Design and Optimisation of Washing System for Demoulding Supports

Abstract

This thesis project was carried out at Geberit Production Oy in Tammisaari and focuses on the design and partial implementation of a new enclosed washing system for demoulding supports in SACMI ALS casting cells. The existing open washing method caused uncontrolled water splashes within the robot cell, posing safety, hygiene, and equipment risks. The goal was to improve containment, cleanliness, and integration with the automated environment. The project followed a practical engineering process: from analysing the current setup, conceptualising design improvements, selecting components, to building the physical structure in the workshop. The design incorporates an aluminium profile frame, sheet metal panels, an inclined drain pan, and a brush seal to allow robot arm movement without splash leakage. SolidWorks and the Item Engineeringtool were used to generate the technical documentation and order files. The construction was partially completed during the project timeline, with the frame and main components assembled in the workshop. Due to factory scheduling, final integration into the SACMI cell and functional testing will take place during summer maintenance. However, component-level testing and assembly evaluations were conducted and documented. The thesis concludes that the enclosed design and chosen components meet the functional requirements and allow future improvements. The project also demonstrated the importance of effective communication with suppliers and structured documentation. Once fully installed, the system is expected to improve overall functionality, including water control, cleanliness, operational efficiency, workplace safety and sustainability at Geberit Production Oy.