September 28, 2021
Experts from Kaijo-Shibuya will be at the 2021 WESTEC trade show booth #1856 in Long Beach, CA, November 16-18, 2021 to talk about how Kaijo’s Phenix+ and Phenix Hyper ultrasonic cleaning systems can handle some of the most challenging cleaning problems when other ultrasonic cleaners fail. The secret? Frequency selection is key! REGISTER NOW!
Why Clean with Ultrasonics?
Conventional Methods are Too Harsh
Some products can’t be exposed to heat, chemicals and mechanical scrubbing used with traditional cleaning methods. Certain cleaning approaches also require the use of hazardous, toxic chemicals that require special disposal methods.
Broad Range of Applications
Ultrasonic cleaners offer an ideal solution for cleaning parts and assemblies made of delicate materials with irregular shapes by providing gentler, yet complete removal of contaminants. Believe it or not, the scrubbing action of the bubbles generated by ultrasonic generators and transducers can also be powerful enough to remove even tough grease and grime deposits using just water or water that contains mild detergents.
Here are just some of the manufacturing applications and industries currently using Kaijo cleaning technologies:
- “General purpose”
- High End Metal Finishing
- Plastics manufacturing
Products made of Heterogeneous Materials
Some products and components present special cleaning challenges because they are made using a combination of materials with differing durability characteristics. Kaijo’s ultrasonic cleaners can handle these situations as well.
The typical, conservative approach is to use a process determined to be safe for the least durable material.
Correct Frequency Selection is Critical
Effective use of ultrasonic cleaning systems requires selecting the proper frequency based on the application.
While the ultrasonic cleaning process is simple, selecting the right operating frequency is critical. Every application is different, and using the wrong frequency can damage parts/components, while using the right frequency (based on the part material and nature of the containment) can provide rapid and complete removal of surface contaminants.
Which Frequency Should I Use?
Lower frequencies are usually below 40 kHz. Typical cleaning frequencies used include 26 kHz and 38 kHz to provide robust cleaning for hard metals, glass and porcelain parts.
Mid-range frequencies range from 40 kHz to 160 kHz. Typical frequencies used include 78 kHz, 100 kHz, 130 kHz and 160 kHz for cleaning softer materials, soft metals, aluminum, and ceramic parts.
Higher Frequencies range from 200 kHz up to the 1+ MHz range. Typical frequencies used include 200 kHz, 430 kHz, 950 kHz and 1.6 MHz for delivering very gentle cleaning of parts with very soft surfaces, delicate coating and fragile micro-structures.
Flexible Cleaning Options
For many cleaning applications, it’s important to perform cleaning using industrial ultrasonic cleaners that operate at the appropriate frequency. Kaijo ultrasonic systems whose frequencies can be adjusted and configured to match the cleaning requirements of a wide range of devices and components so that all surface contaminants are cleaned quickly and completely. In addition, Kaijo also offers different cleaning tank sizes required to accommodate the wide range of part and component sizes to meet a customer’s needs.
Proprietary 3D Hyper Waveform
Kaijo stands out from others in the industry by offering a proprietary 3D hyper waveform that effectively cleans the whole part. This provides performance that no other ultrasonic cleaning manufacturer can match.
Kaijo’s Expert Guidance is the Key
Kaijo also distinguishes itself from its competitors through the expert consulting and individualized guidance we provide to customers to help them find the right ultrasonic cleaning system configuration and characteristics for their specific application.
Kaijo’s Ultrasonic Cleaner Products for Manufacturing Applications
Kaijo’s ultrasonic cleaners can handle a wide range of cleaning applications. It’s just a matter of picking the right combination of equipment and cleaning frequency. Many applications don’t require the use of any detergents at all.
The most efficient and easy to use system
- Ease of Use / Self-regulation features
- Auto calibration and auto tuning functions allow you to maintain high efficiency even when changing load conditions
- No field calibration needed for simple replacement of the generator or transducer array
- Easy to use system controls; clear and simple error messages
- Auto-activated cooling fan runs only when needed
- Remote control operation and monitoring for ease of integration
Exclusive 3-D cleaning capability
- The Hyper Mode achieves three-dimensional cleaning of complex shaped objects to ensure all surfaces of irregular shaped objects are cleaned. This capability is exclusively available in Phenix Hyper from Kaijo-Shibuya.
- Solves problems with poor or incomplete cleaning or surface damage to cleaned parts
- Use with plain water or with mild detergents in cleaning solutions heated up to 80 degrees C
- User friendly interface
- Easy Install and Setup with Turn-key configuration
How Much Does Ultrasonics Cleaning Cost?
At first glance, the upfront cost of ultrasonic cleaners for large scale manufacturing applications may seem high, but you need to look at the big picture in terms of what you are spending now to do an accurate comparison. When answering this question, you need to add up all the costs you incur with your current cleaning approach:
- Solvents and Solvent Disposal
- How many different solvents do you need to use, how toxic are they, what is the materials cost, and how much does it cost to dispose of them safely after you’re done?
- Meeting Regulatory Requirements
- How much are you paying now to meet local regulations and compliance with disposing used chemicals and solvents?
- Special Support Supplies
- How much does it cost to purchase special equipment and suiting for your workers?
- How much do you spend on storage space for chemicals and solvents?
- How many times do you need to run the contaminated objects through your cleaning process?
- What is the total time needed for your cleaning process, and what does that cost you in time in terms of productivity, equipment and labor?
- Quality of Cleaning Applications
- How clean is the end result?
After assessing all the above and adding it all up, you may find that moving to an ultrasonic based cleaning process will actually save you money and also help you score some big “eco-friendly” points with your customers.
Ultrasonic cleaners, used in combination with water or the mild detergents, can work safely to clean more components effectively and safely when approaches using strong solvents cannot. Even then, a “one-size-fits-all” approach does not work; each problem has to be examined closely to understand the limiting factors. We often will actually do testing to figure out the exact combination of frequency, tank size and detergents to do the job for you.
Kaijo-Shibuya is the only supplier that can safely clean delicate component with irregular surfaces effectively using their proprietary “3-D hyper wave” technology. Kaijo’s consultants are experts in the field and their consultative approach to working with you ensures you get the best, most cost-effective solution to your specific cleaning problem.
The extreme flexibility of Kaijo’s ultrasonic cleaning systems allows them to easily manage even the most challenging device cleaning requirements.
Want to Know More?
Come talk to us at the WESTEC 2021 Trade Show in Long Beach November 16-18, 2021. We’ll be at booth #1856.
Hope to see you there!
If you can’t make it, you can always give us a call at 408 675-5575 to schedule a free consultation.
About Kaijo Corporation
Kaijo Corporation has been an innovative contributor and global leader among ultrasonic cleaner manufacturers for over 70 years. Ultrasonic cleaning systems use the energy of ultrasonic waves to provide powerful and precise cleaning of manufactured machine parts. These include ceramics, circuit boards, semiconductor wafers, medical tools, and optical components including LCDs and solar panels. Represented in North America by the Kaijo Shibuya America Inc. in Santa Clara, California, Kaijo seeks to provide the most innovative and advanced solutions available among industrial ultrasonic equipment manufacturers.