Process Control & Optimization Series: Process Control System

Control, monitor, and react to changes in your wash bath. 
–Jack Reinke

Q: Can the PCS run any chemistry?
A: Type III PCS must be calibrated to a specific product before use.  While most chemistries are controllable via sonic velocity, some are not.  With rare exception, all KYZEN cleaning products are calibrated for control by sonic velocity.  Cleaners from other suppliers must first be calibrated on a case-by-case basis to work with the Type III PCS.

Q: Can an upgrade from a Type II to a Type III PCS offer savings?
A: One customer carefully tracking use of chemistry with their PCS, upgraded from a Type II to a Type III and reported a drop in hourly chemical consumption by 0.14 gph. We believe because the sonic velocity sensor measures continuously, bulk additions of chemistry are no longer called out, conserving chemistry.  So, for that customer, based on their annual usage, that drop in hourly consumption saved them 400 gallons or $25,000/year in cleaning chemistry.

Q: What kind of routine maintenance is required for the PCS
A: While little daily maintenance is needed, a dedicated individual should be assigned responsibility and establish full command over the PCS.  Access into various levels of authority on the PCS is password protected to guard against frequent, arbitrary changes and adjustments in readings.  Flush out the float box after every 3 or 4 bath change-outs; check drum uptake stick, drum floats and quick connect fittings.  Refer to manual for complete operation and maintenance.

Q: How many KYZEN Process Control Systems are in the field today?
A: Between 200 – 250 units have been sold into the global marketplace since 1997, holding wash bath concentration tighter than + or – 1%, eliminating or dramatically reducing multiple operator functions and quickly paying for itself in savings created by enhanced, fully automated process control.