In the fast-paced and dynamic world of food production, maintaining a high standard of cleanliness is essential to ensure food safety and prevent contamination. One crucial aspect of this process is the regular and efficient washing and sanitisation of tote bins.
These containers are essential for storing, transporting, and handling ingredients and products throughout the facility and between processing stages. Proper cleaning and sanitisation not only uphold strict hygiene standards but also protect product quality, reduce the risk of cross-contamination, and safeguard consumers.
In this Tech Talk we will explore the importance of tote bin (or buggy) washing and investigate the effectiveness of various jetting systems used within the industry.
Tote Bin Washing for Food Industries
Food safety is a primary concern for food manufacturers and consumers alike. Tote bins, which come into direct contact with raw materials and intermediate products and finished goods, can harbour harmful bacteria, allergens, pathogens and foreign contaminants. Regular cleaning routines reduce the risk of cross contamination and maintains a hygienic environment within the food processing facility.
Food producers and processers are subject to strict regulations and standards set by governments and industry bodies, and proper cleaning of tote bins and buggies are necessary to meet these requirements.
What Are the Risks of Not Cleaning?
Moisture, warmth, and organic residues create ideal conditions for microbiological growth. If tote bins are not thoroughly cleaned, they can become a source of bacteria, mould, and other pathogens. As a a result, contamination can be transferred between different areas of the facility, particularly via the bin wheels.
Thorough cleaning is essential to prevent allergen cross-contamination between products. This is critical for maintaining consumer safety and ensuring compliance with approved manufacturing processes.
Tote Bin Washing Methods
There are several methods for cleaning tote bins (buggies) in a food factory. The most common approach involves using a high-pressure lance to manually jet both the interior and exterior surfaces.
However, this method has several drawbacks. If bins are tipped during cleaning, it can damage both the bins and the washroom floor, unless a dedicated tote bin wash frame is used. Even with such equipment, the process consumes thousands of litres of fresh water each day. Given the cost of both water supply and effluent disposal, this can be an inefficient and expensive cleaning method, as well as having a notable environmental impact.
In addition, high-pressure washing can create airborne aerosols, increasing the risk of cross-contamination. As a result, strict segregation and control of the wash area are required to maintain hygiene standards.
In addition to the challenges associated with manual cleaning, the facility also relies on staff to judge when a bin is ‘clean’ and to apply cleaning standards consistently. This introduces a level of subjectivity, which can lead to variability in hygiene outcomes.
This is where the use of a tote bin washer can quickly pay for itself in a short period of time, minimising utility usages, introducing a consistent level of cleanliness and speeding up the washing process.
Modern systems can incorporate a range of wash cycles to handle varying levels of contamination. These may include pre-wash stages, followed by detergent cleaning and a hot water final rinse. Depending on the machine design, different throughput rates can also be achieved to suit operational demands.
However, selecting the right equipment requires careful consideration, as different manufacturers use varying wash methods and technologies.
The following section outlines the typical cycles used within a cubicle-style washing system.
Pre-Wash
For heavily soiled tote bins, particularly those contaminated with sauces such as mayonnaise, a pre-wash cycle may be beneficial. This can be carried out using hot or cold water, depending on the type of residue.
Pre-wash water should be discharged directly to drain to prevent contamination of the main wash and maintain detergent effectiveness. The selected system should perform this stage efficiently, minimising water and energy use.
Detergent Wash
A detergent wash cycle (generally at 65°c/185°f) is used to jet the soils from the bin, and is re-circulated and filtered to remove debris from the solution, ensuring the detergent within the wash section maintains its effectiveness.
Various methods of filtration can be employed, including screen filters, filter drawers, or in the case of heavy solid soiling, automatic belt or rotary screen filters.
Final Rinse
A final rinse with fresh water is used to remove any remaining detergent residues before the bins exit the machine. This can be supplied at ambient temperature or heated, depending on requirements. Heated rinse water may be recirculated to reduce consumption and can also promote “flash drying” as bins leave the system.
If required, an additional sanitising or disinfecting stage can follow to enhance hygiene control.
Regardless of the process configuration, the system should operate as efficiently as possible, minimising water and energy use. While many machines offer similar cleaning stages, manufacturers differ in how they deliver the jetting and cleaning process, as outlined below.
Jetting and Cleaning Processes
Internal Spray Ball / Jetting Array
This method uses pump pressure to rotate a spray ball or jetting manifold inside the bin, directing water across internal surfaces to remove debris. Larger droplets provide greater impact than fan sprays, improving cleaning over distance.
However, full surface coverage can take time, increasing wash duration, and the method may be less effective on products such as cut vegetables that adhere to surfaces. Higher flow rates are also required to achieve adequate internal and external cleaning, which can increase pump size, energy use, and operating costs.
Rotating components are prone to debris build-up, which can restrict movement and cause jet failure. As reliable rotation is essential, fine filtration is typically required; otherwise, increased maintenance, more frequent tank cleaning, and potential downtime may result.
Conventional Fan Jets
Conventional fan jets used with fixed or oscillating spray bars can be effective for bin cleaning, but they have limitations. While external jets can be positioned close to surfaces, internal jets must operate from a distance (typically around 750 mm), reducing impact due to atomisation. Narrow-angle jets can improve impact but require higher flow rates to maintain adequate coverage. In addition, flat fan sprays may provide limited contact time on the front and rear internal faces unless cone-pattern nozzles are used.
Quick-release nozzles can help reduce cleaning downtime. However, plastic-bodied versions may become misaligned during maintenance, so stainless steel quick-release nozzles are generally preferred for reliability.
Motorised Jetting Arm
A motorised rotary manifold can reduce the number of jets required, lower pumping energy, and shorten wash cycle times.
In this method, the bin is inverted over a rotating arm fitted with flat fan jets, which clean the internal surfaces while additional jets simultaneously clean the exterior and wheels. Positioning the jets closer to the surfaces improves effectiveness, with the flat fan spray creating a “wiping” action on soiled areas.
The system can also be designed so the same pipework and spray head are used for both wash and rinse cycles, aiding pipework flushing and allowing a single pump—particularly for heated rinse—to be used. This results in a more compact, efficient system that reduces cycle times and utility consumption, making it a more cost-effective solution for the business.
Overview
There are multiple approaches to achieving effective bin cleaning, with different manufacturers justifying their chosen methods. While each system can deliver the required results, there are notable differences in utility consumption and processing speeds.
At Unitech Washing Systems, our tote and bulk bin washers use a motorised jetting arm system. This approach enables shorter cycle times, reduced utility usage, and consistent, high-quality cleaning. Stainless steel jets maximise efficiency, while features such as quick-release nozzles, hygienic pipework, and manifold flushing points help minimise cleaning and maintenance time.
In addition to cubicle systems, in-line solutions are also available for higher throughput applications, incorporating the same stages, including pre-wash, wash, and rinse.
For more information on tote bin washing or our extensive range of wash equipment, please visit the products page on our website.