||18 FEB 1998, revised 12 July 2000, revised 29 June 2001
|| MART SALES, ENGINEERING & SERVICE STAFF
||GARY MINKIN, MART PRESIDENT
|COMPARISON OF THE MART POWER WASHING PROCESS JET SPRAY MACHINES
|IN-HOUSE REPORT Comparing the MART Power Wash Process to Bupi, Storm Vulcan, InterCont, Better Engineering, CUDA, Landa, Peterson and K.I., AXE, Rotojet, J-Mar, A.R.E., Proceco, Olcott, HydroBlast, Alkota, Kemac, TurboMax, Little Swede, Rotomatic, Viking, Hanson, JBI and other Jet Spray Parts Washers. This document was originally written for the exclusive use of the MART Engineering, Technical Services and Sales Staff and is published, in our Website and made public, for the first time.
To the best of my knowledge the information I present is accurate and data in the MART files support each statement and claim. This section was revised at the request of a jet spray parts washer maker and not because of inaccuracies.
MART also has two IN-HOUSE REPORTS that provide direct comparisons between the Power Wash Process, the Proceco System, the Goff Hydropulse. Contact MART Technical Services department for details.
GENERAL. The purpose of this document is to help our Engineering, Technical Services, Sales Department and Chemical Group understand the differences between MART Power Washers and conventional Jet Spray Parts Washers. The following information applies equally to all Jet Spray Washers.
ENGINEERING. It is likely that MART has invested more in engineering and new technology than all other washer makers combined. MART is also the only washer maker that accurately reports its performance and engineering data. While there are many examples in our records of misleading and false reporting by competitors, a good file to review is the MART Protest to the US GAO-OFFICE OF THE GENERAL COUNSEL, dated December 17, 1995, in response to a GSA contract awarded to Jet Spray washer maker.
The contract called for over 100 identical washing machines. A specification in the RFQ limited the amps that the washing machines could draw. MART met the specs which added over $400 per unit to our cost to build the machines. The Jet Spray maker did not meet the specs but, at their lower selling price, was awarded the contract. MART, in its protest, furnished engineering calculations that were verified, independently, in affidavits by engineers from electric heating element manufacturers. MART proved that the Jet Spray washing machines would either over-amp or would not heat to the required operating temperature in the time allotted, and could not perform to the specs.
Note that the Jet Spray washer maker wrote the original specs that were used for the RFQ. Their reply to the protest made reference to a "Load Shedding Device" they would furnish with each jet spray machine to "reduce the amp draw," but did not explain the device or its operation, or how such a device could reduce amps and still provide sufficient energy to heat their machines in the time required. MART engineers, and the six electrical component manufacturers we contacted, had never heard of a "Load Shedding Device", and no one could explain its operating principles if such a device did exist. We subsequently learned that the "Load Shedding Device" was not a device but, rather, an electrical circuit that deenergized the heat element while the wash pump was operating. This did not resolve the issue that their machines would either over-amp or not heat to operating temperature within the time allotted.
Washing machine customers generally assume that the pump performance data provided by the Jet Spray Parts Washer makers are taken at the nozzle tips. Not true. The data they report are taken from pump curves that presume an optimum installation and do not account for pump suction and discharge losses that can be considerable. The only data of value is the actual energy that discharges from the nozzles because pump losses consume energy and reduce the energy available for parts washing. For details see Pump Technology.
An example of this is that one washer maker reported that its 10 horsepower pump produces 105 PSI at 180 GPM at the nozzles. Were this possible, their 10 hp pumps would operate at an efficiency rating of 110%, making it a perpetual motion system. When Jet Spray makers are challenged, none can produce data of pump performance taken at the nozzle tips.
POWER WASHING vs JET SPRAY COMPARISON. As we know, there are two distinct and different cleaning principles available in cabinet-style parts washers: MART Power Washing and Jet Spray. The patented MART Power Washer process utilizes the hydraulic force of impact pressure to blast off the difficult soils. Heat and chemical augment the MART process. Jet Spray machines rely mostly on cascading to flood the parts with chemical and hot solution, much like a home dishwasher.
The impact pressure produced by Jet Spray machines is negligible. Further, their pump options are limited. Two spray washer makers offer larger pumps but their efficiencies are low so that cleaning performance is marginal. Jet Spray machines operate at low flow and moderate pressure - typically 45-70 PSI at 1.5 to 3.8 GPM per nozzle and velocities under 90 ft/sec - so that removing soils with impact pressure is not a factor with their process.
Difficult soils and shorter wash cycle requirements call for larger pump systems. MART offers a wide selection of pumps and unique technology to ensure that our Power Washers are capable of handling the work.
The smallest MART pump is the 7-1/2 horsepower offered on the CYCLONE 2.2 Power Washer. The 10 Pump horsepower on the CYCLONE 30 and TORNADO 40 delivers, at the nozzle tips, an operating pressure of 75 PSI at 180 GPM, with a flow per nozzle of 11.0 GPM, at a velocity of 100.2 ft/sec. Larger MART pump systems, like the 140 Horsepower Quadroplex and 175 Horsepower Duplex, deliver flows up to 862 GPM and impact pressures of 600 PSI. Flow per nozzle is 18 to 22 GPM or more, with velocities up to 190 ft/sec.
Next, Jet spray machines aim their nozzles at the center point of the turntable so the same surfaces are hit from a single angle of impingement throughout the wash cycle. The solution spray reaches some surfaces while many other surfaces are missed. MART invented moving manifolds to ensure that all surfaces are blasted by solution, The third MART patent is the reciprocal Power Blast Manifold (PBM). We now offer four different moving manifold systems for the different Power Washer models.
Note that every washer maker would offer the oscillating MART Power Blast Manifold (PBM), SHIM Manifold, POWER OF ZERO Manifold (POZ) and MHT TUMBLER Manifold if MART did not hold the patents on these devices. A simple explanation to MART owners and prospective customers of the PBM Manifold follows:
As the wash load rotates on the turntable, the PBM pivots on its vertical axis, making a 46-degree arc and quick return every 10 seconds, throughout the wash cycle. The sweep of the PBM is not synchronized to the rotational speed of the turntable, so the parts load is blasted from a different angle with each pass at the nozzles. For example, in 15 minutes a CYCLONE 30 Power Washer turntable will have rotated 60 times and the PBM will have swept back and forth 180 times (x) 16 nozzles for 2,880 unique angles of impingement to reach every conceivable blind spot and hidden recess within the wash load. In this manner, whether the wash load is a single casting such as an engine block or case, or a complex basket load of randomly loaded, nested small parts, the entire parts load will be clean. The logic of the MART PBM is this: If a washer can't reach a surface, it can't clean it either.
MART Pump performance, coupled with its patented Power Blast Manifold (PBM) and other moving Manifold Systems, ensures a level of parts cleaning not possible in a conventional Jet-type wash cabinet.
There are 55 manufacturers of Jet Spray washers. While the operating principles and performance of all Jet Spray machines are similar, some do provide more quality than others. Storm Vulcan and Proceco can be considered the highest quality, and Kemac, CUDA, Better Engineering, JRI, HydroBlast, and InterCont will be the poorest in terms of quality, performance, maintenance required, reliability, technical service support, and life expectancy. Proceco machines are built heavy, are capable of handling large wash loads and managing high concentrations of waste, and they market to many of the same heavy duty markets serviced by MART.
JRI, CUDA, LANDA, HYDROBLAST, KEMAC, BETTER ENGINEERING, INTERCONT & SIMILAR JET SPRAY WASHERS. These machines are built to be price competitive and are acceptable for light duty automotive-type cleaning. They are of marginal value where heavy soil removal is required in such applications as diesel and locomotive shops that must remove carbon, paint, scale, sludge and road soils. Most Jet Spray washer makers claim to provide engineered solutions to parts cleaning problems but their claims of technology are unfounded and their machines should not be considered engineered products in my view.
Note, for example, the MART in-house reports titled REPORT No 1-FILTR.MMO and REPORT No 2-RINSE.DOC that respond to the manufacturer's claims of performance for two accessories they offer ahow that they do not work as advertised. These claims are typical of the "low end" Jet Spray washer makers' claims and their equipment.
PUMP TECHNOLOGY. I spent much time addressing pump systems because the pump is the heart of any washing machine. The pumps used by such washer makers as BE, CUDA, Landa, Hydroblast, Hanson, Kemac and InterCont are automotive grade, designed for low production and light soil removal. Pump efficiencies on these machines averages 40% to 52%.
MART pumps, depending on Power Washer model and Pump style, operate at 72% to 86% efficiency so that a 20 horsepower MART pump will provide the same hydraulic energy and cleaning power as a 30 horsepower on a typical jet spray machine. Other washer makers could improve their efficiencies as well, if they did the engineering (as MART has done) to minimize losses and then install higher grade pump systems that will withstand the operating environment without flashing, pulsating or cavitating, and that will not create foam from pump-related causes.
EPA/OSHA. A washing machine has the potential to present significant dangers to its owners and the company's employees. Consider: A washing machine has hot alkaline or caustic solution in its reservoir, and the solution is sprayed inside the cabinet; high voltage electric service; maintenance and repair required, and periodic cleanouts; and is often operated by many of the people in a shop. Jet Spray machines often do not address these issues or conform to the lowest environmental, electrical and safety standards.
As we know, MART systems are designed and built to NEMA and NEC Standards and specifications for Industrial Machinery, which provide the necessary margin of safety and reliability for our customers. As an option, MART customers can select our Industrial Control Package that includes compliance with ANSI/NFPA 79 Codes Latest Revisions for Industrial Machinery.
Next, to control leakage of solution and steam, most Jet Spray makers use plastic door seals that become brittle and crack, and can expose workers to solution spray. MART provides its patented steel-to-steel compression-type door seals that cannot fail, yet keep steam and solution from discharging into the general shop area.
TECHNICAL ASSISTANCE AND EXPERTISE. The MART Tech Services Department is unique in the industry. Our staff knows the equipment and cleaning processes. MART also has a Chemical Group to ensure that a customer's cleaning process and standards are met. MART provides its customers the most comprehensive and generous warranty in the industry. This is all part of the package for customers of MART.
TYPICAL MART POWER WASHER OWNERS. Note that the MART Users List reads like "Who's Who In Industry and Rebuilding". Of the thousands of MART owners, many operate two or more MART Power Washers, and some have ten to 25 or more units. These are repeat customers where MART has maintained ongoing, long-term relationships, in many cases for a decade or more. Their reliance on the MART product line is a testimonial to our equipment and service.
CONCLUSION. This document is intended to educate the MART staff regarding the uniqueness, technology and benefits of MART systems, and how MART systems compare to other make washers. MART will continue improving its product line to meet the changing needs of MART customers. The MART Mission Statement and Defining Statement sum up what MART is all about by stating our philosophy and goals, and our responsibility towards our product line, our company, and the customers who buy our equipment and services.