Continuous Dishwasher Self-Cleaning With Cascade Water Reuse
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Solution Overview
Problem
Conventional methods for cleaning continuous dishwashers are inefficient, requiring large amounts of fresh water and energy, and are heavily dependent on manual labor and subjective cleaning quality, leading to incomplete and time-consuming processes.
Innovation Solution
An automated method that utilizes a cascade principle to recycle and filter cleaning fluids across treatment zones, using relatively clean water from one zone to clean the next, with circulating pumps and additional nozzles for thorough internal cleaning, reducing resource consumption and improving ergonomics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning methods are used for continuous dishwashers, then cleaning can be performed with simple equipment, but large amounts of fresh water and energy are required and cleaning quality is subjective and incomplete
Solution Approach 1:
The dishwasher cleaning system uses itself to clean its own components. The circulating pumps that normally circulate cleaning fluid are repurposed to circulate fresh water through the storage tanks during cleaning. The nozzles that normally spray cleaning fluid are used to spray fresh water onto internal surfaces. This self-service approach eliminates the need for external cleaning equipment and operators, while dramatically reducing water consumption by using the system's own circulation infrastructure.
Solution Approach 2:
The system drains and discards the used cleaning fluid from storage tanks, then recovers fresh water from the clear rinsing zone storage tank to clean other zones. The circulating pumps recover and redistribute this fresh water throughout the system during the cleaning cycle, maximizing the utility of each unit of fresh water and minimizing overall consumption.
2Productivity
If manual cleaning methods are used, then equipment complexity is low, but cleaning time is excessive and labor-intensive
Solution Approach 1:
The automated cleaning system operates without human intervention by utilizing the dishwasher's existing pumps and nozzle infrastructure. The control system automatically sequences the cleaning operations, activating circulating pumps to drain tanks, filling tanks with fresh water, and spraying internal surfaces. This transforms a previously manual, labor-intensive process into an automated self-service operation that completes cleaning in minutes rather than hours.
Solution Approach 2:
The circulating pumps and nozzles serve dual functions: during normal operation they circulate and spray cleaning fluid for dishwashing, and during cleaning operations they circulate and spray fresh water for system cleaning. This multi-functionality eliminates the need for separate dedicated cleaning equipment, maintaining low system complexity while achieving high cleaning productivity.
3Quantity of substance
If conventional cleaning methods are used, then no additional cleaning infrastructure is needed, but water and energy consumption are high
Solution Approach 1:
The system uses its own circulating pumps and water distribution infrastructure to perform cleaning, eliminating the need for external high-pressure washers or separate cleaning systems. The pumps that normally consume energy to circulate cleaning fluid are repurposed to circulate fresh water during cleaning, utilizing existing energy infrastructure efficiently without requiring additional high-energy equipment.
Solution Approach 2:
The system drains used cleaning fluid and recovers fresh water from the clear rinsing zone for cleaning other zones. This recovery and redistribution process maximizes the utility of each unit of fresh water and the energy used to pump it, eliminating the need to continuously supply fresh water at high energy cost throughout the cleaning process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves efficient, automated, and high-quality cleaning of continuous dishwashers with significantly reduced water, energy, and labor costs, ensuring all inner faces are thoroughly cleaned with minimal raw materials and time.
Implementation Method 1
a filter that can be used to continuously filter the cleaning fluid located in the respective storage tank
Implementation Method 2
the heated rinsing liquid is drawn out of the storage tank associated with the treatment zone through a further circulating pump and sprayed over the items for rinsing
Implementation Method 3
In the at least one cleaning zone adjoining the pre-cleaning zone, dirt particles still clinging to the items for rinsing to be cleaned are removed by means of a conventionally alkaline rinsing liquid. For this purpose, the heated rinsing liquid is drawn out of the storage tank
Implementation Method 4
In the clear rinsing zone adjoining the at least one cleaning zone, the alkaline rinsing liquid, which wets the surface of the items for rinsing, is rinsed away together with any remaining food remnants from the surface of the items for rinsing by means of hot fresh water
Data Source
AI summary
A method for an automated self-cleaning of a continuous dishwasher for items to be cleaned with at least one rinsing zone, at least one clear rinsing zone and also a transporter. Items to be cleaned are conveyed in the direction of transportation via the transporter. The continuous dishwasher comprises at least one fine filter with a back-rinser on at least one storage tank and also at least one device for emptying each of the storage tanks. The continuous dishwasher automatically carries out a self-cleaning cycle in which cleaning liquid located in each of the storage tanks is used several times in succession in the various zones for cleaning thereof. The cleaning liquid is circulated by means of circulating pumps in the respective storage tanks and supplied to spraying systems, which are already present in the respective zones, or to separate nozzles or nozzle heads for wetting the inner side of the faces delimiting the respective zone.