Arcus

Case Study: VASA Automated Barrel Cleaning System

Client: Global Pharmaceutical Manufacturer, England, United Kingdom

Industry: Pharmaceutical

Summary: Bespoke VASA system cuts total cleaning time by 48%, halves detergent consumption and doubles peak daily capacity

1.   The Challenge

A global pharmaceutical manufacturer required a safer, faster and more consistent method of cleaning reusable production containers ranging from 45 to 200 litres.

The existing manual process was labour-intensive, required two technicians for larger containers and was struggling to keep pace during periods of peak demand. It involved manually filling each container with hot water and detergent, allowing it to soak, pumping out the solution, rinsing the container and transferring it for drying.

The process presented several operational challenges:

·         Total cleaning and drying time of approximately 145 minutes per barrel

·         Two technicians required to handle larger containers

·         Significant lifting and manual handling above waist height

·         Containers occupying floor space while soaking

·         A single pump creating a bottleneck

·         High detergent consumption, particularly for larger barrels

·         Regular overflow of cleaning work into the following day

The department typically cleaned eight containers per day, increasing to approximately ten during peak periods. This was not always sufficient to meet manufacturing demand.

2.   The Arcus Solution

Arcus developed a bespoke automated washing system capable of processing containers between 45 and 200 litres.

The system cleans each barrel in an inverted position, allowing water and detergent to drain naturally and removing the need for a separate pumping stage.

An integral tipping mechanism enables larger barrels to be loaded and positioned without operators lifting them above waist height.

The system also automates the main washing, dosing and draining stages, creating a more controlled and repeatable process while reducing direct chemical handling.

The soaking stage was eliminated completely.

3.   The Results

·         A 48% reduction in total cleaning time: The total time required to take a barrel from unclean to ready for reuse was reduced from approximately 145 minutes to 75 minutes. The washing stage for the largest containers was reduced from approximately 74 minutes to 18 minutes.

·         Peak daily capacity doubled: The previous manual process cleaned approximately 8 containers per day during normal demand and 10 containers per day during peak demand. Following automation, this increased to approximately 14 containers per day during normal demand and 20 containers per day during peak demand. This provided the client with greater capacity during busy production periods and significantly reduced the likelihood of unclean containers carrying over into the following day.

·         Approximately 50% lower detergent use: The previous process used different quantities of detergent depending on container size. Larger 120–200 litre barrels could require between 1.2 and 2 litres per wash. The automated system uses approximately 0.9 litres per cycle, irrespective of container size. This delivered an estimated 50% reduction in annual detergent consumption and cost. It also reduced the storage, handling and operator exposure associated with the detergent, which is classified as a skin and eye irritant.

·         Reduced labour requirement: The manual process required a minimum of two technicians to lift and position larger containers. The VASA system can be operated by one technician, with a second person only required in limited circumstances when positioning larger containers on the drying rack.

·         Improved operator safety: The integral tipping system reduced the need to lift and manoeuvre heavy barrels above waist height. Automated dosing, washing and draining also reduced manual contact with detergent and made the overall process less physically demanding.

·         More effective use of floor space: Containers no longer need to be filled and left soaking around the cleaning area. Instead, barrels can be processed sequentially through the washer, reducing congestion and improving the use of available space.

Performance and continuous improvement:

The client continued to assess the washer after installation using overall equipment efficiency measurements.

Between October 2025 and February 2026:

•          Availability increased from approximately 82% to 92%

•          Quality increased from approximately 93% to 100%

•          Overall OEE increased from approximately 58% to 65%

The system was still not operating at its full available capacity, demonstrating further potential for increased throughput as operator training and process optimisation continued.

Potential future enhancements include:

•          Expanding the system to clean smaller 15 and 25 litre containers

•          Increasing machine utilisation across the working day

4.   Conclusion

The Arcus VASA Automated Barrel Cleaning System helped a global pharmaceutical manufacturer address a key production bottleneck by replacing a labour-intensive manual process with a controlled, automated cleaning operation.

The project reduced total cleaning and drying time by 48%, doubled peak daily throughput and reduced detergent consumption by an estimated 50%. Its integrated tipping mechanism and automated washing and draining stages also reduced manual handling and the need for direct operator contact with cleaning chemicals.

Continued performance monitoring showed further improvements in availability, quality and overall equipment effectiveness, with additional opportunities identified through operator training and process optimisation.

5.   Contact Us

Arcus Cleaning Systems designs bespoke container cleaning solutions around container sizes, process requirements and production demands. Contact our team to discuss your cleaning challenges and explore a suitable solution:

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