How Niagara Systems Built a Custom Washer for Nuclear Fuel Rods

The Challenge: Processing the Inside of a Nuclear Fuel Rod

Fuel rods are a cornerstone of nuclear reactors, so the stakes for manufacturing them couldn’t be higher. Even the slightest variation in their internal structure can compromise efficiency, safety, or regulatory compliance. For one prominent nuclear reactor supplier, internal machining of fuel rods had become a bottleneck. They needed a fully automated solution that could deliver unwavering precision while withstanding the highly corrosive chemicals used during processing.

This wasn’t a typical washing or machining application. The system had to accomplish three critical goals:

1. Ensure Even Internal Treatment: The inside of each fuel rod required uniform flushing to maintain structural consistency and support nuclear performance standards.
2. Operate with Micron-Level Precision: Internal diameters had to fall within extremely tight tolerances, demanding accurate, repeatable measurement tools integrated into the process.
3. Survive a Harsh Chemical Environment: The use of strong acids and aggressive cleaning agents ruled out many conventional materials and significantly narrowed the design window.

In short, traditional industrial automated washers couldn’t handle the job. This nuclear supplier needed a custom-built system to manage extreme accuracy and chemical exposure without compromising throughput or long-term reliability—a tall order by any standard, but well within Niagara’s capabilities.

The Solution: Precision, Anti-Corrosion, and Automation

Our team approached this challenge knowing we weren’t looking to retrofit or modify any of our existing washers—we needed a fully custom-engineered system designed from the ground up to meet the unique demands of nuclear fuel rod processing.

Precision at the Core: Internal Flushing + Ultrasonic Measurement

To achieve even internal treatment, our engineers developed a flushing system that ensured uniform chemical exposure throughout the internal cavity of each rod. This addressed the customer’s demand for consistency and minimized the risk of defects.

To meet strict tolerance requirements, ultrasonic measurement technology was integrated into the process. This advanced system continuously monitored internal diameters (ID) to micron-level accuracy, allowing real-time quality control and immediate detection of any out-of-spec dimensions.

Built for Harsh Chemistry: 316SS + Polypropylene Protection

Understanding the corrosive nature of the cleaning agents used, we selected 316 stainless steel (316SS) as the structural base—an alloy renowned for its superior corrosion resistance in aggressive environments. But we couldn’t stop there. To further insulate the system from chemical attack, the entire framework was encased in polypropylene, a chemically inert material that provides an added layer of durability and protection.

Integrated Expertise Across Disciplines

This solution wasn’t the product of a single specialty. It was the result of collaboration between our mechanical designers, controls engineers, and automation specialists. Because of this, we created a breakthrough in custom industrial washing machines: a fully automated, corrosion-resistant line with uncompromising accuracy, even in the most unforgiving conditions.

The Results: Long-Term Performance in a High-Stakes Environment

Once installed, our custom automation line quickly became a vital component in the customer’s nuclear fuel rod manufacturing process. Every rod produced now moves through this tailored system, ensuring that each one meets the exacting standards required for use in a nuclear reactor.

Uncompromising Quality Control

Thanks to the integration of ultrasonic measurement and uniform internal flushing, the system maintains consistent quality across every cycle. Tolerances are no longer a variable; they’re a guarantee. This level of control is essential in the nuclear industry, where even microscopic imperfections can lead to costly rework or regulatory non-compliance.

Reliable Operation in Harsh Conditions

Where conventional industrial automated washers might break down or degrade under prolonged exposure to corrosive chemicals, Niagara’s system thrives. The combination of 316 stainless steel and polypropylene cladding delivers exceptional resistance to corrosion and chemical wear, reducing maintenance needs and increasing operational uptime.

Efficiency Through Intelligent Automation

Beyond durability, the custom line enhances production throughput. By automating processes that were previously manual or inconsistent, Niagara’s solution reduces processing time, eliminates variability, and supports scalable fuel rod production, all while maintaining rigorous safety and quality standards.

This isn’t just a case of solving a problem; it’s an example of strategic innovation. The supplier now benefits from a streamlined, dependable process that empowers them to meet current demand and scale confidently for the future.