Winter Glass Washer Care: A Step-by-Step Guide

Regular maintenance is vital to prolonging the life of your glass washer and achieving consistently spotless glass. Merely having clean glass does not ensure the machine is performing at its best. A machine that receives proper care, backed by a routine service schedule, operates more effectively, reducing both downtime and expensive repairs.

During winter months, when usage tends to decline, it’s crucial to maintain a regular maintenance routine, particularly if you plan to shut down for the winter. The cold weather can be tough on your equipment, and overlooking such tasks could result in costly damage. With proactive maintenance, you not only extend the life of the machine but also ensure it delivers high quality of the glass, even when the temperatures drop.

Billco Washer History: Z-Series

Since 1956, Billco Manufacturing has been a leader in glass cleaning technology, providing cleaning solutions for various industries, including aerospace, military, medical, automotive, window/door, and many more. In the 1950’s Billco’s initial washers varied from 14 inches to 48 inches wide. Today, the company offers an extensive selection of award-winning glass washers tailored to meet needs of low, mid or high-volume operating customers. Horizontal models range from 16 inches to 144 inches wide, while vertical models range from 48 inches to 84 inches high.

The Z-Series washer, known for its simplified maintenance, is especially popular for is access to internal components,

reduced parts, and integrated self-cleaning trays for debris removal. Its corrosion resistant stainless steel and polymer components, coupled with a nearly zero water consumption system and use of interchangeable parts, contribute to reduced operating costs. More key features include:

• Helical Gear Drive System
• Autofill and Auto-drain Tank Controls
• Hinged Guarding with Observation Windows
• Roll Out Tank Carts
• Quick-Change Bearing Blocks

Learn more or speak to a solutions specialist by contacting Billco at 724.452.7390 or visit our page.

New Washer Maintenance Routine

Establishing a maintenance routine is crucial, especially if your washer is new or if it has been some time since its last maintenance check. Before starting the scheduled maintenance interval, it is recommended to prep the washer:

1. Tighten Fasteners: Ensure all connections, including electrical, are secure.
2. Grease the Machine: Apply grease in each fitting but avoid getting grease on the outside of the bearing housing, rolls, brushes and belts. Too much grease will push out the bearing seals and cause moisture to enter, and lead bearing failure. Immediately wipe off any grease that spills onto the bearing house to prevent it from seeping into the wash and rinse tanks and being transferred to the brushes and rolls.
3. Check Motor Rotation: Confirm motor is rotating in proper direction. A blower operating in reverse may produce some airflow at the air knives, but it will not be sufficed for optimum glass drying.

Looking for assistance contact Billco’s service team at 724.453.2310 or visit our service page.

Scheduled Maintenance Intervals

While daily maintenance is critical, additional maintenance tasks should be performed regularly to ensure the washer operates efficiently. Every washer comes with a check list specifying the recommended intervals of component inspection and machine cleaning. These tasks include checking the rolls, brushes, drive mechanics, cleaning tanks, and internal baffling. Following this maintenance schedule will help ensure your machine runs smoothly for many years.

-Every 40 Hours

1. Clean Tanks and Screens: Remove standpipes and drain both detergent and rinse tanks. Clean tanks and removable screens thoroughly. Refill the tanks with fresh water and add detergent. With the use of treated water and the processing of coated glass, we recommend draining and cleaning the tanks after every shift. Do not refill if shutting down for winter, drain all water from tanks and lines to prevent freezing.
2. Check Air Filters: Inspect air filters for visibility. If the filter is clogged and you can no longer see through it, replace it with a new one.
3. Lubricate Pinch Roll Drive Gears: Lubricate the pinch roll drive gears (ONLY for steel gear washers).
4. Gear Pinch Roll Bearings: Grease pinch roll bearings in both the wash and rinse sections.

Immersion heaters should be fully immersed in water, but above any sludge buildup. If you observe any scale forming on the heater blades or sludge on the bottom of the tank, it must be cleaned out prior to operating the machine again. Ongoing accumulating in the tank can lead to overheating and potential system failure. Other possible failure may arise if any lubricant comes in contact with the heater blades. Therefore, it is crucial to exercise caution when greasing components.

-Every 250 Hours

1. Grease brush and roll bearings.
2. Preform all standard 40-hour maintenance.

-Every 500 Hours or Every Week for “soft” coatings glass

1. Preform all 40 hour and 250-hour maintenance.
2. Inspect brushes and rolls for damage or glass chips by opening up the machine.
3. Check brush adjustment.
4. Check belt and chain condition and adjustment.
5. Thoroughly clean all rolls.
6. Lightly oil the chain with a quality 30 Weight petroleum oil without additives. Winter can make oils and lubricants thicken, verify with the Billco service team if you are unsure of the proper grease or oil for cold conditions.
7. Lightly oil the brush bearing guides, pinch roll adjustment screws, and brush idler pulley slides with a light machine oil.
8. Check grease level in gear reducer.
9. Remove plugs in ends of spray pipes and clean out with wire brush bore cleaner and drill bit.
10. Clean line strainers in the in-line pump filters if equipped with them.
11. Clean air filters and inside the air tubing, by sliding a thin piece of metal back and forth in each air knife slot to dislodge any debris, then blow out.
12. Clean the inside of the washer using a low-pressure sprayer with hot water to remove dirt, grease, and slime. Avoid spraying the bearings, motors, brush bristles and other water sensitive components.

Slime Prevention and Cleaning: BioClean™

Slime buildup is common in glass washers that use treated water. Similarly to a swimming pool without chlorine, the absence of chlorine in the deionized, DI or reverse osmosis, RO water grows bacteria. The bacteria will present itself as slime. To minimize this bacterial slime growth:

1. Install UV Light: Place an ultraviolet light in the treated water plumbing system. This light will kill bacteria in the re-circulating water, but not in still water.
2. Drain Water: Do not leave water in the tanks overnight or over the weekends. Drain and wipe down the internal surfaces of the tanks with a mild detergent and flush with clean water. This is recommended each day when the machine is finished operating.
3. Weekly Steam: Once a week, use a low-pressure steam cleaner to clean all the internal metal surfaces of the machine that are contacted by treated water. This includes the tank and sheet metal surrounding the rollers and brushes.
4. Chlorination: Re-circulate a 5% solution of ordinary, non-scented household bleach through the washer on a periodic basis. It is important to follow a specific set of rinsing steps after chlorination. Flush your machine for five minutes to remove any residual chlorine solution. Allow for the machine to dry and visually inspect the machine for any signs of damage.

Billco’s BioClean™ filtration system is a modern, near-zero maintenance option to simplify the washing process. This system eliminates bacterial buildup in the washer without the use of harsh chemicals, ensuring optimal glass cleanliness. A key advantage is that it reduces the need to pressure wash as part of your regular maintenance schedule, all achievable with the touch of a button. Additionally, the BioClean™ system is available in a non-automated design, compatible with all washers utilized in your facility.

It is essential to regularly monitor water quality indicators such as ion levels, total organic carbon (TOC), and suspended solids periodically to ensure optimal washing performance. Ensuring proper filtration in the re-circulation zone is avoids contamination of the final product glass.

Dry Section Maintenance

Internal cleanliness of the drying system is essential for maintaining glass quality. Utilizing a high-grade air filter and regular cleaning the internal blower, tubing, and air knifes will prevent the drying section from accumulating direct, which could be transferred to the glass. Positioning your machine away from doors and processing equipment that release exhaust fumes, aerosol and paint sprays that may contain oil mists, can further protect the clean glass from contamination.

-Brushes

1. Adjust brushes so no more than 1/32 inch (0.7mm) of bristle touches the glass. Excessive bristle contact with the glass causes a “mopping” action, reducing the effectiveness of the scrubbing and leading to faster bristle wear.

Utilize the entire width of the conveyor for loading glass, alternating between the right, center, and left. Consistently loading glass in one section of the conveyor will lead to uneven wear on the brush bristles. When the brush is worn unevenly it affects the brushes’ ability to be adjusted properly.

-Rolls

1. Adjust the top pinch rolls to lightly touch the lower conveyor rolls. The full weight of the top rolls should never rest on the bottom rolls to prevent flat spots in the rubber and marks on the coated glass.
2. Ensure rolls are clean and free of cuts or gouges. Dirty rolls in the drying section will deposit debris on clean glass. Cuts or gouges in these rolls can cause water leave streaks on the glass.

Conclusion

Winter maintenance is especially crucial for keeping your glass washer running smoothly during the colder months. Whether you are shutting down for the holidays or operating through the winter chill, it is essential that the machine stays properly maintained. Following a regular maintenance routine is essential for running an efficient production line. Well-maintained washers operate seamlessly to save money and time by identifying potential issues before they cause production downtime. It is recommended to keep a supply of replacement parts on hands to prevent shutdowns and avoid high expedited shipping costs. The preventative maintenance schedule increases the lifespan of the washer, by reducing risk of malfunction and prevents the machine from being overworked. Ultimately, this results in higher-quality glass product, fewer costly repairs, and larger return on investment, making your production line run seamlessly all year round.

Stock up on parts by contacting the replacement parts team at 724.452.7390 or visit our parts page.