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Automatic Carwashing in Pakistan

For Inquires call 0314-8483247 or contact muhammadzaman@msn.com

Cars

have become the essential part of human life. People enjoy driving cars. They enjoy more when the car they drive is clean and shiny. Even the owners of public transport (Buses, Taxis, Wagons and Pickup Suzukies) realize that they make more money when they offer clean vehicles to their customers. 2. In Pakistan the car revolution came in early 90s when the banks started financing cars. Now there are more cars on roads of Pakistan then ever before. Almost one fourth of the population either owns a car or has access to use it. 3. Everywhere in developed countries the cars are washed in Automatic Carwashes. Unfortunately Pakistani people do not have the Automatic Carwashing available to them and they still go to hand wash service stations for washing of their cars. Usually the time required there is ONE to THREE hours. Wasting that much amount of time is really pinching. 4. Moreover, People dont like leaving their cars in hands of attendants of service stations for three reasons. The drivers at service stations are not well trained. Two the belongings left in car are stolen. Third most dangerous is that some attendants of service station are aligned with the car lifters and allow them make the duplicate keys of cars left for washing. These cars are subsequently stolen.

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Mission.
Manufacture automatic carwashing equipment and accessories in Pakistan.

Trends
People cannot stick to the old hand wash systems and sooner or later they have to adopt Automatic Carwashing. Money is not a big consideration for people, but time is. If they can buy a car, they certainly can afford its washing. Fact of the mater is that people are waiting eagerly for some one to introduce Automatic Carwashing in Pakistan. If we dont do that someone else will do it and we will be left behind. Our is a nation of styles. Any new style has all the chances of success amongst our people. May it be a new restaurant, a car colour, a dress design, or a drive through carwash where young driver has the facility to keep sitting in while his car is being washed?

Past Experiments in Pakistan

Two automatic carwashes have been reported working in the past One in Islamabad and other in Lahore. Both were closed with in a short period of time, not due to lack of income but due to following reasons: The equipment was imported from abroad at high cost. The operating cost was also heavy. Spare parts have to be imported at heavy cost. Everything was motorized causing too much consumption of electricity. The operating staff was not well trained. The plant was imported and no local mechanic could carry out even minor repairs. Presently one plant is installed in Islamabad but that is out of action due to non availability of minor spare parts like a sensor. We are going to keep in mind all points which caused failure to these experiments.

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PLAN

We have a plan to establish a Mechanical Workshop where automatic carwashing equipment will be manufactured. The work shop will be located on a one acre plot in Rawat Industrial Area (Near Rawalpindi). The workshop will have all necessary machines and plants and enough space for display and testing of equipment manufactured. We are manufacture the carwashing equipment which will be environments friendly and befitting with our economic and electrical conditions. Carwashing Equipment manufactured, will be combination of manual and electric operations. The aim is to reduce the consumption of electricity thus lowering the operating cost. We will also train a large number of mechanics to help our future customers to maintain their business at low cost. We also aim at manufacturing the all needs of carwashing industries like chemicals required and spare parts. At a later stage we intend manufacturing washing equipments for big vehicles like buses, trucks, construction machinery and industrial machines.

Management and Work Team

Muhammad Azhar Zaman has worked in a plant like this in USA and has full knowledge of the mechanics of carwashing equipments. He is going to be the director of the project. Mr. Faizan Akbar is electrical engineer presently working in an Oil refinery in Karachi. He has the vast knowledge of electronics. He is fully capable of linking mechanics with electronics. Mr. Muhammad Aslam and Mr. Iqbal Beg have more than 20 years of experience of running mechanical workshops. We all have very strong belief in the success potential of the products. We are enthusiastic and eager to work together on the project. Other Necessary staff will be hired accordingly.

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Market and Customers


Carwash is an essential service like Barber shop, Tailors shop and laundry shop. People are certainly willing to pay for it. If they can buy a car they can pay for its washing. Presently only conventional carwashing service is available but sooner or later it has to be substituted with automatic carwashes. We have seen this happening in case of other industries like wheat threshers and tractors in agricultural industry. Construction and Excavating Machines, Computer documenting, ATM Banking, Electronics laundries, Electronics dispensers on Petrol Pumps and CNG stations Electronics scales and everything else. A number of potential owners of the carwashing business were contacted in resent past. They are impressed by the idea and are showing interest in the business. But almost none of them have seen the system and they would like to see the demonstration before they decide to purchase. It is expected that if they are satisfied with the system they will purchase. At the moment no city in Pakistan has the automatic Carwashing but when we introduce all cities will have as is true in western countries. In fact we are expecting that all the existing hand carwashes will switch over to automatic Carwashing.

Financial Plan

To start such a big manufacturing plant requires a large amount which is not available to us. We have therefore, decided to follow the pattern of emergence of wheat threshers in Pakistan. They are being manufactured by small workshops in every town. To establish a new workshop of that nature requires approximately Rupees 1 Million. The Complete equipment for the first Carwash will be ready for Rupees 1 to 1.5 Million. After manufacturing and installing first carwash in Rawalpindi the marketing will start and potential investors or purchaser will be asked to deposit the amount in advance. This is exactly the pattern followed by the Wheat Thresher Manufacturers.

Rupees 1.5 Million is Must for the start of this business


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HOW Carwashes WORK


Car washes fall into five categories
1. Self service- An open bay is typically used in these systems. Self-service systems have a pressure sprayer, and a foaming brush, that is connected to a large central pump. The sprayer has a coin-operated dial system to select the option you want, such as "soap," "rinse" and "wax." A timer shuts the water off after a certain period of time, at which point you must put in more coins if you want more water. 2. Exterior rollover - A system that is growing in popularity, exterior rollover car washes are automated systems where you drive your car inside the bay. Once your car is in the correct position, a signal informs you to stop. At that point, the car-wash equipment moves over your car on a track, performing a specific function, such as applying soap or rinsing, with each pass. It may or may not perform drying. Exterior rollover systems are very common at gas stations, where the price is often discounted or free coupon given in conjunction with buying a tank of gas. This system requires less space and usually no attendant is required. 3. Exterior only in Tunnel. This automated system is popular because of very less time is required and low price. People prefer using it when their cars do not require interior cleaning. You drive your car into the entrance of a long, tunnel-like bay. The front tire, usually on the driver's side, is positioned on a special conveyor belt, and you put the car in neutral. The conveyor belt guides the car through the bay, where the car goes past several pieces of equipment, each with a specific purpose of cleaning process.

People washing their cars at a Self Service Carwash

A Rollover Exterior washing Plant

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4. Full service - A modification of the exterioronly system, full service uses the same conveyorbelt-based automated system. The difference is that the interior is manually cleaned by attendants, and some exterior services, such as hand-drying and wheel-cleaning, are available. 5. Detail shop A detail shop may hand wash or use an automated system to wash the car. Then, attendants completely clean and polish the car, normally applying wax and using a tool called a buffer to remove the wax and polish the car. Detail shops are often able to remove dull paint and small scratches, steam clean carpets and seats, brighten chrome, remove tar and perform a variety of other services.

Vacuum Cleaning Shed Out side a Carwash

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PROCEDURE
Car washes are normally either touchless or cloth friction wash. Touchless car wash relies on high-powered jets of water and strong detergents to clean the car. Only water and cleaning solutions actually come in physical contact with the car. Cloth friction wash systems use soft cloth that is moved around against the surface of the car. The system that we will discuss uses cloth friction wash technology, but quite a few of the same components are used in touchless car washes.

Drive In
First, the car is placed on the conveyor track. At the beginning of the conveyor is a device called correlator. This is simply a series of wheels or rollers that allow the wheel of the car to slide sideways until it is aligned with the conveyor.

Figure 1

Conveyor Track with Guide rail and Correlator.

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Pushing Rollers

The car is turned off and placed in neutral. Most conveyor systems have small rollers that pop up behind the wheel once it is on the conveyor. The roller pushes the wheel forward, causing the car to roll along through the tunnel, which is the term used to describe the long bay used for exterior-only and fullservice systems. There are two standard types of conveyor systems: * Front-wheel pull (FWP) - Engages the front left wheel * Rear-wheel push (RWP) - Engages the rear left wheel

Figure 2

Rollers

This car wash uses RWP to pull the car along the conveyor system. Infrared Eye
Once the car enters the tunnel, it passes through an infrared beam between two sensors, called eyes.

Figure 3

Infrared Beam Eyes

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The eye on one side emits infrared light that is picked up by the eye on the other side. As soon as the beam is interrupted, the eyes send a signal to the digital control system (DCS), the computer that runs the automated portion of the car wash. By measuring the amount of time that the signal is interrupted, the DCS determines the length of the vehicle and adjusts the system accordingly.

In this photo, you can see the tire applicators, the mitter curtain and part of the pre-soak arch.

Pre Soak
Immediately after the eyes, most car washes have a pre-soak. This is an arch that contains several small nozzles that spray a special solution all over the car. This solution does a couple of things: Wets the car down before the application of any detergents Begins to loosen the dirt on surface of the car.

A lot of car washes also have a set of nozzles arranged near the ground that are called tire applicators. These nozzles spray the tires with a solution designed specifically for removing brake dust and brightening the black rubber of the tire.

Mitters
Mitters are series of long, soft strips of cloth that hang from a frame near the top of the tunnel. The frame is connected to a motorized shaft that moves the frame up and down in a circular pattern. This makes the cloth strips rub back and forth or side to side across the horizontal surfaces of the car.

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Front to Back Mitters

Side to Side Mitters

Front to Back Mitters

Side to Side Mitters

The mitter curtain cleans the hood, roof and trunk of the car by swishing back and forth or side to side over the surface.

Top Brushes

Car washes usually have top brushes and Mitters for the cleaning of horizontal surface of vehicles. Rollover plants use top brush only. Full service tunnel carwashes use mitters or combination with top brushes. The top brush is attached with a sensor which adjusts its upward or downward movement with the contour of the vehicle while it is in spin.

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Foaming

The next item in our car wash is the foam applicator. The foam applicator applies a detergent to the car that becomes a deep-cleaning foam on contact.

The nozzles on the foam applicator, as well as most other spray systems in a car wash, can be adjusted to change the angle of the spray and the size of the

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opening. The foam is created by mixing a chemical cleaner, which varies between car washes, with water and air. There are usually separate adjustment controls for determining the exact mix of the three components. The chemical typically contains some coloring agent to make the foam more eye-pleasing and obvious.

Scrubbers

Scrubbers are large vertical cylinder like brushes with hundreds of small cloth strips. The scrubbers rotate rapidly, anywhere from 100 to 500 rpm, spinning the cloth strips until they are perpendicular to its axel. Although the cloth strips are quite soft, it would feel like a whip if you got hit by them. Scrubbers normally have hydraulic motors that spin them. There is at least one scrubber on each side, and there may be two or more. As the car moves past the scrubbers, the cloth strips brush along the vertical surfaces of the car.

Figure 4

Scrubbers or Side Brushes

Some car washes also have wrap-around washers. These are scrubbers on short booms that can move around to the front and rear of the vehicle, scrubbing those vertical surfaces as well.
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Figure 5

Wrap-around washers clean the front and back of the car

Like most of the mechanical equipment in the car wash, the washers are run by a combination of electric motors and hydraulics. Normally, a single, large hydraulic power unit is connected to all of the various hydraulic pumps throughout the car wash. The cloth used in the scrubbers is very soft and regularly cleaned to ensure that there is nothing caught up in them that could scratch the cars. They are replaced once they become worn or too soiled to clean effectively. The scrubbers remove the dirt that the foam and pre-soak has loosened up. In addition to the mitter curtain and scrubbers, a lot of car washes have a high-pressure washer.

Blast

The high-pressure washer is a system of rotating water jets that spray concentrated streams of water onto the car. The nozzles of water jet are typically arranged like a pinwheel, with each nozzle angled slightly away from the center.

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The force of the water shooting from the nozzles causes the water jet to spin rapidly. This means that the stream of water moves in a circular pattern as it hits the car. The strength of the stream and the circular motion combine to provide a powerful scrubbing action on the surface of the car. The force of the water is incredible, with some systems rated at 1,000 pounds per square inch (psi), enough to easily knock a person off his or her feet! The powerful water jets remove most of the detergent and grime from the car. High-pressure systems use a lot of water -- perhaps 300 to 400 gallons (1,100 to 1,500 liters) per car. In order to pro The pressure tank for a high-pressure washer A lot of car washes, particularly those in areas where winter means lots of snow, have a device called an undercarriage wash applicator. This system is located at ground level and has several nozzles pointed upward to wash dirt, mud and salt from the bottom of the car. vide so much water in a rapid manner, a car wash usually has a special pressure tank nearby that holds the water for this specific system. In most systems, almost all of the water is recaptured and recycled back to the pressure tank after each use.

Rinse

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Next, the car goes through a rinse arch. This is a series of nozzles arranged on an arch that use clean water to remove whatever residue is left after the highpressure washer, scrubbers and mitter curtain have done their respective jobs.

In an average car wash, there are multiple rinse arches, usually after each major cleaning station. A typical car wash may have the following stations: 1. Pre-soak 2. Mitter curtain 3. Rinse arch 4. Foam applicator 5. Scrubbers 6. High-pressure washer 7. Undercarriage wash applicator 8. Rinse arch 9. Wax applicator 10. Mitter curtain 11. Scrubbers 12. Rinse arch 13. Dryer As you can see, the example above has three rinse arches. It also has two mitter curtains and two sets of scrubbers, which is also common in most installations. In fact, some car washes have even more of each type of station! Most car washes have two or more mitter curtains along the tunnel.

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The last rinse arch in the tunnel, aptly called the final rinse, should always use clean, non-recycled water to ensure that all residues is removed from the surface of the car.

Waxing

A standard feature of the car wash is the wax arch. The wax that is used in a car wash, which forms a water-resistant coating, is quite different from the wax you would apply by hand. One of the key differences is that car-wash wax is formulated to work on glass, chrome and rubber, as well as the painted plastic and metal surfaces of the car. Also, it leaves a clear, thin film that does not have to be polished first. However, car-wash wax does not provide the same level of protection, nor help to remove or cover up tiny scratches, as standard wax does.

The wax arch uses one of two methods to apply wax. The first type of wax arch uses a system of foam applicators, the most common being a triple-foam applicator, to apply a foam wax. The wax foam is applied to the car in a heavy coating. The second type uses nozzles, similar to those of the rinse arch, to apply a liquid wax. In this case, the next step is usually to go through a rinse arch. But when wax foam has been applied, the car usually goes through another set of scrubbers and another mitter curtain before going through a rinse arch.

Drying

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After the car is completely washed, the final step in the automated process is the dryer. Much like a giant hair dryer, the dryer in a car wash heats large amounts of air and forces it out through a series of nozzles. These heated blasts of air rapidly dry the surface of the car. The dryer has a large, flat, round section just before the nozzle opening. This section is called the silencer. Like a muffler or the silencer on a gun, the dryer's silencer deadens the noise created by the air being forced through the

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system.

A dryer in a full-service car wash does not completely dry the car because attendants will go over the car with towels once it leaves the tunnel. Some car washes apply a special chemical after the final rinse, before the dryer, that speeds up the drying process. The temperature and force of the dryer can be set. Most full-service car washes set the dryer lower than exterior-only car washes. This is because a full-service car wash usually has attendants who hand-dry the car with towels to remove all of the water.

Touch Up

As the car comes out of the tunnel, it is pushed off of the conveyor track. In an exterior-only system, you most likely remain in the car. When it comes out of the tunnel, you put it in park, start the engine and leave.

In a full-service car wash, an attendant drives the car over to the finishing station. Here, attendants clean the interior of the car, removing trash and vacuuming. They usually clean the windows wipe down the dashboard and doors, add some air freshener and hand-dry the exterior. They may also clean and polish the wheels and polish any chrome, depending on the service options available.
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The vacuum system at a car wash is a lot different from your typical home

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Vacuum

vacuum. It normally has a large central vacuum with multiple hoses connected to it. The hoses are usually either stretched overhead to each vacuuming station or buried underground.

COMMERCIAL VACUUM CLEANERS This vacuum is about 6 feet (1.8 m) tall and over 2 feet (0.6 m) in diameter. The air pump on this vacuum is very powerful, which is necessary to support all the hoses and handle the distance that each hose must cover. The Controls All of the equipment in an automated car wash requires a heavy-duty power source. Each station has its own fuse-protected circuit. Most car washes are designed so that the car wash can continue to operate even if one of the stations completely fails. The digital control system (DCS) is the brains of the car wash. The digital control system From the moment that the eye tells the DCS that a car has entered the system, the DCS controls every aspect of the car wash. It knows exactly where the car is at all times and turns on the appropriate stations as they are needed.

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