Beyond the labour cost, manual cleaning introduces avoidable quality and safety risks. Hand-cleaned parts rarely achieve the same standard every time, resulting in ink build-up, streaking, and preventable print defects. Repeated handling increases the chance of dropping and damaging expensive chambers and trays, while ongoing exposure to liquids and solvent fumes places unnecessary risk on operator health and site safety standards.
As job lengths shorten and demand for fast turnaround increases, these issues compound quickly. What once seemed manageable becomes a clear bottleneck.
In short, manual parts washing leads to:
Slower changeovers and reduced press utilisation
Greater risk of print defects from inconsistent cleaning
Higher maintenance and replacement costs due to part damage
Increased operator exposure to cleaning liquids and fumes
Skilled press staff tied up on cleaning instead of production work
Growing bottlenecks as run lengths shorten and speed expectations rise
An automated parts washer replaces manual scrubbing with a controlled, repeatable cleaning process. Instead of spending valuable time brushing and rinsing components by hand, operators simply load parts into the system, initiate the wash cycle, and return to press operation. The parts washer manages the full process producing consistently clean parts ready for immediate use.
This shift removes the variability and labour burden associated with manual washing and establishes a consistent, reliable baseline for cleaning performance. Crucially, it places skilled operators back where they deliver the most value: running presses and overseeing production quality, rather than performing cleaning work.
Once automation delivers reliable cleaning as a baseline, the next question becomes how to adapt the cleaning performance to different press parts, liquids, and production requirements. This is where modular systems and specialised washing technologies unlock a higher level of efficiency and control.
Trolley-based loading allows operators to work directly at the press, placing parts onto a dedicated grid before transporting them to the washing unit. The grid then slides directly into the wash chamber, meaning parts are only handled once. This not only removes unnecessary heavy lifting and movement across the pressroom floor, but also provides a clean, organised way to collect and transport components immediately after production.
Efficient handling across press sizes: Whether you are printing labels or wider formats, trolley systems can be scaled to suit the length and volume of parts in use. Larger chambers and trays can be managed with minimal physical strain, supporting safe lifting practices and helping operators maintain efficient, repeatable routines.
By integrating a trolley system into the cleaning workflow, pressrooms remove one of the most overlooked sources of lost time and operator fatigue: manual handling and parts logistics. The result is a safer, cleaner and more efficient production environment.
Buckets play an important role in flexographic production. Unlike flat components, buckets have curved surfaces, deep cavities and dried ink residues that are difficult and time-consuming to remove manually. Achieving consistent cleaning by hand is challenging, and soaking or scrubbing adds time, mess and operator exposure.
Rotating Nozzle Technology for Thorough Coverage: Flexo Wash Bucket Wash uses rotating nozzles designed to deliver 360-degree internal and external coverage. Buckets are positioned over the nozzles, which direct cleaning liquid into every surface area and recesses where ink tends to collect. This motion ensures complete and repeatable cleaning performance without the dead zones often seen in manual washing or standard static spray systems.
Flexible Capacity and Modular Integration: Bucket wash systems can be configured to handle multiple buckets per cycle, with capacity depending on machine size and wash area layout. Bucket washing can also be integrated alongside trays, chambers and other parts in the same machine, allowing pressrooms to consolidate their cleaning workflow into one automated system.
This modular flexibility ensures buckets and containers are cleaned to the same standard as other press parts, while reducing operator handling and contact with ink and cleaning liquids.
While trolleys optimise handling and rotating nozzles solve bucket cleaning challenges, the pump system creates the pressure and flow needed for thorough cleaning. Modern systems offer a choice of pump configurations depending on liquid type, safety requirements and production demands:
Pneumatic pumps are standard for ATEX-rated solvent systems, providing safe, reliable performance where spark prevention is essential.
Electrical pump options increase pressure and flow rates, reducing wash time and improving cleaning consistency, particularly valuable in high-volume operations or environments with demanding contamination levels.
High-capacity pump upgrades are available for large-format systems, delivering up to 600 L/min at 7 bar pressure for dual-level wash chambers and complex part geometries.
A key performance advantage lies in the use of moving nozzle arms. Rather than relying on static spray bars, the nozzle system moves throughout the wash cycle, directing cleaning liquid from multiple angles and ensuring complete coverage. Meaning that, compared to static nozzles, fewer moving nozzles are required. Resulting in less power and energy needed. This translates into significantly lower electricity bills.
This approach eliminates dead zones and produces more uniform, repeatable cleaning results.
The full benefit of automated cleaning in flexographic production is realised when each module functions as part of an integrated system. Instead of treating parts washing as a series of separate tasks, modern pressrooms use combined solutions that automate the entire cleaning process.
In a typical flexo packaging plant, an integrated configuration might include trolley-based loading for one-touch handling, rotating nozzle systems for buckets and inkcontainer cleaning, and a high-performance electrical pump set-up to ensure consistent pressure and faster wash cycles. Together, these elements create a complete, automated parts washing system designed specifically for the demands of flexographic printing.
This approach does more than clean parts. It standardises wash quality across shifts, reduces manual handling, and supports quicker press changeovers, key factors in today’s high-mix, short-run production environment. It also helps protect chambers, trays, and other critical components by eliminating the risks associated with manual transport and scrubbing
From an operational standpoint, integrated automated parts washing leads to:
Higher press uptime
Fewer production interruptions caused by cleaning-related issues
Reduction in maintenance spend on damaged parts
Many flexo printers quickly see payback on their investment by experiencing:
Reduced labour input
Improved press utilisation
Reliable, repeatable cleaning performance that supports consistent print quality
Every flexographic operation has its own mix of press equipment, part types, liquids and production schedules. For this reason, there is no single “standard” cleaning system that suits every pressroom. The most effective approach is to match the parts washer configuration to your operational needs.
Part Types and Cleaning Volume: High-volume facilities with a variety of chambers, trays, buckets and tools typically benefit from integrated systems that combine trolley handling, bucket washing and high-pressure pump technology. Smaller or more specialised lines may prioritise ergonomic handling or targeted cleaning modules for specific components.
Space and Layout: System footprint and access are key considerations. Machines are available in compact and large-format configurations, with flexible wash-area layouts to maximise capacity within your space.
Solvent or Water-Based Cleaning: If your workflow uses solvent liquids, ATEX-certified designs are essential to ensure safe and compliant operation. For water-based or alternative liquids, standard configurations deliver the same cleaning performance without the additional ATEX complexity.
Rather than supplying off-the-shelf units, systems are typically configured around your press requirements, part sizes, wash cycles and floor layout. This ensures the right balance of cleaning capacity, ergonomics and throughput for your production environment.
Model ranges such as the PK series - available in compact, XL and XXL formats, allow capacity to scale from narrow-web lines to large flexible-packaging facilities. Read more about the models in our brochures, which you can download here.
Manual parts washing may have been sufficient when print runs were longer and changeovers less frequent, but today’s flexographic production environment demands speed, consistency and operator safety. Automated systems not only remove the physical burden of scrubbing and handling components. They also create a controlled, repeatable cleaning process that supports stable print quality and higher press utilisation.
By integrating ergonomically designed trolley handling, dedicated bucket-cleaning capability and high-performance pump technology, modern parts washing systems provide a reliable and efficient cleaning workflow.
If you would like to discuss configuration options, ATEX considerations or expected return on investment based on your production volumes, our team is available to help.