How to Minimize Downtime in Can Lines with Self-Cleaning Rinsers

Downtime is the enemy of every high-speed can line. Whether caused by mechanical failures, contamination issues, or slow changeovers, even a few minutes of unplanned stoppage can ripple into lost production, delayed shipments, and frustrated customers. In the beverage industry, where margins are tight and demand is high, keeping lines running is the most crucial of operational goals.

The Cost of Unplanned Downtime

Industry research estimates that a single hour of downtime on a beverage canning line can cost thousands of dollars in lost product, wasted labor, and recovery expenses. For high-volume producers running at 2,000 cans per minute, that translates to more than 100,000 cans of lost opportunity in just 60 minutes. Multiply that by the cascading effects on downstream processes like filling, labeling, and packaging, and the financial hit quickly compounds.

Beyond direct costs, downtime erodes trust with retailers and distributors who rely on consistent supply. A missed production target can jeopardize relationships with some of the most important players in the value chain.

Why Rinsers Are Critical to Uptime

Before every can is filled, it must be rinsed and cleared of dust, debris, or other contaminants. If rinsers are unreliable or difficult to clean, they often become bottlenecks that slow production. Traditional systems with pneumatic changeovers or exposed ion bars invite inefficiencies like stranded cans, dirty air recirculating back into the rinse, and time-consuming manual changeovers that keep operators tied up instead of keeping cans moving.

That’s why forward-thinking beverage companies are turning to self-cleaning rinser technology.

How Self-Cleaning Technology Safeguards Reliability

Entech Fabrications has engineered its Gatling Gun® rinsers with self-cleaning at the core. By integrating vacuum debris extraction and enclosed rinse zones, these systems prevent dust and contaminants from re-entering cans while constantly turning over the air inside the rinser house.

This design does two things exceptionally well:

• Keeps cans clean automatically. Ionized air streams neutralize static and remove particles before filling, while debris is actively extracted and removed from the line. Operators don’t have to stop and manually clear build-up.
• Protects uptime. With the ion bars fully shielded from debris, performance remains consistent. That means fewer unscheduled stoppages for maintenance or repairs.

Fast, Repeatable Tool-Free Changeovers

Downtime isn’t only unplanned. Planned, manual changeovers between can sizes can drain valuable hours from production schedules. Entech’s patented design eliminates removable parts and allows operators to switch can sizes in under four minutes, tool-free.

This not only saves time but also removes the risks of misplaced or damaged change parts. Every twist remains permanently mounted on the machine, ready for use. The result is repeatable, consistent changeovers that don’t depend on operator guesswork.

Speaking of operators. When you reduce operator touchpoints, you reduce human error and injury related to heavy lifting, manual adjustments, and handling of change parts. Entech’s self-cleaning rinsers are safer and simpler.

Proven Performance and ROI

Self-cleaning Entech rinsers are designed to run at 99% efficiency and support speeds of up to 2,000 cans per minute per lane. In customer installations, that reliability translates into measurable financial returns.

These benefits aren’t just theoretical. Beverage producers across North America are already seeing measurable gains by switching to self-cleaning, ionized air rinsers.

Real-World Proof: Case Study in California

A major California brewer recently converted from a water-based rinser to Entech’s ionized air system. The project replaced a four-lane water rinser running two active lanes at ~1,000 CPM per lane.

The results were immediate and measurable:

• 4 million gallons of water saved annually, aligning with the brewer’s sustainability goals.
• Zero failures in routine can inclusion tests, from cardboard dust and glass to string and toothpicks.
• Improved efficiency of 0.6%, even though no efficiency gains were originally anticipated.
• Better taste outcomes in blind trials, with lower TPO (Total Packaged Oxygen) contributing to longer shelf life and superior product quality.

Those gains mean more cans on the shelf, fewer maintenance headaches, and a stronger bottom line. In fact, many Entech customers see payback on their investment in as little as 72 days

Why Entech Fabrications?

With advanced self-cleaning design, patented tool-less changeovers, and a 99% uptime guarantee, our rinsers help can lines eliminate costly downtime and keep production flowing smoothly.Ready to protect your line from downtime? Schedule a call with Entech Fabrications today to learn more.