1.Fully Automatic Bucket Loading & Unloading System
This system adopts a 2-station cylinder turnover design, independently developed by our company. Its unique horizontal loading and unloading structure effectively solves common problems such as misalignment during loading, failed unloading, bucket tipping, jamming and excessive noise.
It is fitted with two sets of evenly spaced adjustable stoppers, enabling accurate bucket positioning and separation. The turnover plates for loading and unloading feature a V-shaped perforated structure, which reduces structural stress, overall weight and running resistance.
Empty buckets are delivered to the unit via the conveyor belt. The pushing cylinder shifts buckets into the stopper slots. The turnover cylinder tilts the mechanism to align with the support seats of the washing machine, then the pushing cylinder pushes the buckets into place.
For unloading, the turnover mechanism receives the buckets, and the pushing unit moves them away to prevent jamming. The mechanism then flips back to the conveyor level, and the pushing unit feeds the buckets onto the conveyor for discharge.
2.Fully Automatic Internal Bucket Washing Machine (Alkaline & Sanitizer Washing)
1. Equipment Composition
This machine consists of alkaline liquid washing unit, disinfectant washing unit, sanitary circulating water tank, independent washing pump, independent pressure gauge, lifting & rotating flushing system, alkaline liquid heating system and electric control system.
2. Working Principle
Buckets cleaned by the external washing machine are conveyed to the loading station via the bucket feeder. The photoelectric sensor detects and feeds two buckets into the machine, while the bucket stop cylinder holds back the rest. The pushing cylinder shifts the buckets onto the turnover frame, which tilts the buckets to a horizontal position.
After the turnover cylinder is in place, the loading cylinder pushes the buckets into the tray holders. The buckets rotate 90° upward along with the chain, turning upside down with the openings facing downward, and then pass through the stations for alkaline liquid, disinfectant and sterile water washing.
3. Washing Process
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1st station: Draining
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2nd & 3rd stations: Hot alkaline solution rinsing① The alkaline solution is heated electrically;② Heated alkaline solution effectively removes dirt inside buckets;③ The heating water tank adopts automatic temperature control. Heating and heat preservation switch automatically via temperature controller signals to save energy;④ Air vents are installed above the stations to exhaust steam.Equipped with Zhejiang Nan Pump Model CDL3-6LS.
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4th & 5th stations: Recirculated water rinsing to thoroughly flush residual alkaline solution and prevent it from flowing into the disinfection section.Equipped with Zhejiang Nan Pump Model CDL3-6S.
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6th & 7th stations: Disinfectant rinsing for effective sterilization inside buckets.Equipped with Zhejiang Nan Pump Model CDL3-6S.
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8th & 9th stations: Purified water recirculating rinsing to remove residual liquids.Equipped with Zhejiang Nan Pump Model CDL3-6S.
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10th & 11th stations: High-concentration ozone water rinsing.Equipped with Zhejiang Nan Pump Model CDL3-6S.
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12th station: Final draining
Please refer to the attached station layout diagram for the above process. The procedures can be adjusted as per customer requirements.
4. Technical Features
- Made of integral SUS 304 stainless steel plates with thickness over 3mm via laser cutting and bending, ensuring high machining accuracy. Equipped with glass doors and windows as well as silicone anti-vibration sealing strips for an elegant appearance.
- Each rinsing station is fitted with an independent water pump to maintain stable rinsing pressure and avoid pump interference and malfunction. Sanitary diaphragm pressure gauges and pressure sensors are installed at every station to monitor real-time pressure for timely troubleshooting. Sanitary-type pressure gauges are adopted to prevent oil leakage into water. The upper and lower water tanks are separated and designed with inclined surfaces and integral bent plates to avoid water stagnation and effectively inhibit bacterial growth.
- The entire washing process is controlled by PLC. Spray nozzles extend deep into buckets for internal cleaning. Adopting advanced technology, the nozzles deliver even and efficient spraying. High-pressure water and retractable rotating nozzles perform 360° dead-angle-free rinsing across all inner surfaces of buckets, so as to ensure excellent cleaning results and improve product quality.
- High-quality stainless steel chain is applied, featuring precise positioning, low wear, easy installation and adjustment as well as long service life, which reduces the frequency of chain replacement caused by clearance issues.
- Driven by worm gear motor. High-precision sensors enable accurate positioning. The conveying chain moves 5-gallon buckets to designated stations steadily and reliably.
- Each circulating water tank is designed for easy draining and cleaning at the bottom. It is equipped with 100-mesh filter screens, which are easy to clean and replace and can filter both circulating water and added liquids.
- Waterproof LED lights are mounted on the top of washing stations for convenient observation of the cleaning performance.
2. Integrated Filling & Capping Machine
1. Equipment Composition
This machine consists of filling water distributor, variable-frequency filling pump, sanitary diaphragm regulating valve, non-contact filling valve, bucket clamping & positioning device, capping feeder, capping unit, transmission system and electric control system.
2. Working Principle
Clean and disinfected buckets are transferred to the shifting mechanism via the main shaft and then enter the filling area. The offset pusher moves the buckets to the filling stations. Meanwhile, buckets in the rear row move into the waiting area.
After the bucket is in place, the filling cylinder lowers the positioning unit to clamp the bucket neck. The filling pump starts and the filling valve opens to begin filling. When reaching the preset high-speed filling duration, the valve closes and switches to low-speed filling until completion.
Once filling is finished, the positioning unit releases the bucket. The pusher pushes the filled bucket out of the filling station. The conveyor transports the bucket to the cap feeder for cap loading, then the capping head automatically presses the cap tightly. The whole filling and capping process is completed.
3. Technical Features
- Fabricated from integral SUS 304 stainless steel plates (3~5mm thick) with laser cutting and bending for high machining accuracy. Equipped with glass doors and windows plus silicone anti-vibration sealing strips for a neat appearance.
- The filling process and structure are independently developed by our company. It adopts the advanced enclosed clean inline filling technology.
- Equipped with variable-frequency filling and pneumatic valves for timed filling, ensuring stable operation. The filling buffer tank stabilizes the output pressure and flow of the filling pump.
- Continuous capping is realized by stainless steel chain. Caps are fed stably and accurately. The chain-type capping runs smoothly without bucket tipping, delivering a high success rate.
- The whole machine features a compact and reasonable structure, which greatly saves the floor space of the clean workshop and reduces operating costs.