Washing machines for - DW RENZMANN Apparatebau GmbH

Washing machines for
gravure cylinders, anilox rollers, anilox sleeves and printing sleeves

Services
Room concepts
Integration into other existing rooms and cylinder logistics
Contamination
wash item
Gravure cylinder up to 10
pieces/wash cycle
Gravure cylinder up to 2
pieces/wash cycle
Anilox rollers/sleeves up
to 2 pieces/wash cycle
Flexo printing sleeves up
to 2 pieces/wash cycle
Flexo printing sleeves up
to 5 pieces/wash cycle
Toluene
inks
Further systems by DWR
Service
NC-inks without
bonding agents
NC-inks with
bonding agents
PVB, PVC, PA
360
360-W
150
HA/HA-S
HA/HA-S
HA/HA-S
Sleeve-Washer
Lining adhesives
Sealing waxes
2 K-inks /
lacquers
Water-based
inks
Washing machine type
2
Cleaning effect: very good good – satisfactory adequate – mediocre not useable
3
360
360-WW
HA A /
HA-S A-S
Sleeve Washer asher
150
Wash
principle
from
page 4
from
page 8
from
page 14
from
page 18

Services
Wash trials in RENZMANN technical centre
In the RENZMANN technical centre, all wash procedures used by RENZ-
MANN can be tested in original washing machines with real wash items
and under realistic circumstances.
Our customers can assess the results achieved with the relevant washing
machine type and the applied wash procedure.
In addition, it can be illustrated how contaminated wash solvents are
treated in distillation systems. Avoiding wastewater can also be achieved
by evaporating the contaminated rinsing water und used aqueous
alkaline cleaning agent.
The strictly documented trial results (in writing and photos) are the basis
for the contractually promised cleaning qualities by RENZMANN.
Trial examples
Detailed project planning
RENZMANN not only assist the customer in choosing the right wash procedure,
but also explicitly plans the integration of the relevant washing
machine or complete washing facility (possibly several washing machines,
distillation systems, containers, pumps, fi xtures, etc.) into the energy
supply, air discharge, wastewater disposal and into the existing or
new rooms.
Process descriptions and layout plans are created as early as the negotiation
phase. Pipework schemes as well as circuit and pneumatic
schemes are also created when the order is processed.
Concerning the interfaces to already existing energy supply systems
(electricity, pressurized air, mains steam, thermal oil) as well as to
wastewater and air discharge systems, clarifi cation shall be sought.
Furthermore, RENZMANN offers its support when it comes to communicating
with authorities, architects and consultants as well as creating
authorization documents.
4 5
P2.3
A2
DN250
Waschmaschine
340- 27
V2.10
K2.8
K2.6
Schmutziges Lˆsemittel
CO 2
R2"
Die Pumpe f¸r das Schmutzlˆsemittel hat
die folgenden Daten:
Fˆrdermenge : ca. 5,4 cbm/h
K2.1

Room concepts Integration into the existing rooms and cylinder logistics.
D.W. RENZMANN is not only a supplier of machines, but also a certifi ed
business according to the ATEX directive and Water Ecology Act.
Ex protection of the machines and facilities at the operation site
• Zoning, risk assessment and suggestions regarding ex protection
measures and the preparation of documents required for the explosion
protection document.
• Supply with closed, ex-protected cabins for solvent washing machines,
partitions and suction apparatus for the confi nement of ex areas as well
as gas warning devices.
Water and soil protection
• Planning and delivery of tested fl oor pans, fi tted according to the appropriate
facility with water-hazardous substances and to the room situation.
Steel construction
• Planning and delivery of statically tested steel constructions and platforms
for a space-saving assembly of the wash facilities according to the
room situation.
Special options for the installation of gravure cylinder wash facilities.
Ex-area Non-ex area
Loading and unloading in non-ex area
Integration of the RENZMANN gravure cylinder washing machine into the fully automatic cylinder
production lines and cylinder storage/logistics centres.
6 7

TYPE 150 TYPE 360
8 13

Type 150 Operation scheme: Closed solvent circulation of a cylinder wash facility
Type 360
Washing machine type 150 Size 20 Size 30 Size 40 Size 50
Max. diameter of gravure cylinders 500 mm 500 mm 500 mm 500 mm
Max. length of gravure cylinders 2000 mm 3000 mm 4000 mm 5000 mm
Number of gravure cylinders Z1 Z1 Z1 Z1
Capacity of wash pump 33 m³/h, 10 KW 50 m³/h, 12,5 KW 66 m³/h, 15 KW 83 m³/h, 20 KW
Internal exhaust 2200 m³/h, 1,85 KW 2200 m³/h, 1,85 KW 3500 m³/h, 2,5 KW 5000 m³/h, 3,6 KW
L x W x D L x W x D L x W x D L x W x D
Dimensions mm 4300 x 1960 x 1530 5300 x 1960 x 1530 6430 x 1960 x 1530 7300 x 1960 x 1530
Required space mm 5500 x 3500 x 4000 6500 x 3500 x 4000 7500 x 3500 x 4000 8500 x 3500 x 4000
Clearance for installation mm 3200 x 1900 x 1800 4200 x 1900 x 1800 5200 x 1900 x 1800 6200 x 1900 x 1800
Number of gravure cylinders Z2 Z2 Z2 Z2
Capacity of wash pump 66 m³/h, 15 KW 100 m³/h, 24 KW 133 m³/h, 36 KW 166 m³/h, 36 KW
Internal exhaust 2200 m³/h, 1,85 KW 3500 m³/h, 2,5 KW 5000 m³/h, 3,6 KW 5000 m³/h, 3,6 KW
L x W x D L x W x D L x W x D L x W x D
Dimensions mm 4300 x 2460 x 1530 5300 x 2460 x 1530 6430 x 2460 x 1530 7300 x 2460 x 1530
Required space mm 5500 x 4000 x 4000 6500 x 4000 x 4000 7500 x 4000 x 4000 8500 x 4000 x 4000
Clearance for installation mm 3200 x 2400 x 1800 4200 x 2400 x 1800 5200 x 2400 x 1800 6200 x 2400 x 1800
Type 150
• Machine to be loaded from top with
closed wash cabin and separate,
machine-integrated wash solvent reservoir
• Machine can only be operated when
machine lid is closed
• Accommodation of gravure cylinders
consisting of two moveable trolleys
driven by two pairs of rollers on which
the cylinders are placed together with
their journals. Rollers are powered by
external ex-gear motor
• Individually designed wash and re-rinse
spray system
• Powerful wash pump / ex-motor power
unit
• Removable fi lter elements for the protection
of spray systems, pumps and
piping.
• Fill-level control for the integrated
wash solvent reservoir (operation level,
max. level)
• Internal exhaust system with powerful
ventilator and pneumatically controlled
air-intake and air-admixture chokes
• Automatic wash program (PLC), includes
washing - rinsing - drip off
- internal exhaust. Individual program
steps adjustable.
Equipment
• Self-cleaning device
• Automatic lid-locking device, alternatively
a pneumatically-operated lid
• Solvent cooling, alternatively with thermostatic
safety valve, water cooler or
recooler
• Workplace vapour extraction
• Measuring and control system of solvent
concentration for the connection
to a waste-air purifi cation system
Ideal machine design
• Integration into existing rooms and
cylinder logistics (see page 7)
• Extension to a combined machine for
alternative cleaning of the gravure cylinder
and other printing press parts in
a mobile wash basket (type 140)
Setting up the system for safe operation
Indoor air
Indoor air Indoor air
• Ex-protection of all electrical and mechanic components according to explosion protection guidelines 94/9EG
(Atex 95), spray system with type examination.
• The compliance with all applicable EC safety regulations is evidenced by a declaration of conformity
and a CE notice on the machine.
• Solvent stability of all parts, which are in contact with the medium.
• Washing machine with overload protection (LS1).
• Pumps, pipes and spray register are protected against contamination by large
perforated baskets in the washing machine.
• Spraying only possible if door is closed due to automatic retrieval of door position.
• Dry-run protection of wash pump (P1) due to retrieval of minimum fi ll-level in the washing machine (LS1)
before wash process starts and due to locking of discharge function during the wash procedure.
• Many more safety precautions according to known Atex risk assessments.
Exhaust air decontamination
Washing machine Typ 360 Size 3 Size 4 Size 5
Number of gravure cylinders 3 4 5
Max. diameter of gravure cylinders 300 mm 300 mm 300 mm
Max. length of gravure cylinders 2000/2500/3000 mm 2000/2500/3000 mm 2000/2500/3000 mm
Capacity of wash pump 80 m³/h, 20 KW 105 m³/h, 28 KW 160 m³/h, 47 KW
Internal exhaust 3000 m³/h, 3,6 KW 4000 m³/h, 3,6 KW 5000 m³/h, 3,6 KW
Required space mm
L x W x D
Dimensions mm
L x W x D
Clearance for
installation mm
L x W x D
Size 3/2000 5500 x 6500 x 3500 3900 x 3080 x 2000 4200 x 3200 x 2300
Size 3/2500 6000 x 6500 x 3500 4400 x 3080 x 2000 4700 x 3200 x 2300
Size 3/3000 6500 x 6500 x 3500 4900 x 3080 x 2000 5200 x 3200 x 2300
Size 4/2000 5500 x 7400 x 3500 3900 x 3520 x 2000 4200 x 3650 x 2300
Size 4/2500 6000 x 7400 x 3500 4400 x 3520 x 2000 4700 x 3650 x 2300
Size 4/3000 6500 x 7400 x 3500 4900 x 3520 x 2000 5200 x 3650 x 2300
Size 5/2000 5500 x 8300 x 3500 3900 x 3960 x 2000 4200 x 4100 x 2300
Size 5/2500 6000 x 8300 x 3500 4400 x 3960 x 2000 4700 x 4100 x 2300
Size 5/3000 6500 x 8300 x 3500 4900 x 3960 x 2000 5200 x 4100 x 2300
9 10 11
12
Outgoing air
Cooling water
Washing machine Distillation container Vacuum system Distillation Used solvent container
RENZMANN units for category 1 according to ATEX for Zone 0 on the inside
Fulfi llment of the „CRITERIA FOR THE SELECTION OF EQUIPMENT AND PROTECTIVE
SYSTEMS“ according to the ATEX workplace directive 1999/92/EC (ATEX 137)
D.W.RENZMANN:
uses a certifi ed quality assurance system according to ATEX and consistently implements all relevant
legal requirements.
The operator:
is required by ATEX 137 to use equipment of the correct category for the respective hazard zones,
e.g. category 1 equipment for zone 0.
D.W.RENZMANN supplies category 1 washing machines with a type examination according to ATEX
and thereby protects customers from any liability due to unsuitable or prohibited washing machines,
irrespective of the solvent used.
Type 360
• Machine to be loaded from the front
with closed wash cabin and separate,
machine-integrated wash solvent reservoir.
• Pneumatically driven machine infeed,
machine door is designed as machine
front; operation of washing machine
only possible if door is shut.
• Machine infeed with powered rollers
for the accommodation of the gravure
cylinders. Adjustable rollers are powered
by external ex-gear motor.
• Stainless steel catch basins under
machine infeed; prevents contamination
of fl oor; moves synchronously to
slide-in.
• Individually designed wash and re-rinse
spray system
• Powerful wash pump / ex-motor power
unit
• Removable fi lter elements for the protection
of spray system, pumps and
piping.
• Fill-level control for the integrated
wash solvent reservoir (operation
level, max. level)
• Internal exhaust system with powerful
ventilator and pneumatically controlled
air-intake and air-admixture chokes
• Automatic wash program (PLC), includes
washing – drip off – re-rinse
– internal exhaust. Individual program
steps can be adjusted.
Equipment
• Self-cleaning device
• Solvent cooling, alternatively with
thermostatic safety valve, water
cooler or recooler
• Workplace vapour extraction
• Measuring and control system of
solvent concentration for the connection
to a waste-air purifi cation
system
Ideal machine design
• Integration into existing rooms and
cylinder logistics (see page 7)
• Throughput washing machine with
2 doors (see page 7)
• Itemization 360-W for aqueous
alkaline cleaning systems

Washing machine Type HA Size 15 Size 20 Size 25
Number of rollers / sleeves / cylinders 1 1 1
Max. diameter 250 mm 250 mm 250 mm
Max. weight 380 kg 380 kg 380 kg
Max. length of rollers / cylinders 1500 mm 2000 mm 2500 mm
Max. length sleeve 1200 mm 1700 mm 2200 mm or 2x per 900 mm
Capacity high pressure pump P2 3 KW, 10 l/min 3 KW, 10 l/min 3 KW, 10 l/min
Heating capacity 2 KW 4 KW 4 KW
L x W x D L x W x D L x W x D
Dimensions mm 2870 x 1000 x 1300 3370 x 1000 x 1300 3870 x 1000 x 1300
Required space mm 4200 x 2800 x 1900 4200 x 2800 x 1900 4200 x 2800 x 1900
Clearance for installation mm 3000 x 1800 x 1800 3500 x 1800 x 1800 4000 x 1800 x 1800
Type HA
• Top-loading machine with closed,
stainless steel wash cabin
• Machine made of stainless steel;
operation of washing machine only
possible if lid closed; opening only
possible after completion of entire
wash program.
• Roll turning and bearing devices
consist of two stainless steel axle
shafts supported at the front side of
the machine; powered by external
gear motor.
• No exact positioning in the machine
required; lengths of wash items
variable and no adjustments at the
machine required.
• Wash medium system for even
spraying of contaminated wash item
surfaces with alkaline medium.
• Wash medium system consists of
stainless steel wash medium container
under wash chamber, circulation
pump and a spray pump system.
• Wash medium container equipped
with instant water heater (temperature
up to 60°C), fi ll-level control (operation
level, max. level) and large,
removable clarifying fi lter.
• High-pressure system for directed
spray wash of the wash item surfaces
previously treated with the
wash medium.
• High-pressure system is equipped
with high-pressure piston pump
(pressure 100 bar) with connection
to customer‘s water network and
horizontally oscillated carriage with
high-pressure slot nozzle (travel adjustable).
• Blower on horizontally moving carriage
to remove any remaining water
from wash item surfaces.
• Control (PLC), including control elements
and operating state lamps,
located in timing case fi tted to wash
chamber. Automatic wash program
includes: Spraying with wash medium
– drip-off – high-pressure spray
wash with longitudinal axis – blow-off
with pressurized air; all operation
processes take place while wash
item is rotating.
Equipment
• Separate water cycle for high-pressure
system; provision of warm water
in a second, separate stainless steel
high-pressure water container positioned
under the wash chamber.
Use of warm water for high-pressure
spray wash; therefore further optimization
of wash result und reduction in
water consumption.
TYPE HA TYPE HA-S
• Water container for high-pressure
pump including immersion heater
(temperature up to 60°C), fi ll-level
control (operation level, max. fi ll level)
and large, removable clarifying
fi lter.
• High-pressure pump made of stainless
steel
• Clean water rinsing (only when
connected to water cycle); includes
separate rinsing pipe made of stainless
steel, heat exchanger pipe and
stainless steel piping.
• Emptying of machine container by
means of diaphragm pump.
Washing machine Type HA-S Size 20 Size 25 Size 30 Size 35 Size 40
Max. diameter 300 mm 350 mm 350 mm 400 mm 400 mm
Max. weight 700 kg 1000 kg 1000 kg 1500 kg 1500 kg
Max. length of rollers / cylinders 2000 mm 2500 mm 3000 mm 3500 mm 4000 mm
Max. length sleeve 1700 mm 2200 mm 2700 mm 3200 mm 3700 mm
Number of rollers / sleeves / cylinders Z1 Z1 Z1 Z1 Z1
Capacity high pressure pump 3 KW, 10 l/min 3 KW, 10 l/min 5,5 KW, 20 l/min 5,5 KW, 20 l/min 5,5 KW, 20 l/min
Heating capacity 4 KW 6 KW 6 KW 8 KW 8 KW
L x W x D L x W x D L x W x D L x W x D L x W x D
Dimensions mm 3200x1400x1350 4200x1460x1400 4700x1460x1400 5200x1460x1400 5700x1460x1400
Required space mm 5000x3200x2250 5500x3200x2300 6000x3200x2300 7400x1460x2300 7900x3200x2300
Clearance for installation mm 4000x1550x1450 4500x1600x1600 5000x1600x1500 5500x1600x1500 6000x1600x1500
Number of rollers / sleeves / cylinders Z2 Z2 Z2 Z2 Z2
Capacity high pressure pump 5,5 KW, 20 l/min 5,5 KW, 20 l/min 11 KW, 40 l/min 11 KW, 40 l/min 11 KW, 40 l/min
Heating capacity 6 KW 8 KW 8 KW 12 KW 12 KW
L x W x D L x W x D L x W x D L x W x D L x W x D
Dimensions mm 3400x1460x1500 4200x1560x1500 4700x1560x1500 5200x1760x1500 5700x1760x1500
Required space mm 5000x3200x2550 6400x2200x2650 6900x3300x2650 7800x3400x2750 8300x3400x2750
Clearance for installation mm 3700x1600x1600 4500x1700x1600 5000x1700x1600 5500x1900x1600 6000x1900x1600
14 15
Typ HA-S
Similar design to type HA, however,
with the following differences:
• Turning devices for rollers / cylinders
consisting of two journals with two
powered rollers, one journal moveable
for different wash item lengths;
sleeves can be loaded with end/journal
plates.
Set-up for safe operation of facility
• Two high-pressure nozzles
on carriage and double the
capacity of the high-pressure
pump, double carriage
speed and therefore half
the time /cylinder length for
high-pressure cleaning.
• Larger wash medium container.
• The facility meets the requirements of all EC safety guidelines. This is certifi ed
by means of a conformity declaration and a CE notice on the machine.
• Cleaning medium consistency of all parts in contact with the medium.
• Pumps, piping and spray nozzle protected against contamination by fi lters F1
and F2.
• Splashing only possible if lid of washing machine is closed due to automatic retrieval
of lid position and locking of lid during wash program.
• Dry-run protection of pumps and heaters with the help of fl oat switches LS1 / LS2.

TYPE Sleeve-Washer
Washing machine Type Sleeve-Washer Size 1 Size 2
Number sleeves 5 5
Sleeve inside diameter 70 to 146,6 mm 146,6 to 292 mm
Sleeve outside diameter up to 170 mm up to 305 mm
Sleeve length 300 to 1400 mm 1040 to 2000 mm
L x W x D L x W x D
Dimensions mm 2850 x 1100 x 2315 3450 x 1300 x 2415
Required space mm 4500 x 3400 x 2315 5100 x 3600 x 2415
Clearance for installation mm 3200 x 1300 x 2000 3800 x 1500 x 2000
Sleeve Washer
• Base frame of machine made of
aluminium profi le system. Protective
housing consisting of 2 pneumatic,
upward-moveable safety doors with
4 mm toughened safety glass and 2
rigid sidewalls.
• Drum magazine with 5 jointly driven
sleeve seats and 5 spring-loaded
sleeve seats.
• Rotary motion of drum magazine of
72 degrees each above three-phase
induction gear motor; in automatic
operation the motor moves the drum
magazine to the wash position; when
loading the machine with sleeves,
the drum magazine can be moved in
any desired position with the help of
the pedal switch.
• Wash system contains wash medium
circulation system and wash brush,
designed as strip brush, which, with
the help of a motor-operated drive
system, is moved towards the sleeve
and, with the help of a short stroke
cylinder, is put in a cyclic-horizontal
stroke movement during the automatic
wash process.
• Wash medium circulation system
consists of separate stainless steel
container with integrated fi lter, lowpressure
pump (in manual operation
the pump can be used to pump out
the contaminated wash liquid) as
well as a nozzle pipe for the spraying
of the sleeves.
• Control (PLC) including controls and
operating status lamps located in
timing case fi tted on the base frame
of the machine.
16 17
Equipment
• Re-rinse system consisting of separate
stainless steel container, lowpressure
pump (in manual opera-
tion the pump can be used to pump
out the contaminated wash liquid)
and a nozzle pipe for the spraying
of the sleeves.
Set-up for safe operation of facility
• Subsequent cleaning system (only
in connection with re-rinse system),
consisting of 2 wash brushes
• Illumination of wash chamber for
better supervision of wash process
• The facility meets the requirements of all EC safety guidelines. This is certifi ed
by means of a conformity declaration and a CE notice on the machine.
• Cleaning medium consistency of all parts in contact with the medium.
• Pumps, piping and spray nozzle protected against contamination by fi lters F1
and F2.
• Splashing only possible if lid of washing machine is closed due to automatic retrieval
of lid position and locking of lid during wash program.
• Dry-run protection of pumps and heaters with the help of fl oat switches LS1 / LS2.

RENZMANN parts washing machines and distillation systems
Distillation systems Parts cleaning systems
DW 130 100 / CLEANfl eX
M 160 140
ROTO 310 300
Further systems by D.W. RENZMANN
Depending on the number and size of the parts to be cleaned, the product range includes various models
for part washing.
The amount of the wash medium to be processed as well as the requirements on operational convenience
are the dis tinguishing features of the distillation systems of the product range.
ROTOmaX 3500 3400
Service
We want you to benefi t from our know-how:
We determine the profi tability of your project in terms of performance,
staff requirements, investments costs and operating costs, taking into
account all relevant laws, regulations and directives. We support you in
planning the site of your new equipment, dealing with the authorities and
obtaining the required approvals and connecting your equipment to existing
or future exhaust air systems.
In our lab, we provide distillation units for practical tests with your solvent
or washing agent. All tests are documented electronically and the
results are made available to you after the conclusion of the tests.
We take customer service literally: we want to serve our customers.
Our top priority is to ensure smooth proceedings on your premises.
To eliminate potential problems from the start, we offer to have our
staff check the conditions on site and determine the possibilities of
connecting our products to existing equipment.
RENZMANN engineers are trained and experienced experts that repair,
install, commission and service our equipment worldwide.
When spare parts are needed, we do our utmost to supply these
parts as quickly as possible.
18 19

D.W. Renzmann Apparatebau GmbH
Industriestraße 1
D-55569 Monzingen
Germany
Phone: +49 (0)67 51 878-0
Fax: +49 (0)67 51 878-111
www.dw-renzmann.de
info@dw-renzmann.de
RIOBEER AG Cleaning Solutions
Schützenmattweg 33
CH-5610 Wohlen
Switzerland
Phone: +41 (0)56 6186464
Fax: +41 (0)56 6186418
www.riobeer.ch
info@riobeer.ch
UK 04/12