What Kind of Equipment is Needed for Washdown Areas?

Industrial washdown is prevalent in food processing, pharmaceutical, and other sanitary industries where components need to be cleaned on an ongoing basis with a combination of pressurized water and chemicals. Those are harsh environments in which standard office-grade computers or displays will die.  

Electronics that aren’t sealed may let moisture, chemicals, and dust in, leading to short circuits and corrosion. On the other hand, washdown-ready computer products are necessary to meet demand for reliability and cleanliness.  

This article discusses the most important types of computing equipment for a washdown area, including industrial PCs, HMIs, displays, and protective enclosures, and what certifications, construction materials, and design features make them suitable for these conditions.

Understanding Washdown Environments and Challenges

In industrial washdown procedures, machinery and surfaces are thoroughly cleaned with high-pressure sprays of hot water and cleaning chemicals. These washdowns are necessary for hygiene but very challenging for electronics.

Every day, water, cleaners, as well as airborne particles such as dirt can seep into electronic components causing short circuits, component failure and lost production time. Equipment used in these settings needs to be able to endure regular high-pressure washings without harm.

Regulatory and safety requirements also drive the need for washdown-capable equipment. For example, food and beverage plants are required to adhere to particularly stringent cleaning standards to satisfy need for regulations and avoid contamination.

Typically, any PC’s or operator interfaces on the production floor are not conducive to removal during a clean as is the washdown process must be capable of withstanding. Choosing the appropriate equipment with adequate protection features means that cleaning can be carried out effectively without fear of damage or injury.

Industrial PCs for Washdown Areas

Industrial PCs are the heart of many control systems and data applications in washdown environments. Unlike consumer PCs, industrial models are purpose-built with rugged enclosures, aseptic designs and components to handle extreme conditions like moisture, temperature fluctuations, and vibration.

In washdown areas you’ll generally find industrial PCs in the form factor of a panel PC (computer and touchscreen in a combined unit) or an embedded box PC contained inside a protective case.

Key features of industrial PCs for washdown areas include:

• Aseptic Waterproof designs, dustproof enclosures: These PCs are commonly sealed to IP65 or IP66 standards. Many stainless-steel industrial computers have even been assigned IP69K ratings, which means that they are able to handle a high-pressure, high temperature washdown without water getting inside.
• High-grade stainless-steel construction: Industrial PCs deployed in open food/pharma environments are typically constructed with stainless steel enclosures (often 316 stainless) to protect against corrosion and maintain hygiene levels. Stainless steel will not rust and tolerates corrosive cleaning chemicals, unlike standard PC cases.
• Sealed cooling and connectors: Most washdown-duty PCs employ fanless cooling concepts and sealed cable glands or waterproof connectors to keep the integrity of the enclosure.
• Mounting flexibility: Industrial PCs can be mounted flush in control panels, walls, or on pedestals, with non-corroding mounting hardware.

Companies can benefit from the advantage of being able to put computing power right on the production floor without worrying about water harming the sensitive electronics when employing industrial PCs with these attributes.

HMIs and Industrial Displays for Washdown

Human-Machine Interface panels and industrial displays are the front-line devices that operators use to interact with control systems in washdown areas. They include touchscreen panels, indicators and big digital display for process visualization. For wet and clean conditions, HMIs and displays must meet similar durability and cleanliness requirements:

• Waterproof front panels and enclosures with at least IP65 or IP66 ratings. Fully enclosed stainless steel models can achieve IP69K ratings.
• NEMA 4X certified designs for corrosion resistance and ingress protection.
• Hygienic, easy-to-clean design that uses flush, seamless touchscreens and sloped surfaces to prevent water from pooling.
• Readability and operability in harsh conditions, including high brightness / glove capable touch screens.

By deploying washdown-rated HMIs and displays, facilities can provide plant-floor operators with real-time control and access to equipment data without concerns of equipment damage.

Washdown Enclosures: Panel-Mounted vs. Stand-Alone

In many cases, the most practical way to use standard computing hardware in a washdown area is to protect it with a washdown-rated enclosure. These are cabinets, most often made of stainless steel, designed to protect PCs, monitors, printers, and other equipment.

• Panel-Mounted Enclosures: Installed directly into control panels or machine enclosures with gasketed seals for a flush, waterproof finish.
• Stand-Alone Enclosures: Floor-standing workstations or wall-mounted cabinets with sealed doors and accessories like waterproof keyboards and pointing devices.
• Shared Features: Typically 316 stainless steel, waterproof seals, NEMA 4X/IP66 ratings, and thermal management.

Enclosures provide flexibility by allowing companies to implement the computing device of their choice into a portable or protective cabinet, thereby extending the life of cable equipment, while making service easier.

Ingress Protection (IP) and NEMA Ratings Explained

When choosing computers to run in washdown locations, it is important to consider ratings of environmental resistance:

• IP65: Dust-tight, protected against low-pressure water jets.
• IP66: Dust-tight, protected against powerful water jets.
• IP69K: Highest protection, withstands high-pressure, high-temperature cleaning.
• NEMA 4: Waterproof/dustproof, protects against hose-directed water and rain.
• NEMA 4X: Same as NEMA 4 with added corrosion resistance.

Devices to be used for daily high-pressure cleaning should be NEMA 4X or IP69K rated.

Material and Design Considerations

• Stainless Steel Construction: 304 or 316 stainless steel for corrosion resistance and hygiene. 316 is preferred for food and pharmaceutical settings.
• Hygienic Design: Rounded edges, canted surfaces, fully welded corners and food-grade gaskets for cleanability.
• Shatterproof Viewports: Polycarbonate or tempered glass to eliminate debris from broken glass.
• Climate Control: Built-in Fans, Heaters or Coolers sealed enclosure for temperature and  condensation control.

Operational Benefits of Washdown-Ready Equipment

• Reduced Downtime: Equipment can stay operational during washdowns, avoiding stoppages.
• Compliance and Hygiene: Washdown-ready devices meet sanitation regulations and avoid contamination risks.
• Worker Safety: Fully enclosed, grounded equipment reduces electrical hazards and allows safe operation with gloves.
• Cost Savings: Higher upfront investment pays off with longer lifespan and fewer failures.
• Productivity: Operators access computing power directly on the floor, speeding decision-making.

Conclusion

Equipping an industrial washdown area with the right computing hardware is vital. Industries essentials such as industrial PCs, washdown safe HMIs and hardwearing Enclosures. Look for IP66/IP69K and NEMA 4X ratings, as well as stainless steel and hygienic design. Washdown-capable equipment increases uptime and keeps you safe, compliant, and operating efficiently long into the future.