Optimization of Top Load Washing

Machine Pulsators

Author: Aadit Saha

Organisation: IFB Industries Ltd.

Washing machines have become an indispensable part of modern households, providing
an efficient and convenient way to clean clothes. Among the various types of washing
machines, top load models are particularly popular due to their ease of use, faster wash
cycles, and generally lower maintenance costs compared to front load models. A crucial
component in top load washing machines is the pulsator, which plays a significant role in
determining the machine's overall wash performance.

Role Of Pulsator

A washing machine pulsator is a component inside a top-loading washing machine that

helps to agitate the water and clothes during the wash cycle. It is designed to simulate
the motion of handwashing by creating a pulsating or spinning action. The pulsator is
typically located in the center of the washing machine drum. It consists of a disk or
cone-shaped device with ridges or fins that help to move the water and clothes around.
As the washing machine operates, the pulsator rotates in one direction and then quickly
reverses its rotation, creating a back-and-forth pulsating motion. This motion generates
turbulence in the water, which helps to dislodge dirt and stains from the clothes. The
pulsator's primary function is to provide a thorough and efficient cleaning action by
agitating the water and garments. It helps to distribute the detergent evenly, ensuring that
all clothes are exposed to the cleaning solution. The pulsator's motion also helps to
remove trapped dirt and debris from the fabric. (Amazon)

Pulsators come in various designs, each with unique characteristics aimed at optimizing
wash performance. Common designs include:

● Disc Pulsators: Flat, disc-shaped structure with fins or ridges

● Impeller Pulsators: Low-profile, cone-shaped design with multiple ridges
● Agitator Pulsators: Traditional vertical columns with large fins or vanes

Figure 1: Various Pulsator Designs existing in the market

Importance of Study

Different designs of pulsators—such as those with fins, discs, or impellers—offer varying

degrees of efficiency in generating this necessary water movement. The optimization of
pulsator designs can lead to significant improvements in wash performance, including
better cleaning efficiency, reduced fabric wear, and enhanced energy efficiency.

The optimization of pulsator designs is crucial for several reasons:

1. Cleaning Efficiency: An effective pulsator design ensures that clothes are

thoroughly cleaned by maximizing water agitation and detergent distribution. This
results in the removal of even the toughest stains and dirt particles.

2. Fabric Care: While aggressive water movement can improve cleaning

performance, it can also damage delicate fabrics. An optimized pulsator balances
cleaning power with gentleness, preserving the integrity of various types of fabrics.

3. Energy Efficiency: Efficient pulsators reduce the time and energy required for each
wash cycle. This not only lowers operational costs but also contributes to
environmental sustainability by reducing water and energy consumption.

4. Consumer Satisfaction: Enhanced wash performance and fabric care lead to

higher consumer satisfaction. As the demand for high-performance and
eco-friendly appliances grows, manufacturers must continuously improve their
pulsator designs to meet consumer expectations.

5. Functionality and Safety: The main purpose of the pulsator design is to prevent
small elements like coins or keys from entering and damaging the machine.

Problem Statement

This study aims to address the need for a comprehensive evaluation of pulsator designs
by comparing the wash performance of several top load washing machines from different
brands. By doing so, we seek to identify key design elements that contribute to superior
wash performance.

Key Objectives

● To compare the wash performance of top-load washers from various brands.

● To analyze the impact of different pulsator designs on wash performance.
● To identify key factors that influence the effectiveness of pulsators.
● To provide recommendations for optimizing pulsator designs to achieve better
wash performance.
Methodology
This study aims to address the need for a comprehensive evaluation of pulsator designs
by comparing the wash performance of several top load washing machines from different
brands. By doing so, we seek to identify key design elements that contribute to superior
wash performance.

Chosen Models

SAMSUNG WA10BG4546BD IFB TL801WR2S

IFB TL-S1RB 8.0KG AQUA IFB TL701WR2S

LG T80SJMB1Z
Comparison of Pulsators

SAMSUNG WA10BG4546BD IFB TL801WR2S

6 vanes 3 vanes
IFB TL-S1RB 8.0KG AQUA IFB TL701WR2S

5 vanes 3 vanes

LG T80SJMB1Z

6 vanes
Research Question

How does changing the number of vanes on the pulsator of a top load
washing machine affect the wash performance?

Collection of Data

To analyse the wash performance of each of the machines, I used data from the test lab.
Upon further inquiry, it was found that the lab follows strict testing procedure listed by the
IEC 60456.

IEC 60456 is an international standard that specifies methods for measuring the
performance of clothes washing machines for household use. It provides standardized
procedures for evaluating various aspects of washing machine performance, ensuring
consistency and comparability across different models and brands. The key performance
metrics defined in IEC 60456 include cleaning efficiency, energy and water consumption,
and fabric care.

Figure 2: The strips used to test the wash performance of the washers
Pages used from the IEC 60456 Handbook

The pages below describe the whole testing procedure in detail to calculate the wash
performance, as listed from the IEC Handbook.
Raw Data from R&D

IFB LG SAMSUNG

BEE pre TL-S1RB

TL801W TL701W TL LG WA10BG4
Model Qualification 8.0KG
R2S R2S T80SJMB1Z 546BD
criteria AQUA

Capacity (kg) 8 8 7 8 10

Number of vanes
5 3 3 6 6
on Pulsator

Wash
≥ 80% 92.24 89.29 87.94 97.12 84.88
performance (%)

Remaining
≤75% 64.18 65.67 65.16 68.88 55.62
moisture content

Rinse
≤2.25 1.55 1.42 1.59 0.75 1.33
performance

Water
consumption per ≤23
16.422 15.743 15.518 12.4 9.49
cycle L/kg/cycle
(L/kg/cycle)

Energy ≤ 0.0107
consumption kWh/kg/ 0.0081 0.0078 0.0082 0.0059 0.01
(kWh/kg/cycle) cycle for 5*

Processed Data

Number of vanes on Pulsator Wash performance (%)

5 92.24

3 89.29

3 87.94

6 97.12

6 84.88
Analysis and Conclusion

Figure 3: Graph representing the relationship between the number of vanes and wash
performance

Upon analysing this graph, it is visible that there exists a positive correlation between the
number of vanes and the wash performance of the top loader, as is shown by the line of
best fit with a positive gradient. This suggests that as the number of vanes on the
pulsator increases, the wash performance also improves. This could be attributed to a
number of reasons:

1. Enhanced Water Movement

Pulsators with more vanes create more turbulent water movement within the washing
drum. This increased turbulence results in:

● Better Agitation: More vanes generate a greater number of water currents and
swirls, leading to improved agitation of the laundry. This enhanced agitation helps
to dislodge dirt and stains more effectively from the fabric surfaces.

● Uniform Distribution: The increased number of vanes ensures a more uniform

distribution of water and detergent throughout the load. This uniformity helps in
achieving consistent cleaning results across all items in the wash.
2. Improved Detergent Dissolution and Distribution

The vanes on a pulsator play a critical role in dissolving and distributing detergent evenly.
With more vanes:

● Faster Dissolution: The increased agitation helps in dissolving the detergent more
quickly and thoroughly. This ensures that the detergent is fully utilized in the
cleaning process, enhancing its effectiveness.

● Even Coverage: The improved water movement ensures that the dissolved
detergent is evenly distributed, allowing it to reach and clean all parts of the fabric
uniformly.

3. Enhanced Stain Removal

Stain removal is a key aspect of wash performance. Pulsators with more vanes can:

● Increase Contact: The increased water movement generated by more vanes

increases the contact between water, detergent, and fabric. This heightened
contact improves the mechanical action needed to lift and remove stains from the
fabric fibers.

● Target Stubborn Stains: The enhanced turbulence can be particularly effective

against stubborn stains that require more vigorous agitation to be removed.

4. Balanced Fabric Care

While improved agitation is essential for cleaning, it is equally important to ensure that
fabrics are not damaged in the process. Pulsators with more vanes can achieve a balance
between cleaning efficiency and fabric care by:

● Controlled Movement: The design of multiple vanes can be optimized to create

effective agitation without excessive force. This controlled movement helps in
cleaning fabrics thoroughly while minimizing wear and tear.

● Gentle Handling: Some advanced pulsator designs with more vanes incorporate
features that gently handle fabrics, reducing the risk of damage to delicate items.

Thus, while designing and optimising the pulsator of a top loader, it is important to
take this into consideration and incorporate more vanes. However, the design must
ensure that the vanes are optimally shaped and positioned.
Extensions to Research

Since we focused on the affect of the number of vanes in this study, a possible extension
could be studying the impact of different shapes and sizes of vanes on wash performance
to identify the most effective designs.