Editor&#;s Note: This article was originally published in August and has been updated with additional information and reposted in August .
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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.
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:
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.
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 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.
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.
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.
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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.
Conclusion
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.
An ultrasonic cleaner can address a wide range of contaminants; it can handle cleaning of virtually any type of object. Tool selection is always important; especially so with ultrasonic cleaning equipment. Not every ultrasonic cleaner is created equal and the right equipment should be selected to meet the specific needs of the company. Before purchasing an ultrasonic cleaner, buyers should identify their ultrasonic cleaning needs and goals.
Size of the parts to be cleaned
Always consider the largest item or part that will be cleaned regularly in the machine. Full measurements of the largest item should be taken and given to the manufacturer so that the proper tank can be specified for the application.
Ultimate cleaning goals
Post cleaning results are of primary concern for people in manufacturing, rebuilding, restoration or the medical field. Ultrasonic is the most thorough process of cleaning known to science. Consequently this methodology is utilized for countless applications around the world today. The time to clean parts is greatly reduced when ultrasonic cleaners are used versus hand cleaning methods. As a result, production is dramatically increased while the cost of cleaning goes down.
Utilizing the correct baskets/racks
The items being cleaned must not touch the ultrasonic transducers located inside the tank. Parts baskets should be utilized and selected specifically for the cleaning application. Any parts or baskets making contact with the ultrasonic transducer packs will eventually cause the surface of the pack to etch or scratch. Even though the packs are constructed of stainless steel, once etching occurs erosion will follow and will over time destroy the integrity of the transducer pack. This damage cannot be repaired and the transducer pack will eventually need replacement.
Ultrasonic cleaners create heat energy as they run. The heat will rise during the cleaning process due to the friction of the cavitation activity being created within the cleaning vessel. The rise in temperature cannot be avoided. Heaters are required to bring the cleaning solution to the desired starting temperature. They are also a necessity when cleaning contaminants such as carbon oil and grease residue. High temperatures help break down these contaminants to better facilitate the cleaning process.
Generator adjustability and wave sweep
Wave sweep is utilized and recommended in virtually all cleaning situations. By dispersing various frequencies with different wave lengths, wave sweep effectively eliminates in active and dead zones in the cleaning tank. This results in more uniform and effective cleaning of all parts especially those of intricate detail. Ultrasonic cleaners equipped with wave sweep do not require degassing modes as engaging the wave sweep accomplishes accelerated degassing of solutions.
Ultrasonic frequency and power
Most ultrasonic cleaners operate between 28 and 120 KHz. The lower frequencies produce larger cavitation bubbles with more abrasive cleaning. These frequencies are recommended for coarse cleaning needs such as removal of lapping compounds from durable metal surfaces. For fine cleaning of very delicate items such as jewelry and soft metals with polished surfaces, higher frequency may be more suitable. The most commonly utilized frequencies are 38 to 40 KHz because they are ideally suited for the vast majority of both commercial and industrial cleaning applications. The power generated by an ultrasonic cleaner should be capable of dealing with the client&#;s most difficult cleaning applications. Controls on the ultrasonic generator allow the operator to dial down the power whenever more delicate cleaning applications are addressed. Because power can be dialed down there is no need to buy cleaners with minimal power capability. Even cleaning delicate items may require more energy when multiple parts are cleaned at one time.
For more than two decades, Ultrasonics International has helped businesses improve profitability by providing their clients with ultrasonic cleaning equipment that feature the latest advancements in wave sweep technology. Our ultrasonic cleaning equipment has a reputation for reliability and longevity. Utilizing the proper ultrasonic cleaning equipment saves money and improves cleaning processes. Cleaning results will be measurably better and less time will be required to complete the cleaning process. Production numbers go up and labor hours go down dramatically because multiple parts can be addressed simultaneously.
At Ultrasonic International Corp. we serve many industries including automotive, marine and government agencies and more. In addition to our wide selection of standard units we consistently and regularly custom-design equipment to suit the needs of the individual customer.
Contact our sales team today to see how our cleaning technology can help you maximize profits.
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