August 3, 2023
Editor’s Note: This article was originally published in August 2019 and has been updated with additional information and reposted in August 2023.
In today’s industrial landscape, meticulous cleaning and maintenance of components have never been more crucial. Ultrasonic cleaners, capable of delivering precision cleaning with high-frequency sound waves, have emerged as an indispensable tool across a multitude of industry sectors.
No matter if you work in healthcare, manufacturing, or fine-tuning high-performance automobile parts, the utility of ultrasonic cleaners is undeniable. To help you make an informed decision about purchasing an ultrasonic cleaning system for your unique requirements, we’ve outlined the top 5 factors to consider when making this investment decision. Read further to gain insights, make the right decision, and unlock the maximum potential of using ultrasonic cleaning technology.
- Selecting an Appropriate Frequency
Choosing the right frequency is the first key step toward unlocking the full potential of your ultrasonic cleaner. The frequency of ultrasonic waves determines the size of bubbles generated in the cleaning solution, and in turn, how the cleaning process interacts with parts to be cleaned.
The ideal frequency depends on several factors, including the material and dimensions of the item you’re cleaning as well as its nature of contamination. As a general guideline, lower frequencies tend to produce larger bubbles for intensive cleaning of robust parts that have heavy contamination, while higher frequencies produce smaller ones for gentle, detailed cleaning of delicate or intricate parts.
Kaijo provides a range of ultrasonic cleaners operating at different frequencies to suit every cleaning need. Below are some general guidelines on selecting the right frequency:
- 26kHz: The lowest frequency, is ideal for cleaning heavy contamination on robust parts such as engine valves or steel components covered in grease or carbon.
- 38kHz: This frequency provides gentler cleaning action and is suitable for many common tasks such as glass and machined part cleaning.
- 78kHz: This is the go-to frequency to use to clean delicate parts that require a lighter touch. Hard disk drives, LCDs, and aluminum parts with fragile surface finishes can all benefit from using this frequency for effective cleansing.
- 130-200kHz: These are higher frequencies used to clean the most delicate components with soft surfaces. This frequency range ensures efficient yet gentle cleaning for components like soft metals, coated lenses.
- 430kHz-2.0MHz: These are the highest frequencies used to clean the most delicate components. This frequency range ensures complete yet gentle cleaning for semiconductors, flat panel glass, electronic parts or delicate medical instruments.
By understanding your cleaning needs and matching them with their frequency, you can ensure an efficient, thorough, and safe cleaning process. With Kaijo’s range of ultrasonic cleaners, you can find the perfect match for your specific requirements.
- Selecting an Appropriate Power Level
Power is an integral element in optimizing the effectiveness of any ultrasonic cleaner, and understanding your power requirements is vital for optimizing its effectiveness and optimizing cleaning operations.
High power levels allow your ultrasonic cleaner to produce stronger cavitation bubbles, leading to more intensive cleaning action. This means faster and more effective cleaning, especially beneficial for high-volume operations or stubborn contaminants.
However, power must be balanced against the delicacy of the parts being cleaned. Too much power could potentially damage delicate components. That’s why it’s crucial to understand the power level that your specific cleaning application requires and choose an ultrasonic cleaning system that can deliver it.
By matching power with performance, you can not only achieve outstanding cleaning results but also enhance process efficiency. Efficient cleaning reduces operational waste and costs – ultimately making your operations more sustainable and profitable.
Kaijo ultrasonic cleaners come with an assortment of power options to find your ideal balance between power and delicacy, tailoring cleaning processes to specific requirements and optimizing results.
- Selecting the Right Cleaning Tank Size
Selecting the right ultrasonic cleaner tank size is crucial to optimizing its cleaning efficacy. The size of the tank you select depends on the components you plan to clean. The components need to fit easily within the dimensions of the tank without touching the sides or bottom to avoid any risk of damage or ineffective cleaning.
When conducting cleaning operations that require specific component types, custom-sized tanks may be the best option. These are especially helpful if your parts have specific shapes or sizes that do not fit well into standard tanks. On the other hand, if you have various parts with differing sizes to clean, a basket may provide the solution you need. A basket provides a flexible platform to hold parts, ensuring they are fully immersed in cleaning solution and away from tank walls and bottom.
Kaijo provides a broad range of tank sizes and custom solutions to ensure each customer can find an appropriate solution for their cleaning operations. The goal is to immerse parts fully into the cleaning solution without them touching the tank. This ensures ultrasonic waves reach every surface on every component, optimizing cleaning effectiveness.
- Cleaning Solutions
Selecting a cleaning solution is another key element that will impact the effectiveness of the ultrasonic cleaning process. Ultrasonic cleaners can work with various solutions, from plain water to deionized (DI) water, or water containing a mild soap or detergent. The cleaning solution you select will depend on the nature of the parts being cleaned and the contaminants being removed.
Using ultrasonic cleaners for industrial applications doesn’t require any chemical additives. Simply water or water combined with mild soap or detergent will work for cleaning most industrial parts. This not only increases efficiency but also contributes to environmental compliance by eliminating exposure to potentially harmful chemicals and substances.
Cleaning sensitive components such as semiconductor wafers, printed circuit boards, or medical devices often requires taking a more careful approach. These components can be sensitive to ingredients in detergents. In these situations, the use of de-ionized water provides the most effective cleaning without damaging components.
Kaijo can provide recommendations on using the right cleaning solutions suitable for a wide range of applications.
- Using Heat to Improve Ultrasonic Cleaning
Incorporating heat into your ultrasonic cleaning process can significantly increase its effectiveness, especially for certain types of contaminants. Heated ultrasonic tanks operating below 100 degrees Centigrade can facilitate the removal of stubborn substances, such as hard carbon deposits, leading to improved cleaning times.
The application of heat works to soften and loosen contaminants, making them easier to remove. However, not all parts can withstand higher temperatures. Therefore, when selecting a heated ultrasonic cleaning tank, it’s essential that the parts being cleaned can endure its elevated temperatures without sustaining damage.
Kaijo provides a range of heated ultrasonic cleaning tanks to enhance your cleaning process. However, before incorporating heat into your process, a thorough, in-depth assessment of the components and contaminants involved is advised.
Keep in mind that every ultrasonic cleaning application is unique. Factors such as the nature of the parts, the type of contaminants present, and the specific cleaning requirements all play a role in determining the most suitable ultrasonic cleaner. By keeping these five key considerations in mind, you will have all of the information necessary to make an informed choice.
Selecting an ultrasonic cleaner is an integral decision that can greatly increase the efficiency and effectiveness of your cleaning operations. By considering factors like frequency, power level, tank size, cleaning solution type, and potential use of heat, you can ensure you find an ultrasonic cleaning system tailored specifically to meet your cleaning requirements.
The reputation and support of the equipment manufacturer are also key factors in this decision-making process. As a leading supplier in the industry, Kaijo offers a comprehensive range of ultrasonic cleaners, to ensure they have a solution for every unique requirement. Kaijo’s commitment to quality and customer service, and in-house experts guide customers to ensure they choose the appropriate cleaner that meets their requirements. Contact Kaijo for a free consultation to get expert help in choosing the right ultrasonic system to meet your industrial cleaning requirements.