A new tool developed through the HPC Innovation Center is helping improve tote cleaning operations at the 3M InSite location in Decatur, Alabama. 

Known as the tote cleaner, or “tote flipper,” the system was created after field employees raised concerns about the old cleaning process, which often required more than an hour, a four-person crew and high-pressure cleaning equipment.  

In the past, crews cleaned totes used for glue and resin products with 10,000 to 20,000 psi shotguns along with manual rinsing. The work was physically demanding and often put employees in awkward positions while working around high-pressure water.

What started as a typical manual job has evolved into a tool that increases production, efficiency and creates a more desirable job for our employees,” said Industrial Services SVP Frank Moll. “A lot of these ideas come from listening to employees in the field and finding ways to improve safety and efficiency.”  

The tote flipper allows crews to invert totes during cleaning, so remaining product drains naturally instead of collecting at the bottom. The updated process has helped improve efficiency while also reducing physical strain on employees.  

“Our 3M Insite team is able to process more totes per day than they ever were before, and the totes are being cleaned more consistently,” said Automation and Technology Engineer Christopher Huck, who led the design of the tote flipper.  

Additional benefits include:

  • Cleaning time reduced to as little as 20-45 minutes
  • Reduced demand on team resources, allowing crews to be utilized more effectively
  • Improved ergonomics by eliminating awkward body positioning
  • Reduced exposure to high-pressure water
  • Lower noise levels during operation

The tool was developed through collaboration between field employees and the Innovation Center team, and is now being used in daily operations. Teams have also started looking at other ways the equipment could be used beyond tote cleaning, including chemical cleaning, filter housing and small tank work.  

This has been an amazing addition to our operation,” said 3M Branch Manager Demarco Smith. “From an ergonomic standpoint, we’re in a much better place, and the process is just more efficient across the board