November 26, 2018
Industrial ultrasonic cleaners rely on the mechanical scrubbing action of microscopic cavitation bubbles to remove contaminants from the surfaces of parts to be cleaned. As a result, the systems don’t need to use harsh chemicals to soften and dissolve surface contaminants. Instead, ultrasonic cleaners work quickly to clean contaminants from all kinds of surfaces and eliminate soaking, pressure washing and mechanical scrubbing. As chemicals and their safe handing increase in cost, industrial ultrasonic cleaners provide an opportunity for substantial savings while reducing negative environmental effects.
Ultrasonic Vs. Traditional Cleaning Methods
Industrial ultrasonic cleaning systems consist of an ultrasonic generator, a transducer and a cleaning tank. The generator produces the ultrasonic signal and the transducer changes it to sound waves when it is immersed in the cleaning solution. Cavitation bubbles form in the low-pressure troughs of the sound waves and collapse in the high-pressure peaks. When a bubble collapses next to the surface to be cleaned, it releases a burst of energy that dislodges contaminants from the surface. The cleaning method is completely safe, environmentally friendly and does not require the use of chemicals. A ten to twenty minute cleaning time is often enough.
In contrast, traditional cleaning methods rely on the action of harsh chemicals to clean parts and components. Depending on the cleaning application, an acid or strong solvent is used to dissolve the contaminants in question and remove the bulk of the dirt from surfaces to be cleaned. Often several baths are necessary and manual removal of some of the dirt is sometimes required. The process takes a lot of time and uses lots of chemicals and water. After the parts are clean, the chemical waste has to be neutralized and disposed of in an acceptable manner. Increasingly stringent health and safety standards, for example for ventilation, add to the cost of the traditional cleaning process.
The inherent advantages of the ultrasonic cleaning process include rapid cleaning and the ability to clean inaccessible places. The adoption of ultrasonic cleaning also provides a safer, healthier workplace and a greener, and more environmentally friendly operation. Both of these aspects provide cost advantages.
In addition to no longer having to purchase chemicals, the extensive chemical handling infrastructure can be eliminated. Harsh and toxic chemicals have special storage requirements and spills can be expensive. Chemical mixing and delivery to the cleaning tanks is hazardous and the corresponding systems are costly. Large quantities of water are required for washing parts between baths and for diluting the chemicals. Finally, chemical waste has to be treated with more chemicals and disposal of the neutralized waste is expensive as well. Traditional industrial cleaning methods are neither green nor safe and meeting environmental and safety regulations in the future will only become more difficult.
Industrial ultrasonic cleaning systems don’t use any chemicals and only occasionally use mild detergents and heat to soften contaminants and make them easier to remove. The systems operate within a completely safe working environment and no special safety measures are required. Water use is limited and wastewater can be disposed of without special neutralization or treatment. The ultrasonic cleaning process is both green and safe.
Kaijo’s Product Line of Industrial Ultrasonic Cleaners
Kaijo’s ultrasonic cleaners are designed to provide a versatile solution so customers can meet the needs of their specific cleaning applications. The company can make recommendations for ultrasonic frequency, system power and type of transducer and propose specific equipment from the complete line of ultrasonic cleaning products. Systems can be turnkey, individual components or retrofitted for existing cleaning tanks. In every case, Kaijo’s ultrasonic cleaning systems will deliver superior cleaning performance in an environmentally friendly and safe fashion. Contact Kaijo for a free consultation or quote on selecting the right system for any industrial cleaning application.
November 8, 2018
Ultrasonic cleaners provide quick and complete cleaning for parts to be plated or coated, saving time and ensuring superior adhesion. The ultrasonic cleaning process leaves bare surfaces free from contaminants, even in hard-to-reach places such as interior cavities and holes. The use of ultrasonic parts cleaners is completely safe and doesn’t require chemicals to soften or dissolve dirt. Benefits include faster processing, higher throughput and better quality output.
Why Use Ultrasonic Cleaning with Plating or Coating?
Parts to be plated or coated, such as parts made from metal or plastic, often have surface contaminants that must be removed before the plating or coating process can take place successfully. If impurities are left on the surfaces, the covering material often will not adhere to the parts and the quality of the product and its appearance will suffer.
Typical contaminants are residues from machining, buffing compound and shop dirt. Traditional cleaning methods include soaking in chemicals, manual scrubbing and washing. These methods are time-consuming and often don’t remove all contaminants in hard-to-reach places. Ultrasonic parts cleaners remove all contaminants down to the bare surfaces everywhere on the parts to be plated or coated, even from inaccessible areas such as interior openings or crevices. Cleaning is fast and complete.
How Ultrasonic Cleaning Before Plating or Coating Works
Ultrasonic cleaning systems work by producing microscopic cavitation bubbles in the cleaning tank. An ultrasonic generator delivers the high-frequency electric signal to a transducer immersed in the cleaning solution. The transducer has a surface that vibrates at the ultrasonic frequency and creates the ultrasonic waves in the liquid.
Ultrasonic waves in a liquid have high-pressure peaks and low-pressure troughs. Cavitation bubbles are created at low pressure and they collapse in the high-pressure peaks. The continuous cavitation action results in a strong scrubbing effect on the surfaces of the parts to be cleaned. Contaminating material and particles are dislodged and carried away by the cleaning solution. The process depends on the type of contaminant and how much has to be removed but cleaning is often complete after ten to twenty minutes.
Choosing the correct frequency, power and type of transducer is important for effective cleaning before plating or coating. The frequency depends on the structure of the parts and the nature of the contamination. The manufacture of some parts results in surfaces coated with heavy, oily or greasy material while other parts only have a light coating of powder or dirt. The parts themselves may be robust and rugged or delicate and easily damaged. Choosing the right ultrasonic frequency takes these factors into account.
Low frequencies such as 26 kHz or 38 kHz generate comparatively large bubbles that deliver strong, aggressive cleaning power suitable for heavy contamination of robust parts. Lighter contamination on more delicate parts can use higher frequencies with smaller bubbles and softer cleaning action. For the more delicate parts, higher frequencies in the 160 kHz to 200 kHz range deliver gentle cleaning. No matter what kind of part and what contaminants, ultrasonic cleaners can be configured with one or more frequencies that will deliver excellent cleaning performance prior to plating or coating.
Once the frequencies are determined, the power has to be adequate to fill the cleaning tank with ultrasonic waves. With adequate power, bubbles and cleaning action will appear wherever cleaning solution is present. Transducers can be built in, such as in turnkey systems, bolt on or immersible. The independent immersible units are especially flexible and can be easily be used in existing tanks, for example, if there is an existing plating or coating line with cleaning tanks already integrated.
Kaijo’s ultrasonic parts cleaners can effectively be used with any plating or coating application. In addition Kaijo will help customers select a system that will provide optimum performance to meet their specific cleaning requirements.
December 22, 2017
The large compressors that utility companies use to move natural gas through pipelines and into storage need extensive maintenance. Both the compressors themselves and the engines that drive them require regular cleaning of parts such as valves, rings, sensors and actuators. Unwanted deposits have to be dissolved, grease and grime have to be cleaned off and contaminants have to be removed.
Traditionally such cleaning and maintenance work has been carried out by hand. Parts are soaked in strong chemical solvents and then scrubbed to remove residues. Soaking takes a lot of time and the chemicals are expensive. Scrubbing is labor-intensive and it’s hard to get parts completely clean. If it’s important to remove deposits completely, it might take several cycles with different chemicals and various cleaning methods. Overall, the cleaning process takes a lot of time and costs a lot of money.
Utilities can achieve better cleaning performance at lower cost by using industrial ultrasonic cleaners. The process uses powerful ultrasonic generators and transducers to generate microscopic bubbles in the cleaning solution. The scrubbing action of the bubbles cleans parts completely and rapidly. Manual cleaning and expensive, harsh chemicals are not needed. Utilities using this process can reap substantial benefits from the advantages that ultrasonic cleaning delivers.
Industrial Ultrasonic Cleaner Advantages and Benefits
Ultrasonic technology can remove deposits from compressor and engine parts using only a water-based cleaning solution. For specific contaminants, mild solvents can be added to the water to speed up cleaning. For hardened grease and oil-based materials, the solution can be heated so the cleaning bubbles can more easily dislodge the softened material. In each case, no additional manual scrubbing is required.
The bubbles generated by industrial ultrasonic cleaners appear wherever the cleaning solution can penetrate. This means that crevices, dead-end holes, bolt threads and inaccessible interior surfaces are cleaned just as completely as the outsides of the parts. As long as a part is submerged in the ultrasonic bath, all surfaces are cleaned equally and completely.
Because harsh chemicals are not needed, ultrasonic cleaning starts out with a substantial operating cost advantage. The savings are even higher when the time saved through faster cleaning can result in increased throughput or reduced downtime. Additional savings come from reduced labor costs. Finally there are savings from not having to neutralize and safely discard the toxic cleaning chemicals used in traditional cleaning processes. The fact that ultrasonic cleaning is environmentally friendly is an additional bonus.
While utilities can save substantial amounts of money switching to industrial ultrasonic cleaning systems, an even stronger incentive is the improved cleaning performance. When machine parts are cleaned down to the bare metal everywhere, maintenance is more effective, easier to carry out and achieves improved reliability for the compressors and engines. Parts that are completely clean have a longer life and extend the lifetime of the corresponding machines. Often failure rates and unscheduled down time is reduced and maintenance intervals can be extended. Overall facility-operating performance can be improved.
Kaijo can help utilities realize the benefits of using ultrasonic technology. The company offers free consulting services to determine which ultrasonic cleaning system is best suited for the customer’s application. Sometimes a turnkey system represents the best solution while at other times retrofitted components using existing cleaning tanks is cost-effective. Kaijo can follow up its recommendations with proposals from its complete line of industrial ultrasonic cleaning systems. Clients in many different industry verticals already use Kaijo ultrasonic systems to reduce their maintenance times and costs. Utilities, with their many stations requiring machine parts cleaning can achieve similar results with Kaijo’s help.Read More
November 8, 2017
From delicate medical equipment to machine parts, there is very little in the world of industrial cleaning where ultrasonic cleaners do not excel, often leaving conventional cleaning methods behind. Making use of sonic waves at frequencies as high as 400 kHz to create and implode millions of bubbles on surfaces that need work, ultrasonic cleaning forms microscopic areas of high cavitation pressure, and momentary bursts of heat at temperatures as high as 5,000° C. These actions create cleaning forces that are both powerful and gentle at the same time. From lime scale and rust to fungus and dried bodily fluids, ultrasonic cleaning is far and away the most efficient and cost-effective way to clean practically any surface.
If you’re a business owner considering a cleaning solution, however, you’re possibly very interested in the latter part of this argument: the one to do with cost-effectiveness. Can a tool as efficient and as high-tech really be cost-effective? How exactly does the cost-effectiveness come about?
You save on materials
Depending on the cleaning task on hand, regular high-pressure spray washers require a great deal of chemical help to get much done. The pressure of the water or other liquid is usually insufficient when it comes to loosening hard stains. Not only are the chemical agents expensive, however, workers often need protective equipment, and articles cleaned can sustain some damage.
These concerns do not exist with ultrasonic cleaners. Cleaning with high-frequency pressure waves does not require chemical action to loosen dirt up. Certainly, a mild detergent solution may be used when you use ultrasonic cleaners — it helps move loosened dirt away from the surface; it tends to be inexpensive, however.
Best of all, with the need for powerful chemicals absent, there’s far less expense made complying with environmental regulations to do with safe disposal.
You save on labor costs
One of the greatest benefits to choosing ultrasonic cleaners over pressure washers appears the form of savings in time and effort expended. The ultrasonic waves generated by these cleaners do not need to be directly aimed at surfaces to be cleaned, no matter how hidden they may be. They get into every part of the work that you need cleaned, no matter how small, inconveniently shaped, or hidden. This means that workers spend less time getting into nooks and crannies. Work becomes cleaner with little effort. With faster cleaning made possible, you get greater productivity out of your labor force.
You save on maintenance
Conventional spray washers can need plenty of energy to operate, and careful, and expensive maintenance. They come with high-pressure pumps, hoses and nozzles. Moving parts don’t last forever. Motors, washers, joints and other parts frequently wear out. If there are toxic chemicals used, you need to take preventive maintenance to make sure that these chemicals cannot get to places where they can cause harm in the event of a leak. Ultrasonic cleaning, on the other hand, simply works. These models come with no moving parts — all you have is an ultrasonic transducer, and a bath of liquid. These models keep working forever.
Work with the best in the business
If the information here has your interest, you should think of Kaijo, one of the top manufacturers of industrial ultrasonic cleaners in the world. Kaijo offers industrial customers everything from customized ultrasonic cleaners to standalone equipment and turnkey installations. With experience catering to the cleaning needs of every kind of industry out there from automobiles to jewelry and from medical institutions to catering, Kaijo is the leader in ultrasonic technology worldwide.Read More
September 21, 2017
Kaijo’s new Phenix Hyper ultrasonic cleaning generator along with the Hyper immersible transducer deliver improved cleaning performance using the latest ultrasonic technology. The generator can be used with the standard sweep frequency mode but also features the new Hyper mode that improves cleaning effectiveness with a uniform ultrasonic pattern that completely fills the process tank.
Typical ultrasonic controls are included in the generator’s standard functions and it can produce up to 1200 W output power. Its user-friendly operator interface makes process control transparent and an assortment of alarm, display and interlock functions ensure safe and reliable operation. Together with the Hyper immersible transducer, the new system helps avoid incomplete or non-uniform cleaning and reduces the possibility of surface damage to cleaned parts. Hyper mode allows finely tuned cleaning and removes small particles and deposits completely.
Phenix Hyper Ultrasonic Generator Features
Operating at 78 kHz and delivering adjustable output power up to 1200 watts, Kaijo’s Phenix Hyper ultrasonic cleaning generator incorporates advanced technology and a complete set of controls and alarms. Specific generator functions include:
- Auto tuning – the generator automatically adjusts to changing process environments
- Oscillation verification and alarm
- Choice of standard sweep mode or advanced Hyper mode
- Eight-level power adjustment through remote oscillation terminals
- Remote interlock terminals
The new vacuum fluorescent display (VFD) shows operators key process variables, alarms and settings and allows control of the cleaning process. Output power is displayed in teal time and alarms displayed include upper output limit, lower output limit, transducer error, abnormal inner temperature, interlock alarm and six different types of memory error.
The ultrasonic generator provides the following characteristics:
- Output 10 to 1200 Watts adjustable in 1 watt increments
- Dimensions 350 x 440 x 165 mm, W x D x H, weight 11 kg
- Power supply 200 to 240 V, single phase, 50/60 Hz, 12 A
- Ambient 1 to 40 degrees C, 0-80 percent humidity (no condensation)
Working with the new Hyper immersible ultrasonic transducer, the system represents an easy-to-use turn-key solution for applications with an existing cleaning tank. The Hyper ultrasonic transducer is matched to the Phenix Hyper generator with a 78 kHz operating frequency and a 1200 W maximum power capacity. The transducer is made of a high polish stainless steel, weighs 17 kg and measures 365 x 280 x 100 mm. It is suitable for immersion in cleaning solutions up to 80 degrees C.
Phenix Hyper Generator and Transducer Benefits
The new ultrasonic cleaning generator and transducer set combines improved cleaning with easier operation and more reliable performance. Parts made from metal, ceramics and glass can be cleaned effectively on all sides, even when they have complex shapes with hard-to-reach places. The Hyper ultrasonic cleaning technology works wherever the cleaning solution can penetrate, removing fine contaminants quickly and completely throughout the cleaning tank.
Benefits of the new technology include:
- The Hyper Mode achieves three-dimensional cleaning of complex shaped objects to insure all surfaces of irregular shaped objects are cleaned
- Solutions to problems of poor or incomplete cleaning or surface damage to cleaned parts
- Can be used with plain water or with mild detergents in cleaning solutions heated up to 80 degrees C
- User-friendly interface is easy to use
- The generator and transducer can be placed into service immediately in a turn-key configuration without a complicated installation and set-up
Kaijo can help customers with ultrasonic cleaning solutions and advise where the new Hyper technology would be appropriate. With extensive experience and unparalleled expertise in the ultrasonic field, Kaijo can evaluate a customer’s cleaning needs and make recommendations from its complete line of ultrasonic cleaning products, including those using the new Hyper technology.Read More
February 15, 2017
Ultrasonic cleaning systems can clean many parts better than other cleaning methods because of the intense scrubbing action of cavitation bubbles generated by the ultrasonic waves. While ultrasonic cleaners often work faster and clean more completely than conventional cleaners, they have to be suited for the cleaning application. Facility managers and other decision makers have to be familiar with ultrasonic cleaning system characteristics and features so they can select cleaners that perform up to expectations. Below are seven things to consider when selecting ultrasonic cleaners. Kaijo can help ensure that such considerations result in the selection of systems that will improve cleaning performance.
- What frequency do you need?
The frequency determines the size of the cavitation bubbles and the intensity of the cleaning action. Low frequencies down to about 20 kHz generate comparatively large bubbles for robust cleaning action to remove heavy contamination from rugged parts. Higher frequencies up to 200 kHz generate progressively smaller bubbles for more gentle cleaning of delicate components. The highest frequencies up to the MHz range can be used for cleaning fragile parts such as electronic microcircuits and medical equipment. For flexible applications an ultrasonic cleaner with multiple frequency ranges is useful.
- What cleaning power do you need?
While the ultrasonic frequency determines the bubble size and cleaning intensity, the system’s power in watts gives the overall cleaning capacity. Larger tanks need more power. A cleaning solution tank of about 400 by 400 mm and 250 mm deep requires about 1200 W.
- What size of tank do you need?
The longest dimension of the largest part to be cleaned determines the size of the tank required to clean the part. Kaijo has a variety of standard tank sizes and can build custom tanks for special requirements. If a basket is used, the part has to fit in the basket and the tank has to be slightly larger.
- Do you need a basket?
Baskets fit inside the tank and hold the parts to be cleaned away from the walls and tank floor. Some tanks use the bottom of the tank as a membrane to transmit the ultrasonic waves, causing parts resting on the bottom to vibrate against the tank. This can cause damage to the part and to the tank.
- Do you need heating?
Heating the cleaning solution can speed up cleaning and improve performance when contaminants include grease and oil that can be softened with heat. For contaminants not affected by heat there is little benefit in heating the cleaning bath.
- What cleaning solution should you use?
While industrial ultrasonic cleaners can work with plain water, adding mild detergents to the cleaning solution can improve cleaning performance. In some cases, slightly acidic or slightly alkaline cleaning solutions will help soften or dissolve the contaminants to be removed.
- Do you need sweep mode?
Sweep mode varies the ultrasonic frequency slightly around the set frequency value. For example, a system set to 38 kHz might cycle through 35 to 41 kHz in a continuous variation. Fixed frequencies result in dead spots without bubbles and hot spots with too many bubbles in the cleaning tank. Parts may resonate at a fixed frequency and suffer damage. Sweeping the frequency avoids these problems.
Kaijo can help with considerations such as these to ensure customers select the ultrasonic cleaning system that meets their requirements. Kaijo’s extensive experience in ultrasonic technology and the company’s broad range of ultrasonic cleaning equipment mean that expert advice is available to ensure the systems customers select deliver the improved cleaning performance and increased productivity they expect. If you would like a free consultation on how Kaijo’s ultrasonic cleaners can be used for your cleaning application call Kaijo or email [email protected].Read More
November 16, 2016
Ultrasonic cleaning systems can provide quick, efficient and effective cleaning of a variety of parts and equipment without the use of chemicals or mechanical action. As a result, companies that use these systems increase productivity and process throughput while reducing the use of consumables. Below are seven reasons for using ultrasonic cleaning systems and the details of why they are superior in each case.
- Ultrasonic cleaning systems deliver improved cleaning performance.
Ultrasonic transducers generate microscopic bubbles whose collapse creates an intensive scrubbing action throughout the cleaning solution. The bubbles act around corners, in crevices and through holes to clean parts and equipment of all shapes and sizes. By adjusting the ultrasonic frequency and the power, the cleaning action of the bubbles can be adjusted in intensity to match the particular cleaning requirements. Contaminants and foreign material are removed quickly and completely.
- Parts and equipment are cleaned faster.
Cleaning with chemicals is slow as the parts and equipment to be cleaned have to soak in the cleaning solution that subsequently has to be neutralized. Additional mechanical scrubbing is often required and the times between batches are substantial because of the time required to change and set up the chemical baths. Ultrasonic cleaning uses only water and occasionally a mild solvent for even the most challenging cleaning tasks. Cleaning can take as little as a few minutes and rarely over two hours.
- Ultrasonic cleaning removes contaminants without damaging parts and equipment to be cleaned.
Cleaning processes that use blasting, scrubbing or harsh chemicals can cause damage such as pitting, scratching and bending in the material to be cleaned. Ultrasonic cleaning systems can adjust the frequency to deliver the cleaning intensity required. Lower frequencies have larger bubbles with more robust cleaning action while higher frequencies provide more gentle cleaning. The frequencies used can be fine tuned to remove dirt while leaving the underlying surfaces unaffected.
- Ultrasonic cleaning systems are environmentally friendly.
Unlike traditional cleaning methods that often use harsh chemicals to remove stubborn contamination, ultrasonic cleaning systems operate in water or in a solution containing mild solvents. Chemicals have to be stored, handled, mixed, used and neutralized. Even when treated they are not benign when discharged and accidents during storage, handling and use are always possible. These environmental threats and pollution do not exist with ultrasonic systems.
- Ultrasonic technology is safer for workers.
Many chemical cleaning processes use materials that are hazardous and cleaning techniques such as water blasting also have safety issues. Operator errors can put personnel at risk and accidents can have severe consequences. Ultrasonic technology is safe and has no hazardous components, materials or processes. Risk to personnel from errors or accidents is much lower than for conventional cleaning systems.
- Ultrasonic cleaners have a higher capacity than conventional systems.
Once installed and set up, ultrasonic cleaning tanks and containers can clean parts and equipment almost continuously without down time. Material to be cleaned can be placed in the cleaning tanks and ultrasonic cleaning can begin immediately. Cleaning is rapid and thorough. When the material is clean, it can be removed and the next batch of cleaning can be started. The cleaning process itself is faster and throughput is higher than with conventional cleaning systems.
- Ultrasonic systems are versatile and can handle a variety of applications.
Ultrasonic systems consist of ultrasonic generators, transducers and the cleaning tanks. Multiple high-powered transducers can be configured in very large tanks to handle the ultrasonic cleaning of large equipment. Low frequencies deliver robust cleaning for such applications. At the other end of the scale, single transducers can be mounted in small tanks to clean a variety of parts and high frequencies can be used to clean delicate components. Ultrasonic cleaning systems can provide the many different cleaning tasks required for industrial plants using heavy equipment.
Kaijo’s ultrasonic cleaning systems deliver cleaning performance that validates the above 7 reasons for using ultrasonic cleaning. The company can evaluate the cleaning needs of industrial customers including those need heavy equipment applications and deliver corresponding solutions. If you would like a free consultation or advice on using an ultrasonic cleaning system for your specific application call Kaijo or email [email protected].Read More