucial in industries where production schedules are tight, and any delay can have a ripple effect on output and delivery timelines. A company who is looking to increase production will also benefit from faster tank cleaning. By limiting the costly downtime you take for cleaning, you increase the time that your line can be running allowing for more uptime. Read more about the experience of a peanut butter producer who achieved quicker tank turnaround with automated cleaning. 

Reduced energy consumption

Energy efficiency is critical to modern operations and tank cleaning can account for a large portion of energy use. By automating the cleaning process, these systems reduce the energy required for heating and applying cleaning fluids. This is because automated tank cleaning equipment limits waste and uses the exact amount of cleaning solution needed. By doing so you limit the overproduction of heated water which can be a time-consuming and costly process. This leads to direct cost savings and contributes to a company's overall sustainability goals. Reducing energy consumption is particularly notable in processes where heated water or chemicals are necessary for effective cleaning. To read more about how we helped a manufacturer save energy with automated tank cleaning click here.

Reduced cleaning fluid consumption

The shift to automated tank cleaning systems marks a significant step towards more sustainable and cost-effective operations. In a manual tank cleaning operation a worker would apply the disinfectant or cleaning solution. This can lead to issues in two ways. One, the worker sprays the solution inconsistently, potentially missing areas or not applying enough of the cleaning solution to be effective. And two, a worker applies too much cleaning solution wasting the solution, increasing the cost of that wash, and creates more waste that needs to be treated. Automatic tank cleaning systems minimize waste and reduce the environmental footprint by precisely controlling the amount of cleaning fluid used. Efficiency is not just about using less water or chemicals; it's about maximizing the impact of every drop. This precision translates into substantial cost savings in industries where cleaning fluids can be expensive and minimizes the amount of waste created.

Reduced manual labor

The automation of tank cleaning systems reduces manual labor. This translates to direct labor cost savings and allows for the reallocation of workforce resources to more value-adding tasks. In an automated setup, the need for personnel to engage in repetitive and labor-intensive cleaning is greatly diminished. This shift not only boosts operational efficiency but also has the potential to increase employee satisfaction, as workers can be redirected to more fulfilling roles. Click here to read how a power plant eliminated the need for employee cleaning and saved $20,000 annually with our TankJet AA190E. 

What’s The Verdict?

Deciding between manual and automatic tank cleaning methods involves considering sustainability goals, tank complexity, and budget. While manual methods have specific applications, it's increasingly evident that automated systems are generally the superior choice for enhancing tank cleaning. Automatic systems stand out for their efficiency and resource conservation, offering consistent and thorough cleaning that aligns with the growing focus on sustainability. The initial investment in these systems is often balanced by long-term savings in labor, resources, and operational downtime.

If you're still considering your options, our tank cleaning evaluation form can help guide you to the best choice for your requirements. Click here to fill out the form. If you would like to speak further about our automatic tank cleaning options click here to your local spray expert. With over 85 years of experience, our trusted spray specialists can provide the best tank cleaning solution for your business.