Stonger than Stainless Steel, beats PVC and Polypro
- Versatile chemical resistance
- Elimination of corrosion and welding
- Reduction of calorific dispersion
The development of IFS Newpac treatment units results from our background in manufacturing high performance Ceramic and Composite materials for over thirty years.
TitaniumComposite
is not fiber glass, neither is it a cheap plastic, polypropylene
or PVC. TitaniumComposite is a new material, lighter, more corrosive
resistant and with more insulating value than Stainless Steel.
Nobody can compete with a Titanium Composite IFS Newpac Washer!
Titanium Composite Washers by Industrial Finishing Systems
IFS once offered two different washer construction options (mild steel or stainless steel). We believed that both had an appropriate place in pre-treatment design. Mild steel having the lowest initial cost and stainless steel offering the greater corrosion resistance. Unfortunately both materials transfer heat making them operationally inefficient and neither material can be altered without extensive rework and in some cases even SST is not totally corrosion resistant.
In the last 15 years, a European alternative has been developed that is the best choice in every application. IFS now constructs washers exclusively out of "titanium composites". The structure is 100% corrosion resistant and offers an insulation factor that no other construction offers. It is by far the most aesthetically pleasing, and is totally inert to any wash chemicals or acids.
Warranty
An IFS titanium composite washer is backed with a lifetime
warranty against corrosion of the composite components. To our
knowledge this is an industry exclusive. As the IFS lineage
dates back some 77 years to 1923, we feel the lifetime warranty
can be taken as a serious commitment to the quality of our washers.
This European Newpac™ technology offers the latest technological advances. The washer body and tank is no ordinary composite. It is an organic and poly-metallic micro fiber blend of high performance resins used to form an insulating ceramic matrix (titanium, silica, aluminum, oxide, etc.).
Material Advantage
The titanium composite material has tremendous strength (equal
to and higher than steel), corrosion resistance, and insulation
value. The titanium composite returns the heat to its source
eliminating heat dissipation from the transfer of radiant heat
inevitable in mild, SST, and polypropylene washers. The tanks
benefit from 2.75"of integral insulation in the form of
a high "R" value PVC foam sandwich that turns the titanium
composite tanks into a one-piece thermos flask. Every component
of the washer helps reduce energy consumption by at least
40%.
Operational Efficiency
The washer is designed for optimal fluid circulation. Your washer
may re-circulate a million gallons of water and chemicals per
day. The interior of the tanks and housings are designed with
this in mind. All edges are rounded without welding, eliminating
any risk of leakage due to oxidation or deformation. The result
is "0" sludge and scale deposition in the washer.
Performance
Performance is guaranteed. Since 1987, 200 titanium composite
washers have operated in 14 countries accumulating four million
hours of service. In addition to exceeding established standards
in the United States, the washer passes the stringent TUV Reinland
(Germany) and CETIM (France) certification. In Europe, washers
must meet the strict zero tolerance design standard for
industrial water use. The washer is designed with a unique "counter
balancing system" that allows the washer to operate
without overflowing to a drain. The combination of "counter
flow" and "counter balance" prevents the wash
stage from being continually diluted with rinse water. The optional
filtration system removes dirt and oils from the wash solution
and extends the life of the bath substantially. This reduces
your waste hauling fees and chemical recharge cost. Many users
have reported six months of usage without a chemical "dump"
or recharge.
The titanium composite washer will consist of a number of simple, lightweight, and self-supporting modular elements. Components are bolted together. High performance polymer joins and protects all joints guaranteeing no leaks.
Flexibility
The washer can also be easily and cost effectively modified,
as your process needs change. It is possible to insert
additional stages or extend an existing stage to accommodate
an increase in line speed. This will add flexibility to
your finishing system. You will be able to adjust to rapidly
changing chemical processes. All titanium composite washers utilize
the same components, except housing modules, which are selected
to meet size requirements. The washer can be easily dismantled
and reassembled which facilitates the reconfiguration of your
shop floor, whether for a plant move or just to increase product
flow.
Ergonomic
The design seeks to improve the working environment through better
ergonomics. The rounded components appear soft to the touch.
Components are color-coded specific to their function. The washer
housing is finished in a white resin, which is highly resistant
to chemicals and light. The housing is not painted, but pigmented
polyester offering outstanding resistance to aging. The high
gloss finish reflects plant light brightening adjacent work areas
and creating a pleasant atmosphere. The design projects the impression
of cleanliness and technological performance. We can provide
your washer with over 24 different colors of this material.
Simplified Maintenance
Every component has been designed to reduce or eliminate the
time and money spent on maintenance and service. 100% of the
components can be dismantled with a simple adjustable wrench.
The header and spray nozzles can be removed by hand. The vital
components are designed for quick extraction. We have chosen
the best available components to reduce the possibility of component
failure. If a problem does arise the washer is designed for easy
component access to allow a single maintenance person to change
out a pump, fan, or heat exchanger in 15 minutes or less.
Corrosion Resistance
The composite material is inert to chemical attack and corrosion
so there is no need to ever descale. Unlike stainless
steel washers, the composite is not degraded by deposits of sludge
and crystals or by electrolytic reactions. A DI or RO halo to
promote spot free drying can be added to the exit vestibule for
a nominal cost (no need to have an extra stainless steel stage).
The alkaline and phosphate chemicals are efficiently used in
"treating" the product and not wasted treating the
metal washer tanks and housing.
Tank Construction
The tanks are one-piece construction eliminating the possibility
of leaking seams. All doors and inspection covers are fitted
to facilitate easy emptying and clean out. Tank bottoms are sloped
15% to low point opposite the inspection doors.
Service-ability
Quick extraction vertical pumps are mounted on an aluminum frame
inserted into the titanium composite tank. The frame is only
in contact with the exterior of the tank and is never in a corrosive
environment. A pump can be replaced without emptying the tank.
Similarly, the heat exchanger is also quick extraction designed.
The frame incorporates 12 clamp wheels to secure the exchanger.
The exchanger can be simply slid out for cleaning.
Fans
Washer exhaust fans are exposed to a continuous attack from vapor;
therefore our housing and blades are titanium composite with
the exhaust motors being mounted outside the contaminated environment
of the enclosure. The exhaust ductwork for both the heat exchangers
and housing are SST. Even the conveyor rail in the washer can
be fabricated from the super strong titanium composite (limited
to enclosed track at this time).
Heated Stages
Heated stages will utilize a Maxon burner firing directly
into a 304 grade SST Heat Exchanger. The unit has a large
surface area to transfer heat efficiently. This method is superior
to the tub-o-flame style common in most competitors' washers.
The water in the tank absorbs a greater amount of the heat created
through the "multiple" numbers of exchange tubes, which
provides more exchange surface for the transmission of the heat
to the water. This efficiency is evident by a lower exhaust temperature.
Economics
Using the latest technology, the entire wash system has been
carefully engineered to provide maximum benefit at a minimum
cost.
