Scenario summary
Cracker, crispbread, hard-tack and Saltine production factories. Bake lines run continuously, 80,000–250,000 units per shift. Tray soil profile: vegetable-oil release film, dry-flour caking, salt residue, sometimes seasoning oil.
The cleaning challenge
Vegetable-oil film accumulates on aluminum baking pans and reduces release quality over multiple cycles. Salt residue causes pitting on SUS304 if not removed. Dry-flour caking on perforated cracker pans is hard to remove from the perforations.
Recommended PTW-1900 setup
Chamber: SUS316 upgrade for salt-resistance.
Heating: Electric 70 kW.
PLC profiles:
- Standard 6-min — daily flour residue, oil film
- Acid Cycle 6-min — weekly salt residue removal
- Deep Cycle 12-min — monthly oil-film stripping (heavy alkaline + acid rinse)
Throughput: 45 perforated trays per cycle.
Critical accessory: Filtered recirculation (catches flour particles before pump damage).
Expected ROI
- Labour savings: 3 wash workers → 1 → ~$70,000 annual
- Pan life extension: oil-film stripping cycle extends pan service from 12 to 30 months
- Payback: ~6 months
Cracker factory FAQ
Q: Perforated cracker pans — does spray reach the perforations? A: Yes. 360° rotating chamber base + multi-directional nozzles produce water impact through perforations from both sides.
Q: Salt residue chemistry? A: Salt residue is removed in the standard alkaline wash (sodium chloride is water-soluble). Acid rinse weekly removes mineral scale that builds from hard water.
Q: Aluminum tray darkening from alkaline cycles? A: Bare aluminum may darken over time. Switch to anodized aluminum or aluminized steel trays — both unaffected by alkaline cycles.