December 28, 2016
Manufacturers of plastic products need effective cleaning solutions to keep their fabrication processes running efficiently. Molds used for creating the plastic shapes and tools used in finishing the plastic products require cleaning before the next production run. Harsh chemicals combined with manual or machine scrubbing can clean molds and tools but such cleaning is time-consuming and can damage tools and mold surfaces. Ultrasonic cleaning systems offer a solution that combines effective cleaning performance with ease of use. These systems can clean more completely, more rapidly and with a lower operating cost than traditional cleaning systems. Factors such as these make ultrasonic cleaning the preferred solution for the plastic manufacturing industry.
How Ultrasonic Cleaning Systems Work
When choosing a system, plastic manufacturers first have to select a tank big enough to hold their largest molds and tools. Ultrasonic transducers are then placed into or bolted onto the tank. An ultrasonic generator delivers high frequency electrical signals to the transducers, which convert them into sound waves that travel through the cleaning solution in the tank. These sound waves create tiny bubbles that act on the surfaces to be cleaned and remove contaminants and dirt. The scrubbing action of the bubbles is powerful enough to clean parts down to the original surface within ten or fifteen minutes. The process is safe, environmentally friendly and doesn’t damage molds and tools.
Choosing the Ultrasonic Frequency and Power
Ultrasonic cleaning systems typically operate at frequencies as low as 20 kHz and as high as 1.6 MHz. The highest frequencies deliver smaller bubbles and a gentle cleaning action suitable for delicate items such as microelectronics. The lower frequencies produce larger bubbles that clean with a strong and robust action. Because molds and tool parts are not delicate, the ultrasonic cleaners appropriate for plastic manufacturing operate between 20 kHz and 40 kHz. These systems deliver powerful cleaning without affecting the surfaces of the molds and tools to be cleaned. If a manufacturer has to clean delicate parts, multi-frequency systems with optional higher frequencies are available.
While the ultrasonic frequency determines the strength of the cleaning action of the bubbles, the number of bubbles is determined by the power of the ultrasonic system. Large tanks may need several transducers for optimal cleaning power that can reach several thousand watts. Suppliers of ultrasonic cleaning systems can suggest configurations for existing tanks or turnkey systems including the cleaning tanks for use in plastic manufacturing applications.
Advantages and Benefits
Ultrasonic cleaning systems have a number of advantages over traditional methods of cleaning molds and tools and they deliver several benefits:
- Completely non-abrasive when the frequency is matched to the cleaning application.
- Quiet operation at frequencies over 30 kHz.
- Leaves no contamination or residue.
- Uses no hazardous chemicals.
- Does not need continuous monitoring or supervision.
- Cleans well inside holes and crevices.
- Completely safe and environmentally friendly.
Plastic manufacturers can use ultrasonic cleaning systems to reduce manpower via a higher degree of automatic control and monitoring and they can reduce operating costs by reducing the use of cleaning chemicals.
Kaijo’s Ultrasonic Cleaning System Solution
Kaijo ultrasonic cleaning systems combine advanced technology with ease of use and low cost of ownership. Kaijo offers a complete range of both turnkey ultrasonic systems and ultrasonic system components as well as advice on how to install such systems in a plastic manufacturing environment. The company can make sure that their systems improve mold and tool cleaning efficiency and help reduce costs while increasing productivity. If you would like a free quote or consultation or want to learn how ultrasonic cleaning technology can be used for your cleaning applications call Kaijo or email [email protected].Read More
December 15, 2016
Ultrasonic cleaners use high-frequency sound waves to remove grease and grime from metal and plastic parts without affecting the surfaces of the parts to be cleaned. Effective and fast cleaning action is important in the automotive industry where used parts are often covered in grease, deposits or contaminants that have to be removed. Cleaning such parts with ultrasound avoids the use of aggressive chemicals and mechanical scrubbing that can cause damage. Instead, parts are placed in a bath with mild solvents and come out clean ten to fifteen minutes later. Ultrasonic cleaners are especially useful for shops and facilities restoring classic cars and for machine shops dealing in used engine parts.
Ultrasonic Cleaners Solve Problems with Traditional Cleaning
Automotive parts operate in close contact with oil, gas or diesel and at high temperatures. As a result, parts are greasy with baked on crusts of oil and carbon residue. Traditionally, parts are soaked in baths with chemicals such as acetone or other harsh solvents and scrubbed mechanically or by hand with wire brushes. Such cleaning methods take a lot of time and are often not completely effective.
The scrubbing, if robust enough to remove tough dirt, can damage the surface of the parts, the seals or the parts themselves. Wire brushes may scratch metal and softer material or remove protective layers on specialized components. Small parts can be hard to hold and difficult to clean.
Many automotive parts have complicated shapes, holes, pits and crevices that can’t be reached with mechanical brushing. Even for relatively smooth shapes, high ridges may get more scrubbing action than grooves and contaminants can hide where they can’t be seen and affect later performance.
Ultrasonic cleaners can solve all these challenging problems. The ultrasonic signal generated in the cleaning bath creates millions of tiny bubbles that produce an intensive scrubbing action everywhere the cleaning bath solution can penetrate. They dislodge all grease and grime throughout the bath and work within ten or fifteen minutes to dislodge dirt down to the original surface.
While the cleaning action of the bubbles is intensive enough to remove dirt quickly, it will not damage metal surfaces. If there is some pitting on softer material, the system can be changed to operate at a higher frequency for that specific cleaning application. A higher frequency produces smaller bubbles that clean more gently.
As a result, ultrasonic cleaners can clean more quickly and thoroughly than traditional cleaning methods. The bubbles treat all surfaces the same and they can get into holes and grooves without a problem. The frequency of the ultrasonic cleaners can also be adjusted to get the cleaning intensity needed for a particular application and, when matched properly to the material to be cleaned, the bubbles never cause any damage to the part surfaces or the automotive parts themselves.
Kaijo Can Meet Automotive Cleaning Needs
Kaijo’s ultrasonic cleaners are available in a wide range of frequencies that can be used for all automotive cleaning applications. Kaijo offers turnkey ultrasonic systems that are complete with a cleaning tank and ready to go, as well as ultrasonic cleaners that can be retrofitted on existing systems or added to existing cleaning tanks. The ultrasonic cleaners deliver reliable and consistent cleaning action that allows automotive shops and restoration facilities to save time on cleaning and money on reduced chemical use. In addition, Kaijo can supply ultrasonic cleaners to meet a customer’s requirements or advise customers on the ultrasonic cleaner best suited to their application. If you would like a free consultation or advice on using an ultrasonic cleaning system for your specific automotive cleaning application call Kaijo or email [email protected].Read More