A TECHNICAL REPORT ON

STUDENTS INDUSTRIAL WORK EXPERIENCE

SCHEME (SIWES)
UNDERTAKEN AT:

NAMPAK BEVCAN NIGERIA LIMITED

BY
OLADOJA ISRAEL OLOLADE
MATRIC NO: 181977
DEPARTMENT OF CHEMICAL ENGINEERING
FACULTY OF ENGINEERING
LADOKE AKINTOLA UNIVERSITY OF TECHNOLOGY
INSTITUTION BASED SUPERVISOR:
25TH JANUARY TO 25TH APRIL 2023
HISTORICAL BACKGROUND OF SIWES
SIWES was established by ITF (Industrial Training Fund) in the year 1973 to solve the problem created
by lack of adequate skills for employment of university graduates by Nigerian industries. Employers
noticed that graduates from various Nigerian Universities, Mono-technic and Polytechnics were lacking
in training or in the practical aspect of their courses thereby making it hard for them to perform their
duties after being employed. This was a problem until 1973 when SIWES was created approved by the
Federal government in 1974.

The scheme is designed to expose students and prepare them for the work situation they are likely to
encounter after graduation. The scheme is aimed at bridging the existing gap between theory and
practice of Sciences, Agriculture, Medical Sciences (including Nursing), Engineering and Technology,
Management, Information and Communication Technology and other professional educational program
in the Nigerian tertiary institutions. It is also a planned and structured program based on stated and
specific career objectives which are geared towards developing the occupational competencies of
participants (Mafe, 2009).

The main thrust of ITF programs and services is to stimulate human performance, improve productivity,
and induce value-added production in industry and commerce. Through its SIWES, Vocational and
Apprenticeship Training Program, the Fund also builds capacity for graduates and youth, self-
employment, in the context of Small-Scale Industrialization, in the economy. The Industrial Training
Fund is a grade ‘A’ parasternal operating under the aegis of the Federal Ministry of Industry, Trade and
Investment. It has been operating for 42 years as a specialist agency that promotes and encourages the
acquisition of industrial and commercial skills required for national economic development.

BODIES INVOLVED IN THE MANAGEMENT OF SIWES.

The bodies involved in the management of SIWES are:

 Federal government
 Industrial training fund

While other supervising agent include:

 National University Commission(NUC)

 National Board for Technical Education(NBTE)
 National Councils for Colleges of Education(NCCE)

The function of these agencies are as follows;

 To ensure adequate funding of the scheme.

 To establish and accredit SIWES in the approved institutions.

 To formulate policies and guidelines for the participating bodies to follow.

 To supervise the students participating and sign their required documents.

 To ensure payment of allowance for the students etc.

ROLES OF THE INDUSTRIAL TRAINING FUND (ITF)

This agency is dedicated to performing the following roles:

 Formulate policies and guidelines on SIWES for distribution to all the SIWES participating bodies;
 Provide logistic material needed to administer the scheme;
 Organize orientation programs for students prior to attachment;
 Provide information on companies for attachment and assist in industrial placement of students;
 Supervise students on Industrial attachment;
 Accept and process Master and Placement lists from institutions and supervising agencies;
 Vet and process students’ logbooks and ITF Form 8.

AIM AND OBJECTIVES OF SIWES

The Industrial Training Fund’s policy Document No. 1 of 1973 which established SIWES outlined the aims
and objectives of the scheme. The aims and objectives of the scheme are as follows:

 It provides an avenue for students in institutions of higher learning to acquire industrial skills
and experience during their course of study.
 It exposes Students to work methods and techniques in handling equipment and machinery
that may not be available in their institutions.
 It makes the transition from school to the world of work easier and enhance students’
contact for later job placements and a chance to evaluate companies for which they might
wish to work.
 It provides students with the opportunities to apply their educational knowledge in real
work and industrial situations, there by bridging the gap between theory and practice.
 The program teaches the students on how to interact effectively with other workers and
supervisors under various conditions in the organization.

THE COMPANY
In fulfillment of the SIWES program, I was attached to NAMPAK BEVCAN NIG LTD,OGUN STATE,NIGERIA.

Nampak Bevcan Nig. Limited is a leading two piece(ends and body) packaging company in the packaging
sector in Nigeria. The period of my industrial attachment was from January 2023 to April 2023. The
washer unit under the production department is the section I was deployed for the duration of my
attachment and as hence experienced the production of aluminum cans, treatment of aluminum can,
waste water treatment and other by-products such as hydrogen gas e. t. c.

HISTORY OF THE ORGANIZATION

NAMPAK (National Amalgamated Packaging) is a South African company based in Johannesburg, South
Africa that specializes in the manufacturing and design of packaging. Nampak is the largest diversified
packaging company in Africa. The company produces packaging in glass, paper, metals(steel and
aluminum)and plastic.
The company's subsidiary, Bevcan group, is one of the largest producers of aluminium cans in Africa.
The subsidiary, DivFood, is one of the largest producers of metal cans for canning, aerosols, and metal
containers in Africa. Currently, the company is focused on expanding operations into the rest of Africa.
Nampak Nigeria Limited manufactures packaging products.

ESTABLISHMENT IDEAL
Safety:

To create a safe workplace by doing the work safely, taking responsibility for individual safety and that
of others.

Excellence:

Commitment to the highest standards in everything, making quality products and delivering professional
work using everyday as an opportunity to learn and improve standards.
Responsibility:

Taking accountability for actions and behaving responsibly towards the environment, customers,
colleagues and suppliers by acting as a responsible corporate citizen and fulfilling basic obligations to the
communities and broader society.

Teamwork:

Working, supporting and sharing mutual knowledge for mutual benefit. Holding team members
accountable for high levels of performance and treating one another with dignity and respect.

Integrity:

Upholding moral and ethical standards by acting honestly and in accordance with applicable laws and
regulations by doing the right thing even when no one is watching.

ESTABLISHMENT OBJECTIVES/SCOPE OF SERVICE

Nampak Bevcan Nigeria is committed to:

 Providing the plastic industry with outstanding products and services of reliable and
consistent quality.
 Producing quality products with a view to establishing itself as the most reliable supplier
in the industry.
 Ensuring complete customer satisfaction.
 Bringing in continuous improvement and improved organizational effectiveness.
 Improving the quality of work through continuous training.
 Establishing and reviewing quality objectives periodically.

ORGANIZATIONAL CHART

QUALITY ASSURANCE
This concept covers a wide range which as an individual or collectively favours the quality of
manufactured product, it is the overall arrangement made in order to achieve consistencies in
production and standardised quality which is appropriate for it intended usage. It looks vividly into what
happens yesterday, today and tomorrow so as to appropriate and ensure quality final product.

QUALITY CONTROL
Quality control is used to describe all measures designed to ensure the uniform output of batches of
products that conform to the establishment specification. It is that part that organizes, documents and
release or hold product in order to ensure that the necessary and relevant tests are actually carried out
and that the starting material, intermediate and finished product are not accepted for use, sale or
supplied to the customer until their quality has been judged to be satisfactory. However, quality control
serve as a medium by which the manufacturer measures the actual quality performance in regard to the
standard and takes necessary steps on the courses of the variation from specification (if there is any) to
ensure good quality product.
 CHAPTER TWO
LITERATURE REVIEW
BRIEF BACKGROUND OF ALUMINIUM
 Aluminium is the most abundant metal on Earth, and one of the cheapest to buy but it used to be
more valuable than gold. Aluminium is the third most common element in the Earth's crust, but it also
bonds easily with other elements therefore it cannot be found in nature as a pure metal. For decades
after it was first identified by British chemist Sir Humphrey Davy in the early 1800s, scientists and
thinkers tried and mostly failed, to find a good method for separating aluminum from everything else
that stuck to it as it usually occur in its impure form called “bauxite”. Few years after Davy’s discovery,
Friedrich Wohler a German chemist at the university of Gottingen, made metallic aluminium in particles
as large pinheads and first determined some properties of aluminium which are specific gravity,
ductility, colour and stability in air.
Aluminum remained a laboratory curiosity until a French scientist Henri Sainte Claire Deville
announced a major improvement in Wohler’s method, which permitted Wohler’s “pinheads” to coalesce
into lumps. Deville’s process became the foundation of the aluminium industry. Although enough was
then known about the properties of aluminium to indicate a promising future, the cost of the chemical
process for producing the metal was too high to permit widespread use. But important improvements
presently brought breakthroughs on two fonts: first, the Deville process was improved; and second, the
development of the dynamo made available a large power source for electrolysis, which proved highly
successful in separating the metal from its compounds.
France's Emperor Napoleon III was an early proponent of aluminum. He hoped the lightweight
metal could be used to produce weapons and armor, giving his soldiers an edge in battle. The emperor
funded the work of Henri Sainte-Claire Deville, who found a chemical method for obtaining pure
aluminum, but it was still a slow process. An often repeated story goes that Napoleon III, frustrated with
progress on aluminum, had much of France's stock melted down and turned into cutlery. He and his
honored guests used aluminum utensils, while everyone else at the imperial dinner table made do with
gold.
Aluminum offers greater malleability, resulting in ease of manufacture; this gave rise to the two-
piece can, where all but the top of the can is simply stamped out of a single piece of aluminum, rather
than constructed from two pieces of steel. The inside of the can is lined by spray coating an epoxy
lacquer or polymer to protect the aluminum from being corroded by acidic contents such as carbonated
beverages and imparting a metallic taste to the beverage. The epoxy may contain bisphenol, a label is
either printed directly on the side of the can or glued to the outside of the curved surface, indicating its
contents. Most aluminum cans are made of two pieces. The bottom and body are "drawn" or "drawn
and ironed" from a flat plate or shallow cup. After filling, the can "end" is sealed onto the top of the can.
This is supplemented by a sealing compound to ensure that the top is air tight.
It is commonly used as a container for food and beverages such as milk and soup but also for
products such as oil, chemicals, and other liquids. Global production is 180 billion annually and
constitutes the largest single use of aluminum globally. In 1856, a method for producing aluminium
products commercially was developed, and the cost of producing aluminium was so high that it was
considered precious, like gold and silver as it has several characteristics similar to silver and gold. Use of
aluminum in cans production began in 1957 and a year after, the first aluminium drinks can was made
by Adolph Coors Company.

leon III, frustrated with progress on aluminum, had much of France's stock melted down and turned into
cutlery. He and his honored guests used aluminum utensils, while everyone else at the imperial dinner
table made do with gold.

CHAPTER THREE
 THE WORK EXPERIENCE PROCESS
DEPARTMENT ATTACHED AND PRIMARY FUNCTION
During my industrial attachment at Nampak Bevcan Nigeria Ltd, I was assigned to the washer unit in the
production department of the organization. This section is tasked with washing and treating of can and
getting it prepared for the next production operation as well as making it safe and ready for use by its
consumer. The department is directly involved in the manufacturing of aluminium can products.

OVERVIEW OF ALUMINIUM CAN PRODUCTION PROCESS

There are various departments involved in the production of aluminium can. The block flow diagram of
units involve in the can production are as follow:

MACHINE INTRODUCTION
The can washer(washer/dryer) is really a combination machine as it cleans cans and dries it during a
constant conveying of cans from the entry of the washer through to the discharge of the oven. Each
section of the washer has been designed to perform a specific task that ensures the best possible can
surface preparation to accept an interior coating and exterior decoration by:
 Removing contaminants (Rolling-mill oils and aluminium fines).
 Bonding a surface conditioner (treatment) coating to the aluminium surfaces.

FUNCTION OF THE WASHER

The main function of the washer are as listed below:
 To remove soils, forming fluids, normal inorganic material(fines) from the metal forming process
to allow uniform adhesion of the applied inks and lacquer later in the process.
 To apply a chemical coating to resist dome de-colorization caused by the formation of
aluminium hydroxide in the pasteurization process.
 To apply a friction reducing and water shedding coating to allow lower temperature drying and
improved can handling.

WASHER SECTION
Cans exiting bodymaker and trimmers are conveyed through a mass can conveyer, towards the
washer/dryer. Immediately preceding the entry of the washer is an accumulating table conveyer that
has its own speed-control drive motor. On this mat area, cans from the individuals bodymakers are
gathered for movement onto the washer mat at a predetermined maximum rate(cans/minutes).
Ideally, the speed of this accumulating table would run slightly slower than the washer mat. This is
done to provide for a small separation around the cans as they depart from the entry dead plate to be
carried further by the fast-running washer mat. The cans are fed into the washer open end down onto a
conveyor belt. They proceed through each stage of the washer in this position while being sprayed with
various solutions in different stages on the washer. In some cases, the washer mat speed may vary
slightly according to the numbers of bodymakers in operation aimed at preventing or minimizing fallen
cans. Each stage of the washer has a recirculating tank from which the solutions are pumped through
nozzles positioned above and below the conveyor belt carrying the cans. To prevent the carry-over of
chemicals from one stage to another air blow-offs are incorporated and mat wipe brushes at the end of
each stage. This ensure that each bath solution remains in its proper tank keeping contamination of
each tank down to a minimum.

MECHANICAL POWER
The washer uses the following drive systems:
 Main conveyor
 Hold down conveyor
 Stage pumps
 Air blow offs
 Exhaust fan
 Vacuum transfer
 Fallen can conveyor (cross conveyor)
 Tornado oven

Main can conveyor

Variable frequency drives are used to control the operation of the washer conveyor, hold-down
conveyors, vacuum transfer and oven conveyor. The washer conveyor drive serves the function of the
“Master” drive. The hold-down conveyors, vacuum transfer conveyor and oven conveyor will be “Slave”
driven from the master drive. The conveyor in the washer is of the open-mesh type and conveys the can
bodies through the different stages in an upright position, open and down. The washer, hold down,
vacuum transfer conveyors and oven are driven by a common AC drive unit fitted with a frequency
regulator unit. The open mesh type mat used is so designed as to minimize the obstruction of the spray
patterns from the spray nozzles situated below the main mat.
The main conveyor is divided into two (2) parts:
 Washer conveyor
 Dry-off conveyor (Oven Kevlar mat)

Hold Down Conveyors

Hold down conveyors ensures the can bodies remain in an upright position in the high pressure
process stages. Hold down conveyors is located in the pre-wash and wash stages. The hold down
conveyors is provided to stabilize the cans under these high pressure wash sections. They have height
adjustment to accommodate various can heights. The hold down conveyors is electrically driven at the
same speed as the washer conveyor drive.

Stage pumps
The recirculation pumps for all stages are horizontal centrifugal pumps. The pumps are direct driven
across accurately aligned flender flexible couplings. Each pump is isolated with a butterfly shut-off valve
between the pump suction and the reservoir tank. Pressure guage and switches are provided at the
discharge of each pump.

Air blow-offs
Ten air knife blow-offs are furnished, one between stages of the washer and at the washer exit.
They are designed to remove the accumulated water in the dome of the can, thus reducing cross
contamination. The blow-offs must not cause instability or tips-overs of the cans. The air knifes are
constructed from stainless steel. Each air knife is designed for vertical adjustment. The air knives are
supplied by individual direct drive centrifugal fans located at the roof of the washer. A damper is
provided at each air knife to adjust the air flow. All ductwork on the exterior of the washer housing is
constructed from stainless steel.
Exhaust fan
A stainless steel exhaust fan is provided. The fan is driven with an efficient motor with terminal block
connections and will include a V-belt drive, belt guard. The fan speed is adjusted to prevent chemical
spray vapour escaping from the washer.

Vacuum transfer
A vacuum transfer cans from the washer belt to the entry of the dry-off oven. The vacuum transfer unit
includes a left and right hand plenum, each with its own vacuum fan. Each plenum has six adjustable
flow control dampers with vacuum gauges for each. The overhead vacuum transfer conveyor is
adjustable for height as its four corners, an adjustable roller is provided for tensioning. The vacuum
conveyor is a perforated flat-top belt carried on plastic sprockets. The mat top is electrically ‘slave’
driven from the washer conveyor drive.

Fallen can conveyor (cross conveyor)

The cross conveyor is a separate conveyor located directly under the vacuum transfer assembly. The
conveyor serves to catch tipped cans and transport them into a reject container. The cross(reject)
conveyor is independently driven.

Tornado oven
The tornado oven is a “direct fired” convective hot air, continuous oven, which utilizes one heating zone.
The unit is designed to dry wet beverage cans at a production speed of up to 3000 cans per minute. The
oven is constructed in such a way that the oven walls, floor and roof consist of low conductivity
insulated “tray type” assemblies constructed in aluminized steel and packed with 100mm mineral wool
insulation material. In this type of assembly, the insulation material is fixed to the inner framework wall
and the outer “trays” are supported with top and bottom carriers, which are offset from the insulation
thus creating an air gap. A ladder and handrails are provided for safe access to the top of the oven.
The tornado oven air distribution system in the heating zone is powered by one direct driven
recirculation centrifugal fan/zone which distributes the air through supply ducting and diffuser plates to
the discharge nozzles. It is then passed over the product/cans in the oven workspace. The air is
subsequently recirculated through the support bed diffuser trays and returned past the combustion
chamber via return ducting on one side of the oven. The delivery nozzle provides sufficient kinetic
energy to provide a heat transfer rate to the product (cans) that will provide sufficient energy/heat to
the surface to the dry can. The greenbank tornado oven’s unique short cycle design delivers a higher
than normal air-flow to the cans to achieve rapid drying in a short oven also, under-bed air pressure
gives the can necessary stability which prevent the can from falling. At the can entry and exit ends of the
oven there are upper and lower suction boxes connected to the return air ducting. These suction boxes
helps to prevent hot air from escaping into the factory.
WASHER STAGES
The washer is divided into different stages with each stage designed to do a specific part of the entire
process. The quality of the can when leaving the washer is dependent on the correct operation and
control of each of these stages. After the drawing process of the can by the body-maker and trimmer,
the exposed surface becomes very dirty, the washer not only cleans the can, it also chemically treats the
can to inhibit rusting, to improve mobility and to prepare it for decoration and internal spray process.
The cans as received from the forming operation are fed with the open end down (upside down) by the
washer belt into the washer and proceed through each stage of the washer in this positon. Each stage of
the washer has a recirculating tank except stage 0 (pre-Rinse) stage. At each stage the washer solutions
are pumped through nozzles positioned above and below the belt carrying the cans.
Soft water is added as make-up water to all of the stages, but the greater proportion of soft water is
added to the last rinse stage and flow back or cascade through the stages to the very first stage of the
washer, this is called “tank stabilization”. Soft water is used because it prevents salt stains on the cans
and reduces scaling in the pipe-work and nozzles. Tank stabilization is particularly important for the
prewash and wash stages because of oil particles that float on top of the water. The overflow removes
these oil particles. If the overflow is not sufficient, then build-up of oil in the water will occur which may
result to poor adhesion on the cans resulting from oil spills on the cans.
The stages in the washer unit are listed below:
 Pre-rinse
 Pre - wash
 Wash
 First rinse
 Treatment
 Second rinse
 DI rinse
 Mobility-enhancer

Pre-rinse(knock-off)
The pre-rinse is the very first stage as the can enters the washer. This stage rinses the majority of the
coolant and tramp oil from the cans, this increases the effectiveness of the washer’s first stage. Scale
and bio-slime cause the nozzles on the spray bars in this stage to block frequently. To prevent this, the
nozzle must be changed daily in order to reduce oil contamination which may reduce the cleaning power
of the chemical cleaner.
The pre-rinse stage have an upper and lower knock-off spray bar. The washer also has a recirculation
bars, followed by a brush wiper and blow down. The pre-rinse stage also receive a little acidic overflow
from the pre-wash stage. Water pumped to the knock-off bars flows to the sump that is pumped to the
effluent plant. The knock-off spray pressures are set to give a very slight pre-rinse tank overflow to
remove surface oils. The total water lost from this stage should match the water pumped out of pre-
rinse stage to flow balance tanks. Cans enter the washer through a set of spray bars (risers) which sprays
back flowed rinse water to the first rinse, this washes majority of the coolants off the cans. Back flowed
water is kept in a tank and pumped through the spray bars allowing higher flow rates and more efficient
nozzle configuration. Scale and bio-slime causes the nozzle to block frequently, therefore it is
recommended to check the nozzles daily or preferably the spray bar must be change daily.

Pre-wash
This stage is temperature controlled, higher liquid pressure and sulphuric acid are used here to remove
the majority of coolant and oils and more importantly to minimize the carry-over of impurities (oil and
coolants) into the next stage. The purpose of this stage is to remove as much as possible water soluble
oil before the can enters the proceeding stage.
The pre-wash bath is dosed with sulphuric acid and maintained at a concentration of 1.2 to 2.5%
(~1.8/2.2 pH). The pH should be controlled in this stage as it can lead to fixing of oils on the can walls
and excessive acid carry over to the next stage. The chemical controller automatically monitors and
controls the pre-wash concentration using a conductivity sensor. The bath strength is displayed in “ml
Free Acid” to match the ml of titration carried-out by the operator, the bath is also heated to typically
45-55 ͦC and maintained at +/1 ͦC. The pre-wash has a recirculating spray bars with no inter-stage spray
bars, the mat and cans drag-in pre-rinse water and pre-wash acid is dragged-out. The bath must be
constantly over-flowed into pre-wash to remove surface oil and refresh with wash stage overflow. High
temperature and low pH cause the oil to spilt out of emulsion and float to the bath surface where it is
overflowed to waste, operating at a high temperature is also an advantage as it helps to kill bacteria
carried in with the coolant thereby making the removal of oil and coolant an easy process.

Wash
The function of the wash (cleaning) stage is to remove organic and inorganic soils remaining on the
surface of the can. Organic soils are soluble lubes from the cupper and bodymaker/trimmer, rolling oil,
finger prints, general shop dirt and tramp oil. Inorganic soils are aluminium fines, natural oxide and
other corrosion-aiding oxides present on can surface. Failure to remove the organic soils may result in
incomplete conversion coating or subsequent adhesion failure of the interior/ exterior coatings. The
wash stage is the hottest, longest and the largest liquid containing volume stage equipped with most
nozzles. The wash stage bath solution is heated and maintained by an independent heat exchanger.
Two chemicals are added to this bath and these are sulphuric and hydrofluoric acid. These are
combined to work together giving a balance of free acid and free fluoride to maximize the activity of the
bath. Bonderite C-1C 120 SNF and Bonderite C-1C 740 E cleaner are typically operated within some
limits to achieve some specific requirements. The alumin4.ium oxide and fines must be chemically
etched from the can surface. If they are not removed from the can interior, it may lead to the following:
 Poor interior adhesion
 High metal exposure
 A build-up of fines on the printer mandrels resulting in loading and stripping problems hence
lost production
If the oil is not properly removed in pre-rinse and pre-wash stage, then the cleaner in the wash stage will
take longer time in removing the oil left unremoved by the pre-rinse and prewash stage and less time to
remove the oxide layer on the can surface this is because etching of can only takes place once the oils
are removed. If the oils are properly removed in the preceeding stages, more time will be available to
remove the oxides.

First-rinse
This is a three stage rinse process with intermediate wipers and blow-down to prevent carryover to the
next sub-stage. The first sub-stage called “First-rinse A” has some set of spray bars which remove as
much wash chemical as possible inorder to stop the etching process. Some of this chemicals are
forwarded pre-wash and small quantity into wash. The lost water is made-up with continuous overflow
form first-rinse B. The second sub-stage of the first-rinse called “first-rinse B” has more cold water rinse
spray bars for further acid removal. The third sub-stage of the first-rinse called “first-rinse C” has set of
spray bars from second rinse to give pH rinse to the can and mat. The flowrate is adjusted to match the
water lost from first-rinse A.
The function of the first-rinse stage is to remove cleaner and loose soils remaining from cans
leaving wash and to prevent the drag-in of acid into the treatment stage. It is important to remove
residual cleaner quickly to stop the chemical etch of the can surface. The backflow through the sub-
stages of the rinse is to maximize rinsing efficiency and minimize water consumption, it is important to
maintain good flow for efficient rinsing. If the stage is contaminated, then a temporary overflow with
fresh water is recommended inorder to eliminate risk to the proceeding stage.

Treatment
The purpose of treatment is to apply a chemical conversion coating by forming a chemical anti-corrosion
layer (zirconium phosphate) which is insoluble in alkali conditions. This prevents formation of an
aluminium alloy stain on the can dome (the only area of an aluminium can that is not coated) in the hot,
alkali conditions of the pasteurizer at the filling plant.
The bath is heated to typically 43 ͦC and maintained precisely at +/- 1 ͦC because the amount of
treatment is temperature dependent. The bath is initially prepared using a start-up solution (Bonderite
M-NT 4040 MU/ 400 series), thereafter it is automatically dosed with Bonderite M-NT 404 which
contains Zirconium Phosphate, Nitric acid and Hydrofluoric acid with replenisher by the ACS controller
using a pH sensor. The bath is static with no water entering from any other part of the washer process,
the tank levels are controlled by an auto top-up system supplied from the main water supply pipe, the
baths equilibrium is maintained by the drag-in and drag-out effect. Bonderite M-NT 4040 MU is a
chromate free product which reacts with the aluminium can surface to form an inorganic conversion
coating which performs the following functions:
 Promotes adhesion of subsequent organic coating such as basecoat, inks, over vanishes and
interior spray systems.
 Resist discoloration of the aluminium surface during pasteurization
 Improves the corrosion resistance characteristics of the aluminium
Treatment aluminium chemistry
Aluminium is a very reactive metal therefore it Rreact violently with water thereby producing a
protective oxide film on exposure to the atmosphere.

Second-rinse
Second-rinse is made up of three sub-stages which are “second-rinse A, B and C” respectively. The
purpose of the second-rinse stage is to completely remove all the excess treatment chemical from the
cans and washer mat, failure to do so will allow the conversion coating to continue reacting with the
cans surface, resulting in over-treatment. The first set of spray bars in first sub stage remove as much
excess treatment chemical as possible in order to stop the process. Water is fed forward to spray bars,
the lost water is made-up with a continuous overflow from second-rinse B. This second set of rinse stage
has more cold water rinse spray bars for further treatment chemical removal than other sub-stages and
also ensure adequate treatment chemical removal before transferring to the last stage of the second-
rinse sub stages where the treatment chemical is completely removed.

DI rinse
The purpose of the DI (de-ionized) rinse is to rinse-off all remaining dissolved salts from the cans and the
mat. The purpose of the DI is to get rid of hard in treating cans, hard water by definition contain some
minerals such as calcium, magnesium, silicate etc. Water containing calcium or magnesium salts in
considerable amounts is termed “hard water” because it is hard to make a lather using them. We know
certain minerals are important in our diets, especially for athletes and older people. By definition
mineral water contains at least 500ppm of dissolved solids- the minimum to be helpful in human
consumption. Soft water will lather very easily but it is also nearly void of some minerals that are
necessary for a healthy life; and it also have excessive amount of sodium ions that has been associated
with hypertension as people grow older. So it is best only used in a home’s hot-water system or
probably eliminated in anyother way.
The water molecule (H2O) takes on some magnetic properties that result in the ability to dissolve
other substances and also defy gravity with capillary action. Pure water can never be found in nature
therefore anything in water that is not H2O is a contaminant or impurity and broadly classified as
 Inorganic salts which is dissolved from minerals in the geological formations containing the
water source.
 Organic matter which is related to aquatic life and vegetative cover of a watershed
Cans exiting the DI rinse stage are rinsed with the best quality available water in the plant. A pump at
the end of the washer takes DI water from tanks and moves it through the filter and resin column this
gives all the cans double shot of DI water first being good DI rinse followed by virgin water directly from
the DI column. No efforts is made to control DI temperature but the system works best at a temperature
below 38 ͦC. In washer operation, DI water quality is always measured and controlled with conductivity
readings. DI system normally has ion exchange units, a conductivity sensor automatically switches it over
when the conductivity set-point is exceeded.
Mobility enhancer
The purpose of the final process of the washer called “mobility” is to apply a solution of demineralized
water mixed with a rinse acid/ mobility enhancer. This product reduces the surface tension of the water
allowing it to drain more rapidly from the cans surface, this solution also effectively gives the cans better
mobility through the can conveyor systems especially at the decorator single filer infeed. This lowers the
surface tension also improves water shedding and allows for faster drying in the oven.
Mobility has one pair of recirculation spray bar, the DI manual fill valve is very slightly opened to
give a constant tank overflow. This removes surface foam, bacteria and keeps the conductivity low

GENERAL QUALITY
The purpose of the washer as stated earlier is to ensure thorough cleaning, treating and drying of cans.
This is achieved by specific stages of the washer. Certain quality checks are to be carried out to ensure
that the various stages perform to the laid down specifications. The quality of the washing process of a
beer and beverages can is of extreme importance. Under no circumstances whatsoever will a can
maker/production mechanic allow cans to be processed if the washer standards do not comply with the
sets standards. Failure to carry out the quality inspections on the washer could result in numerous out-
of-inspection cans being produced and found unacceptable by the customers

Quality Procedures
Good quality can from the washer is achieved by the following:
 By accurately and constantly monitoring the washer process and can quality, one can detect any
trends occurring
 By analyzing these trends, steps can be taken to rectify a situation before the problem occur.
 All can defects found at the washer do not necessarily effect production in the metal forming
department, but will have a major effect on the rest of the downline equipment and at the end
customer.

Quality Checks On The Washer

Process and can quality checks at the washer are as follows:
The process checks
Process Checks Quality Checks
Stage 1- Prewash Temperature
Stage 1- Prewash Free Acid
Stage 2- Wash Temperature
Stage 2- Wash Free Acid
Stage 2- Wash Total Acid
Stage 2- Wash Reaction Product/Aluminium build up
Stage 2- Wash Fluoride RmV or ppm
Stage 3a- 1st Rinse Conductivity
st
Stage 3b- 1 Rinse pH
Stage 3c- 1st Rinse Conductivity
Stage 4-Treatment Temperature
Stage 4-Treatment pH
Stage 4-Treatment Fluoride RmV
Stage 4-Treatment Free Acid
Stage 4-Treatment Total Acid
Stage 4-Treatment Reaction Product
 Stage 4-Treatment Sulphate
Stage 5a-2nd Rinse Conductivity
Stage 5b-2nd Rinse pH & free chlorine
Stage 5c-2nd Rinse Free Chlorine
Stage 6 Conductivity
Stage 6 Free Chlorine
Stage 7-ME (Mobility Enhancer) Concentration & Conductivity
Stage 7 Free Chlorine
Drying Oven Temperature

The can quality checks on the washers are as follows:

 Muffle furnace test
 Can mobility test
 Dome stain test
 Etch rate check
 Water break test
 Salt ring checks

Test chemicals
The following chemical are used when titration checks are done at the washer:
 0.1 N Sodium Hydroxide
 6 N Potassium Hydroxide
 Tetrakis
 Victoria Indicator
 Phenolphthalein Indicator
 Sodium Fluoride
Muffle Test At The washer

Purpose
To check the quantity of the treatment on the cans in stage four of the washer unit
Procedures
Samples of cans were collected from the oven discharge (holding the cans on the inside). Cans are taken
from the left, centre and right. Gloves must be worn as cans emerging from the oven will be very hot.
Using tongs the cans are placed in the muffle furnace for 5 minutes, ensuring the temperature is 537 ͦC
+/-2 ͦC.
The colours of the cans are checked against the following:
Colourless/almost colourless : No treatment
Light golden brown : Under treatment
Golden brown : Satisfactory
Dark brown : Over treatment
Purple : Excessive
If the muffle test is not within specification, all necessary steps must be taken to bring it back within
tolerance. Also, the supervisor must be informed about the anormalities on the surface of the can. If the
can is under treated, finished cans are taken from the end of the Lacquer Spray Machine(LSM) for dome
tarnishing to confirm under treatment.
 Where dome tarnishing is present, team leader or line leader who will sample and isolate cans
where appropriate must be informed. Where there is no dome tarnishing, necessary adjustments must
be made to the washer. If over treatment of cans occur, finished cans must be checked for neck peeling.
Muffle and quality must be rechecked to check their effectiveness.

Can Mobility Test

The function of the mobility test is to check the mobility of cans leaving the washer.
Sample size: 3 Cans.
Procedure
Place 2 cans on the saddle
Place the 1 can on top of the 2 cans (in the opposite direction)
Ensure the protractor is showing zero
Lift up the saddle of the equipment
The top will can slide, note the angle on the protractor at which the can started sliding
Manually record the result in datalyzer system.
Take corrective actions if the angle is higher than the stipulated specification.
Dome stain solution make-up
Purpose
To make up a standard solution for the dome test.
Sample size:
One Beaker
Water bath preparation
Method
Refer to the relevant MSDS for all chemicals used. Ensure that all precautions are taken, including
correct PPE where appropriate. Refer to the MSDS for correct disposal of all chemicals.
Fill the bottle with 5 litres of DI water.
Add three grams of DI Sodium Tetraboratedecahydrate (weighed to the nearest 0.01g)
Mix well
Pour 250ml of the dome test solution into a glass beaker and insert into the dome tester water bath.
The washer water bath is set-up as follows:
Fill the bath with Virgin DI water and heat as follows:
For Dome Tarnishing set at 68 ͦC
For lacquer blush and adhesion set at 68 ͦC
Etch rate check
Purpose
To check the amount of aluminium etched from the can surface in the washer
Procedure
Collect six cans from the back of the washer oven
Weigh each cans using the Sartorious balance.
Tie cans in bundle using wire.
Place cans on washer infeed
At the end of stage 3 remove the cans from the line, put back in line at the end of the treatment.
Remove at washer drier exit.
Re-weigh cans using the Sartorious balance
Etch rate per can= A – B.
Etching is accomplished by the fluoride and hydrogen ions. These attack the can surface as the cleaner
removes the oil from the can. As the pH goes lower the etching becomes less active and as the pH goes
higher it becomes more aggressive.
Low etch will result in
Poor surface for the treatment, resulting in dome staining or patchy domes.
Inadequate removal of smut and fines from forming process.
Dark can interiors.

High etch will result in:

Poor can mobility
Poor loading onto decoration mandrel
Whitish colour on the external.

Test methods
The following test methods are conducted at the washer:
 Free acid test
 Total acid test
 Reaction product (RP)
 pH and pH standard solutions
 Mv & RmV
 Mobility enhancer 70 test
 Fluoride and fluoride standard solutions
 Conductivity
Free acid
Free acid is measured using an acid-alkaline titration which gives a result in mis of titrant. This method is
based on a colour change and accuracy will only be obtained if the end point is taken at the first
appearance of the purple colour.
 Take 10 ml sample
 Add it to a conical flask
 Add a spoon (1gr) of Sodium fluoride (AR grade)
 Add 10 drops of Phenolphthalein (indicator)
 Titrate against sodium hydroxide 0.1 N till the change of colour to light pink.
Total acid
Total acid is measured using an acid-alkaline titration which gives a result known as a mis. This method is
based on a colour change and accuracy will only be obtained if the end point is taken at the first
appearance of the purple colour.
 Take 10 ml sample
 Add it to a conical flask
 Add 10 drops of phenolphthalein indicator
 Titrate against sodium hydroxide 0.1 N till the change of colour to light pink.

Reaction product
The reaction product (RP) is controlled at a maximum value of 2.5 times the cleaner’s free acid. As
aluminium cans are processed through the washer, aluminium is dissolved into the cleaner bath as a
result of the removal of aluminium fines and the etching of the can’s surface. The quantity of dissolved
aluminium in the cleaner bath gradually increases until rate of aluminium dissolution is balanced by the
drag out of the cleaner bath.
RP * 100=ppm aluminium in bath

pH
pH is a measure of the acidity or alkalinity of a solution on a scale from 0 to 14. The midpoint of the scale
is 7 and a solution at this pH is neutral-neither acid nor alkaline. A solution with a pH greater than 7 is
alkaline the higher the number the more alkaline the solution. Similarly, the lower the number below 7
the more acidic the solution.
pH is measured using a glass electrode which gives an output voltage relative to pH. This output is
measured with a meter designed to give a direct reading of pH. It is important that the pH meter is
calibrated before use with standards (buffers) which span the range to be measured.

Mv & RmV
Mv measures the activity of chlorine (from the sodium hypochlorite in stage 5,6 and 7 respectively. RmV
are related to ppm and a table showing the relationship between the two units are available.

Mobility enhancer
Mobility enhancer is used to make the can smooth (by covering the rough surface caused by etching).
ME is also used to enhance can water shedding thereby reducing the requirement of heat of the oven.

Fluoride standard solutions

Fluoride standard solutions are used to calibrate the bench fluoride probe in ISE ppm mode. A 5 ppm,
20ppm and 40ppm are used respectively. Furthermore, the 20ppm is used to calibrate the probe in RmV
mode.

Washer daily checks

 Check if no cans are stuck between washer side rails.
 Check all blow-downs for blockages and scrape them until functioning if blocked. (Use only steel
scraper)
 Check pressures for all nozzles. Check and adjust for good flow balance between stage 0,1,3 &5.
 Ensure all doors are closed on the front and rear of the washer including tank lids.
 Check for unwanted noises on pumps; report to team leader any unusual noises.
 Check condition of washer Kevlar mat for damages.
 Check if all flow meters are working properly and set correctly.
 Check and set the flowmeters after each maintenance.
 Skim oil from stage 1&2 using ladles and PPE, empty into bucket at coalesce.
 Check levels of all chemicals in day tanks, top up with a full tote when Astles panel shows
“Refill”
 Inspect spray bars for blockages using a torch, inform T/L of blockages and clean during available
downline.
 Check that stages 0, 1, 3, 4, 5, 6 and 7 nozzles are not blocked and spraying correctly.
 Pressure clean all filter screens in tanks and change if broken.
 Clean all astles probes and ensure probes are calibrated.
 Clean all cans at vacuum transfer area and washer exit, report high spoilage.
 Ensure that the chemical stock sheet is up to date.
 Ensure no leaks or airlocks in dosing lines and check dosing pumps for operation.
 Ensure all pumps and conveyors are operational.
 Ensure all incidents are reported and recorded in shift handover book and information
transferred to the next shift CPO.
 Ensure that all chemical spills are cleaned up safely.
 Check for excessive fallen cans and report immediately.
 Ensure floors, equipment and area is kept clean at all times. Pressure clean floors regularly.
  Ensure that the Stetfield separator is discharging oil only, dump oil into oil tote outside.
 Check rope skimmers in sump A10A and A10B for operation.
 Ensure that all spare nozzles and spray bars are cleaned immediately.
 Ensure that northern side and coil store roll up shutter doors are closed at all times.
 Check the nozzle spray patterns.
 Inspect piping and valves for leakages.
 Inspect for proper overflow of water levels.
 Check blow-off after each stage to ensure sufficient air pressure.

Safety daily checks

 Check all E-stop buttons are functioning, check acoustic alarm.
 Check lights.
 Check if all doors and lids on washer and oven closed.
 Check if all warning signs are still readable
 Check visually for loose wires, bolts and guards.

CONTROL PANELS
The washer is controlled by its own control panel. The drier has a main panel at the rear of the machine.
The main control panel is equipped with a main circuit breaker, a panel air conditioner is also provided
to maintain an acceptable temperature level inside each panel. A programmable Logic Controller with
software and programming to control and monitor the operation and various functions of the Washer/
Dry-off oven and conveyor system is provided. A panel view colour touchscreen with software and
programming is also provided for start-up sequencing and fault messages. Variable frequency drives will
be used to control the operation of the washer conveyor, hold-down conveyors, vacuum transfer
conveyor and oven conveyor will be slave driven from the master drive.
Included in the main control panel will be motor starters, pilot lights, selector switches, alarm horn
and beacon. One heavy-duty control transformer with electro-static shield will be supplied for control
power. A chemical controller controls the dosing of the tanks with the necessary chemicals.
Temperature control of the heated tanks (stage 1,2 and 4) and the drier will be controlled by PLC
software. Earth leakage jam sensors will be positioned at the discharge end of each stage prior to the
blow-off air knife sections for the purpose of detecting product flow (can) jamming. The control panel
for the washer is usually mounted on the side of the washer near the oven.

Controls
Tank heating startup
Start boiler
Check liquid level in tank( stage 1,2 and 4)
Check pipe work and heat exchangers for leakages
Close the hand valves on the heat exchangers from the outgoing tank pipes.99
Set the set-point of the temperature controllers as low as possible(below the cold water temperature)

The following steps are taken for each tank.

Start the heating recirculation pump.
Open the hand valves downstream to the heat exchanger slowly.
Open the hand valves on heat exchangers to the outgoing tank pipes.
Bring set point +/- 10 ͦC above actual bath temperature regulator (valve should be turned to open)
Check tank water temperature and the reading on the temperature controller when the setting has been
reached.
Bring set point to working temperature.
Repeat these steps for the other tank(s) (stage 1,2 and 4)

Starting the machine in automatic mode

Number Function
F1- Silence alarm Turnoff the sounder( note the alarm stays till it is reset)
F2- Start up washer Start the automatic start up sequence
in auto
F3- Automatic run Indicates if the washer is in manual or in automatic mode
F4-Pumps manual Selection for continues running pumps or follows the mat
signal. When the mat stops the pump go off.
F5- Stop all motors Stop command for all motors
F6- Manual speed Jump to the conveyor screen to change the speed
F7- Conveyor starts Start the conveyor when the washer is in automatic mode,
in auto after a stop command
F8-Conveyor stop Stop command for the conveyors

 By pressing the objects representing the stage and the section marked with pointer 1, you jump
to another screen representing the particular stage.
 By pressing the objects representing the section with pointer 6, you jump to another screen
representing the transfer.
 By pressing the objects representing the section with pointer 5, you jump to another screen
representing the Oven.
 By pressing the objects representing the section with pointer 7, you jump to another screen
representing the heat exchanger.
 Pressing the area pointed by 4 transfers you to the alarm list.
 Switch on the power supply by means of the main switch on the main panel.

The circles in the object represent the status off the pumps, fans or conveyor motors.
  Green Stand by
 Yellow Start-up
 Red Fault
The LED marked by pointer 2 represents the status of the whole washer:
 Washer fault occur when there is failure at the machine
 Standby enable to run is on when the washer is started up and there are no failures
 Line control contact infeed is on when the washer is controlled by the line control PLC when the
light is off the washer returns to standby (if there are no failures)
 Oven ready is on when the oven is at temperature and no failures at the oven sections.
The buttons at the bottom of the screen 9, 11 allow the user to jump to the main screen, previous
screen and the next screen. The previous and next is according the flow of the cans. In manual mode is it
possible to run or stop the pump or fans by pressing the green or red button.
The colours of the pump and fan represent the status. Hertz selection
 Blue Off
 Yellow Standby
 Green Running
 Red Fault
The blue bar pointed with 6 represents the water level inside the tank. The level is pointed in four

colours:
 Red – Low
 Yellow – Fill level (the tank is filled automatically)
 Blue – Normal level
 Purple – Warning level
When the tank is at fill level the fill valve turns green.
If there’s a can jam the bar pointed with 7, turns red
Pressing the buttons pointed by number 8, you can set up the frequency which the blow off fan must
run. The speed is adjustable between 10Hz and 50Hz. With the green button, it is possible to start pump
or fan in manual mode, with the red button it is possible to stop the pump or fan in manual mode. With
the emergency circuit breakers off, the control current is switched on by pushing button “control current
on”
ASTLES CONTROLLER
System overview
The PC500 system controls the chemical concentrations in the stages of a can washer. The chemical
strengths of the stages are measured and in certain stages chemical is dosed to maintain a set point. If
the concentration of the chemical in a stage deviates from set point by more than a preset margin, an
alarm is given and the beacon on top of the panel flashes. The chemical strengths are logged and
historical trends can be displayed.

PC 500 User Interface

The display is touch-sensitive and the system is operated by pressing buttons on the screen. The buttons
along the bottom of the screen are used to navigate the system, for example , pressing the button
marked home will display the home page. The data boxes on the mimic screens are also touch sensitive.
System operation:
Changing the control mode
The control mode of a channel is the way that the system runs a pump to alter the chemical strength of
a stage.
Mode description
AUTO- The system operates the pump automatically to make the bath strength (process variable or PV)
match the set point(SP)
MANUAL- The pump runs at a fixed, user-defined speed. Use this mode if the probe is faulty.
OFF- The pump is not running. The system continues to display the bath strength and raise alarms. Use
this if maintenance is required on the pump.
CANS COUNT- The pumps run for a set time for every 1000 cans that are made.
To change the control mode
From the overview screen, press the channel’s box.
Press the required mode button.
Calibrating the probes
To allow correct operation of the PC500, regular manual checks of the bath strengths and probe must be
done accordingly.
 From the overview screen, press the channel’s box.
 Press the offset field so that the numeric keypad appears.
 Adjust the offset until the process value is set correctly.
Adjusting The Control Set Point
The control set point is the chemical strength that the controller aims for when in auto mode.
To adjust the set point;
 From the overview screen, press the channel’s box.
 Press the set point field so that the numeric keypad appears.
 Adjust the set point is required
Viewing And Acknowledging Alarms
The system has two alarm screens
It shows all unacknowledged and active alarms. To stop the alarm beacon flashing, all alarms should be
acknowledged;
 Press the alarm button . The Current Alarms screen will be displayed.
 Press unacknowledged alarm in the alarm list to highlight it.
 Press the acknowledge button beneath the alarm list to acknowledge the alarm.
 If all the active alarms have been acknowledged the beacon will stop.
 The Alarm history contains a historical list of alarms and accesses on its list.
Adjusting the Alarm Limits
The PC500 uses deviation alarms, which means that an alarm is activated if the chemical strength of a
stage deviates too far from the set point.

To adjust the alarm band

 From the overview screen, press the channel’s box.
 Press the alarm deviation
  Adjust the alarm deviation as required.
Running In Manual Mode
There may be occasions where the system does not receive a reliable measurement of the chemical
strength in the stage, for example if a probe is removed for a long period. To all occasions, the PC500
can run a pump in manual mode.
In manual mode, the pump runs at a constant output, regardless of the chemical strength. To adjust
the amount of chemical added while in manual mode, increase or decrease the manual mode setting.
The manual mode setting is a percentage, so setting it to 50 will cause the pump to run at half speed.
To adjust the manual mode setting;
 From the overview screen, press the channel’s box.
 Press the Manual Mode Setting field so that the numeric keypad appears.
 Adjust the percentage output as required.
Adding a Shot Dose
The shot dose function is a quick and easy way to raise the strength of the process. It can be used to
dose chemical to a fresh tank and quickly raise the strength to operating level. The following procedures
are used for adding a shot dose to a chemical tank.
 From the overview screen, press the channel’s box.
 Press the shot dose time field so that the numeric keypad appears.
 Adjust the shot dose time to the required run time.
 Press the shot dose button to start dosing.
While a shot dose is running, the remaining dose time is displayed. If a shot dose restarted, the system
will reset the dose time to the value in the Shot Dose Time field. To restart the dosing from where it left
off, copy the remaining dose time to the shot dose time field.
Drier control panel

Oven Start-up sequence

 Turn on the oven main circuit breaker on the main control panel.
 Pull-out any depressed E-stop around the washer and oven.
  Press the control power reset on the panel view screen on the oven operator control panel.
 Cancel and clear all alarm messages on the screen.
 Switch from maintenance to run mode on the screen.
 Press the green auto start on the screen.
 On the burner panel view screen, switch the burners to “ON”
 The oven will now automatically start all the fans in sequence, followed by a five minute air
purge of the oven before the burner(s) light-up sequence begins. If a burner fails to light, allow
the post purge to time out (30 secs) before resetting. The burner start sequence will start
automatically.
 The oven temperature controller will now take control of the burner gas control valve and raise
the oven to temperature. The washer (if ready) and the oven will both start when the oven
reaches the low temperature alarm limit.
Oven Shut-down sequence
Press the red auto-shutdown button on the panel view screen ( press for < 5 seconds). The burners will
automatically go off. The fans will not go off until the oven temperature drops below 100 degree
Celsius. You will notice that the fans are programmed to reduce to slow speed when the temperature is
low because of the higher air density. Do not use the emergency stop push buttons for a normal oven
stoppage as this over-rides the auto-shut down sequence, risking thermal damage to the fans. Similarly,
if you press the auto stop button for > 5 secs, the fans go to immediate shut-down.
You can stop the washer, water feed and oven conveyors at any time without stopping the burner or
fans by using the yellow mushroom head push-buttons around the machine. To prevent the cans drying
out, the rinse pumps will be programmed to run for short periods during a mat stoppage.
Press the washer green conveyor start button on the panel view to restart.

A Honeywell Multitrend SX recorder will continuously monitor and document the oven’s temperature
performance over extended periods of time. The oven will be furnished with a Jumo excess temperature
protection device. The controller is wired to shut off the oven and sound the alarm whenever its set
point has been exceeded.
 TROUBLE SHOOTING
The basic steps of troubleshooting are as follows:
Identify the problem
Identify the cause
Eliminate the cause
Check
We can symbolize these four (4) basic steps with a diagram

IDENTIFY THE
PROBLEM
 IDENTIFY THE
CHECK CAUSE

ELIMINATE THR
CAUSE

The importance of troubleshooting cannot be overemphasized because failure to know what to do when
defects occur can prove very costly in terms of poor quality, lost productions and customer complaints.
Troubleshooting

Washer trouble shooting guide

Washer corrective action and troubleshooting
Water breaks on cans
On the washer
 Check free and total acid of stage 2
 Check chemical feed tank and pump controller
 Check temperature of stages 1 and 2 with a hand held thermometer
 Check spray pressures and nozzles for blockages
 Check if pH on stage 1 is not too low, this will cause oil to split on the can (if it is less than 1.8)
 Check that coalesce is in good operation
 Check stage 2 for oil loading
 Check if spray pattern is correctly set

Elsewhere

 Check for high tramp oil and coolant oil concentration

 Check for high lubricant film weight and concentration.
 Check for low coolant flow rate on the body makers.
 Check for high coolant temperature.
 Check for coolant foaming and excessive coolant flow rate.
 Check coolant emulsion stability.
 Check for long line stops.
  Check body maker number against bad cans.

Metal fines inside the can

 On the washer
 Check stage 2 parameters.
 Check for low spray pressure.
 Check for increased pressure.
 Check pH in stage 4

Elsewhere
 Check for low coolant flow rate on the body makers.
 Check for excessive coolant flow rate and foaming.
 Check filters press for bursting. This refers to coolant stack filters and not the effluent filter
press.
 Check body maker tooling for buildup.
 Check for low lubricant concentration/film weight.
 Check body maker number mark against bad cans.

Over etched cans

 Check the fluoride concentration in stage 2 (manual vs astles control system). Check for excess
offset.
 Check the RmV and pH at the treatment stage.
 Check the temperatures, with a hand held thermometer of stage 2 and 4.
 Check for line stoppages with cans in the washer.

Over treated cans (dark muffle)

 Check stage 4 temperature
 Check stage 4 pH, RmV, FA and TA.
 Check for prolonged line stops.
 Check muffle furnace not above 537 +/- 2 ͦC

Under treated cans (light muffle)

 Check stage 4 temperature
 Check if stage 4 pH, RmV, FA and TA are in specification.
 Check if muffle furnace temperature is set at 537 ͦC
 Check furnace door seal for gaps.
 Check if the correct chemical has been refilled in the day tank.
 Check stage 2 parameters, over etching causes uneven treatment on the can.

‘Patchy’ dome-stain tests

On the washer
 Check stage 2 parameters, over etching causes uneven treatment on the can.

Elsewhere
 Check coolant tramp oil concentration and flow rate
 Check lubricant film weight.
 Record coil supplier and batch number.
Adhesion loss
On the washer
 Check conductivity of De-ionized water supply from columns.
 Check mobility enhancer stage for concentration and conductivity.
 Ensure good spray pattern and consistent volume inside the cans.
 Check conductivity of liquid in the can after stage 6
 Check interior of can if it is fully dry after washer oven.
 Check if the washer oven flames are burning blue and not yellow to ensure complete
combustion.

Elsewhere
 Check base coater/decorator mandrels for buildup and ink fly. If aluminum oxide builds up on
mandrels, then rectify washer urgently and clean line.
 Check pin chain of PEG oven for dirty/damaged pins.
 Check L.S.M marks against falling cans.
 Check I.B.O temperatures.
 Check for line stops
 Also check fil weight, spin speed and chucks for free movement.

Mobility problems
Related to the wash stage.
 Check the fluoride concentration in stage 2.
 Check the temperature.
 Related to the treatment stage.
 Check the temperature.
 Check the oven temperature ( high temperature burns off the ME)
 Check that all the parameters are within specification.

Spray bar pressure above specification

Possible causes Corrective action
Blocked spray nozzles: Remove, check and clean
Incorrect spray bar: Remove and check spray bar number
Incorrect nozzles: Remove and check with nozzle schedule
Faulty flow meter: Check calibration/check k factor/ check if the
correct units are depicted
Faulty pressure guage: Replace guage/calibrate the guage/vet the guage

Spray bar below specification

Possible causes Corrective action
Incorrect spray bar: Remove and check spray bar number
Incorrect nozzle: Remove and check with nozzle schedule
Gasket missing or partially locked spray bar Remove and inspect
coupling:
 Missing nozzle or end cap: Remove spray bar and replace
Faulty flow meter Check calibration/check k factor of the flow
meter
Faulty pressure guage: Replace guage/calibrate the guage/vet the guage
Damaged nozzle stalk on type ac nozzle: Remove spray bar and inspect

Spray bar valves

Spray bar valves are widely open but some situation may occur which may cause a reduction in spray
bar pressure. Possible causes and corrective actions for low