How to Use Ultrasonic Cleaners to Remove PFAS Contamination

Summary:Ultrasonic cleaning generators, specifically Kaijo’s Phenix Hyper, offer an effective, chemical-free method for removing PFAS contamination from solid industrial surfaces, thereby supporting operational efficiency, compliance, and sustainability goals.

Table of Contents

1. Introduction
2. Understanding PFAS Contamination
3. Traditional Methods for PFAS Removal: Limitations
4. How Ultrasonic Cleaning Provides a Solution
5. Spotlight on Kaijo’s Phenix Hyper: Precision PFAS Removal
6. Why It Matters for Manufacturing Engineers and Facility Managers
7. Real-World Case Study on PFAS Removal Using the Phenix Hyper
8. Considerations When Choosing an Ultrasonic Cleaning System
9. Future Outlook on Sustainability and Regulatory Trends
10. Conclusion

1. Introduction

PFAS (Perfluoroalkyl and Polyfluoroalkyl Substances), often referred to as “forever chemicals,” are among the most persistent contaminants faced by manufacturers today. The carbon–fluorine bond is one of the strongest and most difficult to break, but some organizations have empirically found that lower-frequency megasonics can break the bond.

Their strong carbon-fluorine bonds also make them resistant to heat, water, and chemicals — qualities that have driven their use in aerospace, automotive, electronics, and construction industries. Unfortunately, these same properties make PFAS extremely difficult to remove from machined parts, circuit boards, and the surfaces of industrial equipment.

As regulatory pressure intensifies worldwide, from EPA thresholds in the U.S. to expanding EU restrictions, manufacturers are under growing pressure to prove compliance. While most public attention has focused on PFAS in water supplies, contamination on solid industrial surfacesalso causes adhesion failures, solderability issues, rejected batches, and costly downtime.

This is where ultrasonic cleaners provide a critical breakthrough. By using controlled cavitation energy instead of harsh chemicals or excessive heat, they deliver a repeatable, chemical-free solution for removing PFAS residues at the surface level. Kaijo’s Phenix Hyper ultrasonic cleaning generator is engineered specifically for this challenge. It provides precision, scalability, and compliance-ready performance for removing PFAS from solid industrial surfaces such as machined parts, circuit boards, and processing equipment. This is where ultrasonic cleaning technology demonstrates its value: a chemical-free and precise process that addresses the distinct challenges of PFAS while aligning with lean and efficient manufacturing production practices.

2. Understanding PFAS Contamination

What Are PFAS?

PFAS (Perfluoroalkyl and Polyfluoroalkyl Substances) are a vast family of over 9,000 synthetic chemicals valued for their ability to repel water, oil, and heat. They are most commonly used in:

• Nonstick or protective coatings (e.g., fluoropolymers on machinery or tools)
• Electronics manufacturing, where durability and chemical resistance are critical
• Automotive and aerospace parts requiring fluoropolymer lubrication or coatings
• Industrial lubricants, release agents, and adhesives

Because they are bonded with strong carbon-fluorine chains — one of the strongest bonds in organic chemistry — PFAS are extraordinarily durable. This durability is why they were once deemed ideal for industrial processes, but it is also what makes them so challenging to eliminate when contamination occurs.

Learn more about PFAS properties from the U.S. Environmental Protection Agency.

How Contamination Occurs

In manufacturing, PFAS residues accumulate in several ways:

• Surface films: Thin, nearly invisible layers form on tools, machined parts, or processing equipment.
• Residues from coatings: Fluoropolymer-based coatings leave behind bonding or release residues.
• Cross-contamination: PFAS migrate from upstream processes into sensitive downstream operations like electronics or food-related components.
• Process runoff: Cleaning baths and lubricants carrying PFAS spread contamination onto surfaces.

While water treatment has been a focus, PFAS on solid surfaces poses an immediate risk for manufacturers. Even trace films can cause adhesion failures, solderability issues, or rejected batches.

Why PFAS Are Concerning

• Persistence: PFAS are often called “forever chemicals” because they do not naturally degrade. Once present on a surface, they remain until actively removed.
• Bioaccumulation & Toxicity: Traces released from facilities accumulate in people and the environment, prompting urgent regulatory action.
• Regulatory Pressures:
  • The EPA is implementing strict thresholds for PFAS contamination.
  • The EU (via the European Chemicals Agency) is advancing broader bans on PFAS use in industrial products.
  • Some US states, including California, have imposed their own disclosure and elimination standards, adding another layer of compliance.

Operational Impact for Industry

PFAS contamination is not just an environmental hazard — it is a production and compliance problem:

• Compromises surface preparation, affecting coatings, assembly, and bonding.
• Increases operational costs when cleaning processes are ineffective.
• Creates exposure to fines or reputational damage if residues migrate into products or audits uncover contamination.

PFAS residues on solid surfaces pose a threat to both manufacturing efficiency and regulatory compliance, underscoring the need for a reliable method of removal.

3. Traditional Methods for PFAS Removal: Limitations

PPFAS compounds are engineered for extreme stability, making them among the most challenging contaminants to eliminate. Traditional methods — filtration, incineration, and chemical treatments — all attempt to mitigate PFAS, but each has serious drawbacks for manufacturers dealing with solid-surface contamination.

Quick Comparison of Conventional Methods

Method	Effectiveness on Solid Surfaces	Drawbacks
Filtration (carbon/resins)	❌ Only effective in liquids, not solid parts	Filters saturate quickly, create toxic waste, and drive up OPEX with frequent replacement
Incineration (high-temp >1,100°C)	❌ Not applicable to surfaces	Extremely energy-intensive, costly, and under regulatory scrutiny for byproducts
Chemical / Advanced Treatments (oxidation, plasma, photolysis)	⚠️ Partial breakdown only; often leaves regulated shorter-chain PFAS	High energy use, safety risks, experimental at scale

Why These Methods Fall Short

• High operating costs: Frequent filter changes, extreme energy demands, or specialized chemical handling drive up expenses.
• Secondary waste streams: Toxic sludge, hazardous filters, or emission byproducts create new disposal and compliance challenges.
• Poor fit for manufacturing workflows: None of these methods directly remove PFAS films from machine parts, circuit boards, or processing tools.
• Compliance risks: Incomplete removal or secondary waste raises audit and liability concerns.

Key Takeaway: While filtration, incineration, and chemical treatments shift PFAS from one medium to another, they cannot directly clean PFAS residues from solid components. This gap underscores the need for a surface-focused, operationally efficient solution, precisely what ultrasonic cleaning generators like Kaijo’s Phenix Hyper provide.

4. How Ultrasonic Cleaning Provides a Solution

Conventional PFAS treatments, such as filtration and incineration, as well as chemical reactions, either push the problem elsewhere or introduce new waste and costs. In contrast, ultrasonic cleaners directly remove PFAS from solid surfaces using physical energy rather than chemicals or high heat.

Cavitation: The Science Behind the Process

When an ultrasonic cleaning system produces high-frequency sound waves in a liquid bath, it produces alternating pressure zones. These zones create microscopic bubbles that expand and collapse in a phenomenon known as cavitation. Each implosion delivers a localized burst of force strong enough to dislodge thin PFAS films from surfaces — even from grooves, blind holes, and complex geometries that traditional cleaning can’t reach.

Unlike scrubbing or chemical baths, cavitation works uniformly across the surface, suspending PFAS residues in the liquid where they can be captured and removed.

Why It Works for Industry

For manufacturers, ultrasonic cleaning translates into benefits that directly address production and compliance challenges:

• Chemical-free operation: Eliminates solvents and oxidizers, reducing hazardous waste streams.
• Precision and safety: Adjustable frequencies clean delicate electronics or rugged components without surface damage.
• Consistency: Controlled power and frequency deliver repeatable results — essential for regulated industries.
• Efficiency: Faster cycles reduce downtime and free production capacity.
• Sustainability: Lower energy use than incineration and no toxic byproducts to manage.

Integration into Operations

Modern ultrasonic systems, such as Kaijo’s Phenix Hyper ultrasonic cleaning generator, are designed for seamless use in industrial workflows:

• Compatible with batch and inline automated processes.
• Equipped with digital monitoring and logging for compliance documentation.
• Scalable tank designs adapt to part sizes and production throughput.

For manufacturing engineers, ultrasonic cleaning reduces defects and supports lean manufacturing processes. For facility managers, it delivers compliance-ready, chemical-free cleaning that aligns with sustainability and cost-control goals.

Comparing PFAS Removal Methods

Criteria	Filtration (Carbon/Resins)	High-Temp Incineration	Chemical / Advanced Treatments	Ultrasonic Cleaning (Kaijo Phenix Hyper)
Effectiveness on Solid Surfaces	❌ Not effective (only liquids)	❌ Cannot be applied to surfaces	⚠️ Variable; incomplete breakdown common	✅ Direct removal of PFAS films from solid components and tooling
Waste Generation	✔️ Captures PFAS, but filters become hazardous waste	❌ Creates emissions / toxic byproducts if incomplete	❌ Generates secondary chemicals / sludge	✅ Minimal; mostly rinsate that is easily managed
Operating Expenses (OPEX)	High – frequent filter replacement and disposal	Very high – extreme energy costs	High – chemical purchases, specialized handling	Low – power consumption only; no consumables
Integration in Industrial Workflows	Poor – stand-alone water treatment	Poor – not scalable on-site	Poor – requires complex infrastructure	Excellent – scalable batch or inline cleaning systems
Compliance / Traceability	Limited – requires offsite disposal proof	Limited – regulatory scrutiny of incineration emissions	Difficult – often pilot-stage, hard to standardize	Strong – consistent cycles, improved safety, audit-ready results
Sustainability	❌ Shifts burden to hazardous waste	❌ High energy footprint	⚠️ Chemical risks, energy-intensive	✅ Chemical-free, low waste, low energy

5. Spotlight on Kaijo’s Phenix Hyper: Precision PFAS Removal

Traditional PFAS treatments are costly, incomplete, or impractical. Kaijo’s Phenix Hyper ultrasonic cleaning generator takes a fundamentally different approach. Engineered for industrial use where precision, reliability, and compliance are mandatory, the Phenix Hyper delivers controlled ultrasonic Hyperwave at 78 kHz that effectively removes PFAS contamination from solid surfaces — without the use of hazardous chemicals or extreme energy inputs.

Advanced Technology Built for Real PFAS Challenges

The Phenix Hyper is more than just an ultrasonic cleaning generator; it’s an engineered system designed for scalability, precision, and repeatability in demanding manufacturing environments.

Key Technical Capabilities:

• Optimized frequency (78 kHz Hyperwave): Waveform optimized for heavy PFAS residues on robust parts or delicate films on sensitive electronics.
• Digital power management with ±1% accuracy: Ensures consistent cavitation performance every cycle, critical for validated compliance.
• Stable energy distribution: Uniform cavitation across the full volume of the cleaning bath produces even cleaning results — no “dead zones” where residues remain.
• Automation-ready design: Built for seamless integration with PLC-controlled production lines, enabling continuous flow or batch configurations.
• Reliability under production loads: Overload protection, temperature compensation, and modular, serviceable design ensure uptime and predictable maintenance cycles.

What Makes Phenix Hyper Effective at Removing PFAS Contaminants

PFAS contamination on solid surfaces is notoriously difficult to dislodge because of strong molecular bonds and film-like residues. The Phenix Hyper addresses this challenge directly by:

• Applying an ultrasonic Hyperwave that disrupts PFAS adhesion.
• Targeting thin, even invisible surface films that conventional methods miss.
• Cleaning complex geometries — from machined parts with grooves to densely packed electronic assemblies.
• Operating without abrasive force or harsh chemistry, preserving the integrity of the base material.

This combination of surface-level precision + process consistency makes the Phenix Hyper uniquely effective for PFAS removal where other technologies fail.

Why Kaijo Stands Apart from Other Ultrasonic Cleaner Manufacturers

Any ultrasonic system can create bubbles. However, not all ultrasonic cleaner manufacturers offer the engineering depth or proven expertise to tackle PFAS contamination in industrial contexts reliably.

Kaijo’s Unique Advantages:

• Decades of specialization in ultrasonic and megasonic cleaning systems for industrial cleaning.
• Integrated product line — from generators (Phenix Hyper, Phenix+) to turnkey systems (Phenix III) to specialty products (Water Resonance System).
• Engineering partnership: Kaijo collaborates with customers to customize frequency, power settings, and system design to their exact production requirements.

Kaijo’s philosophy emphasizes performance backed by science and verifiable results, not hype, making the company a trusted partner for manufacturers confronting PFAS contamination challenges.

6. Why It Matters for Manufacturing Engineers and Facility Managers

PFAS contamination is more than a compliance issue. It directly affects production efficiency, product quality, and overall operational risk. A practical cleaning approach must therefore serve two priorities: supporting manufacturing performance on the floor and safeguarding facility-wide compliance and sustainability.

Benefits for Production and Engineering Teams

Production teams focus on throughput, precision, and consistency. Ultrasonic cleaning meets these demands by:

• Integration with Lean Operations: Ultrasonic cycles can be synchronized with takt time, reducing bottlenecks.
• Consistent Quality: Reliable removal of PFAS films ensures surfaces are properly prepared for bonding, soldering, or coating, reducing defects and rework.
• Reduced Downtime: Automated cycles are faster than chemical soaking or manual scrubbing, keeping lines moving.
• Lower OPEX: No recurring solvent purchases or filter replacements, delivering measurable cost savings.

Benefits for Facility and Operations Leadership

Facility managers prioritize compliance, sustainability, and cost control. The Phenix Hyper system addresses these objectives:

• Regulatory Confidence: Monitored and logged parameters create an audit-ready cleaning process, helping meet EPA or EU standards.
• Sustainable Operations: PFAS removal is achieved without harsh chemicals, minimizing waste streams and environmental impact.
• Risk Mitigation: Effective surface decontamination reduces the chance of recalls, fines, or safety violations tied to PFAS residues.
• Scalability: Systems can scale from single-line integration to facility-wide adoption, ensuring long-term adaptability.

Aligning Two Perspectives

For production teams, ultrasonic cleaning delivers efficiency and quality assurance. For facility leadership, it provides compliance certainty and sustainability gains. By addressing both priorities simultaneously, Kaijo’s ultrasonic technology ensures PFAS removal is not just a cleaning step but a solution that strengthens the entire operation.

7. Real-World Case Study on PFAS Removal Using the Phenix Hyper

An electronics manufacturer faced persistent PFAS contamination on finished components and tooling surfaces. Traditional solvent cleaning, which involved manual brush scrubbing, was ineffective, leading to quality rejections and increased disposal costs.

Action Taken

• Implemented the 78 kHz Hyperwave produced from the Phenix Hyper ultrasonic cleaning generator to effectively remove PFAS contamination from part surfaces.
• Integrated the system into an automated production line to maintain throughput.
• Verified PFAS contamination was removed for compliance.

Results Achieved

• Verified PFAS removal from solid surfaces without chemical solvents.
• Reduced cleaning cycle times compared to chemical treatment.
• Complete elimination of hazardous solvent disposal costs, cutting OPEX.

Key Takeaway

By using the Hyperwave generated by the Phenix Hyper system, the manufacturer gained a repeatable, chemical-free process that not only solved a contamination issue but also delivered measurable improvements in efficiency and cost savings.

8. Considerations When Choosing an Ultrasonic Cleaning System

Choosing the right ultrasonic cleaning system for removing various types of surface contaminants requires more than simply selecting a generator. The effectiveness of the process depends on matching the equipment’s frequency, power, and design to the contamination challenge and the production environment.

Key Technical Factors

• Frequency Range: Low frequencies (25–40 kHz) remove stubborn residues on rugged parts, while higher frequencies (80–170 kHz) are gentler and ideal for delicate parts and electronics. Systems with adjustable frequencies offer versatility across applications.
• Power Control: Consistent cavitation requires precise power management. Digital modulation prevents under- or over-cleaning, ensuring repeatable, audit-ready results.
• Tank Design: Correct sizing and robust tank materials support even cleaning coverage. Optional features, such as temperature control and solution circulation, improve performance on complex parts.
• Safety & Reliability: Overload protection, thermal safeguards, and durable components minimize downtime and protect staff.

Operational Considerations

• Compliance & Traceability: Systems with built-in monitoring simplify documentation for environmental audits.
• Workflow Integration: The system should adapt to batch or automated production lines without disrupting lean operations.
• Maintenance & Support: Local service availability, training, and easy spare part replacement ensure consistent uptime.
• Total Cost of Ownership: Solvent-free operation reduces operating expenses (OPEX) compared to filtration or chemical systems. Energy efficiency and system longevity further cut costs.

Choosing the Right Partner

Not all ultrasonic cleaner manufacturers provide the same level of expertise. The most effective systems come from partners with proven industrial experience, validated PFAS cleaning results, and strong engineering support. Kaijo, with technologies like the Phenix Hyper, provides not just equipment but application-specific guidance and long-term service.

By weighing these factors — frequency, power, design, compliance capability, and manufacturer reputation — decision-makers can invest in a system that delivers reliable contamination removal while meeting operational and regulatory goals.

9. Future Outlook on Sustainability and Regulatory Trends

The pressure to address PFAS contamination will only intensify. Global regulators, customers, and investors are demanding cleaning solutions that are both effective and sustainable, making early adoption a competitive advantage.

Regulatory Momentum

• EPA Standards (U.S.) – Stricter PFAS thresholds are being introduced, in some cases measured in parts per trillion.
• European Chemicals Agency (EU) – Advancing broad bans on PFAS use across coatings, electronics, and industrial applications.
• State and Local Actions (U.S.) – States like California are already implementing disclosure and elimination standards that exceed federal guidelines.

Sustainability Demands

Beyond regulation, companies face increasing ESG requirements from customers and shareholders:

• Carbon efficiency: Lower energy use is now a key performance metric.
• Chemical reduction: Proof of solvent-free processes is often required in supplier audits.
• Sustainable ultrasonic cleaning: Ultrasonic systems directly support ESG goals by eliminating chemical waste streams and lowering energy consumption compared to incineration or plasma-based methods.

Kaijo’s Role in the Future

Kaijo continues to innovate ultrasonic and megasonic cleaning systems that not only solve today’s PFAS contamination issues but also prepare customers for tomorrow’s standards. With:

• Proven PFAS removal from solid surfaces without solvents
• Scalable designs for facility-wide adoption

Kaijo positions manufacturers to lead in compliance, efficiency, and sustainability — turning PFAS removal from a regulatory burden into a strategic advantage.

10. Conclusion

PFAS contamination is one of the most persistent and costly challenges facing manufacturing today. Traditional methods, such as filtration, incineration, or chemical treatments, often add waste, consume excessive resources, or fail to achieve complete removal from solid surfaces.

Ultrasonic cleaning provides a clear alternative. By using controlled cavitation, it effectively removes stubborn PFAS films without the use of chemicals or damaging heat. The result is a cleaning process that is precise, repeatable, and environmentally responsible.

Kaijo’s Phenix Hyper ultrasonic cleaning generator takes this capability further with:

• Wide frequency control for different contamination profiles
• Digital power management for consistent results
• Automation compatibility for lean manufacturing
• Compliance-ready monitoring for audit confidence

For manufacturing engineers, this means higher throughput, fewer defects, and smoother integration into existing workflows. For facility managers, it provides compliance certainty, reduced operating costs, and measurable sustainability gains.

Final Word

PFAS may be “forever chemicals,” but they don’t have to be a forever problem in your facility. With Kaijo’s Phenix Hyper, manufacturers can achieve reliable PFAS removal while strengthening efficiency, compliance, and sustainability.

Ready to see the Phenix Hyper in action? Request a demo or contact Kaijo for a complimentary consultation to discover how ultrasonic cleaning can transform your PFAS removal process.

FAQs

Q1. What makes PFAS contamination so difficult to remove from industrial surfaces?
PFAS are known as “forever chemicals” because their strong carbon–fluorine bonds resist heat, water, and solvents. These properties make them useful in coatings, lubricants, and electronics manufacturing, but they also make PFAS residues extremely persistent on machined parts, circuit boards, and processing equipment surfaces.

Q2. How does an ultrasonic cleaning generator remove PFAS contamination?
An ultrasonic generator utilizes high-frequency sound waves to create cavitation bubbles that dislodge PFAS residues from surfaces without the need for solvents or heat. Not all ultrasonic cleaners can do this effectively. However, Kaijo’s Phenix Hyper generates a unique 78 kHz Hyperwave that effectively removes PFAS contamination from solid industrial surfaces.

Q3. What are the benefits of ultrasonic cleaning for manufacturing engineers?
For engineers, ultrasonic cleaning offers consistent product quality, reduced downtime, and easy integration into lean manufacturing workflows. It helps ensure that parts are correctly prepared for bonding, soldering, or coating, minimizing defects and rework.

Q4. What is the future of PFAS removal in manufacturing?
With EPA thresholds tightening in the U.S. and EU bans expanding, PFAS compliance will only become more demanding. Sustainable ultrasonic cleaning technologies, such as those from Kaijo, position manufacturers to stay ahead of regulations while reducing costs and environmental impact.

Q5. What is Kaijo’s 78 kHz Hyperwave, and why is it effective for PFAS removal?
Kaijo’s Phenix Hyper ultrasonic cleaning generator produces a 78 kHz Hyperwave, a specialized ultrasonic frequency designed to break the strong molecular bonds of PFAS contamination on solid surfaces. This unique waveform provides uniform cavitation energy across the cleaning bath, ensuring consistent removal of even thin or invisible PFAS residues from machined parts, circuit boards, and complex geometries.

 

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Reviewed and approved by Michael Danese -General Manager at Kaijo Shibuya America Inc.