I Tried Using Ultrasonics and It Didn’t Work. What Happened?

Ultrasonic cleaning systems work by creating microscopic cavitation bubbles in a cleaning solution. An ultrasonic generator sends a high-frequency electrical signal to an ultrasonic transducer immersed in the cleaning solution. The transducer converts the signal to sound waves that travel through the cleaning solution and generate cavitation bubbles in time with the frequency.

As the bubbles form and collapse, they produce a scrubbing effect that removes contaminants from the parts to be cleaned. High ultrasonic frequencies create small, less energetic bubbles while low frequencies produce larger bubbles with an intensive cleaning action.

But sometimes, ultrasonic cleaning doesn’t deliver the expected rapid and complete cleaning performance. It’s usually because the cleaning system is not configured to match the cleaning task. To work properly, the bubbles have to be distributed evenly throughout the cleaning solution and there have to be enough bubbles for rapid cleaning.

Here are the factors that need to be specified correctly for the system to work properly:

• Not using the correct frequency – Heavily contaminated parts with hard surfaces (such as those made of steel) are best cleaned with low frequencies. Softer materials (such as plastic) require higher frequencies. Delicate components (such as electronics) or fragile material equipment can be cleaned safely with a high frequency ultrasonic cleaner. Choosing the right ultrasonic frequency based on material of the part or device being cleaned is critical.
• Not enough power – The system needs to have enough power to fill the tank with ultrasonic sound waves. If the system is not powerful enough, there will be dead spots where cleaning doesn’t take place and contaminants won’t be completely removed. In some cases where the parts to be cleaned have several different types of contaminants, two types of frequencies are used to clean those parts thoroughly.
• Uneven distribution of sound waves – Sometimes, the set frequency creates a resonance in the cleaning tank so that the sound waves are concentrated in some areas and lacking in others. Ultrasonic cleaning systems can be programmed to vary the frequency slightly on a continuous basis to avoid resonant hot and dead spots. To achieve an even distribution of sound waves and cavitation bubbles, the system may need more than one transducer, especially when cleaning larger parts. The transducers may have to be placed in different areas around the cleaning tank to ensure even cleaning.

Read our latest article, “I Tried Using Ultrasonics and It Didn’t Work. What Happened?” to learn more. Call Kaijo Shibuya to set up a free consultation to discuss your needs at 408-675-5575 or send any questions you may have to info@kaijo-shibuya.com.

Why Ultrasonic Cleaners Are Essential for the Automotive Industry

The traditional cleaning methods that the automotive industry typically uses to clean oily and greasy parts are time-consuming and expensive. Automotive ultrasonic cleaners, on the other hand, deliver cleaning performance in less time and at low operating costs.

There are many fantastic advantages that automotive manufacturing facilities or parts shop can benefit from using ultrasonic cleaners. But in order to get the full advantages provided by ultrasonic cleaners, the cleaning systems have to be configured correctly.

Once the automotive manufacturing facilities or parts shop switch to ultrasonic cleaners, they will become indispensable.

To achieve a successful cleaning performance, the ultrasonic cleaner should match the cleaning application. While a general-purpose ultrasonic cleaner can clean a wide variety of parts, matching it to the cleaning application can improve cleaning performance and avoid potential damage to part surfaces.

Low frequency cleaners deliver a robust cleaning action that can clean quickly but can result in pitting for parts with soft surfaces. Automotive parts are usually made of steel and often have hard surfaces. They come usually contaminated with oil, grease, and carbon deposits. Such parts are hard to clean but configuring the ultrasonic cleaner correctly will provide enough power to remove these deposits quickly and thoroughly.

Typically, a low frequency cleaner with a 40 kHz ultrasonic transducer will be used. If necessary, heat and/or a mild detergent will be used to soften the grease and expedite the cleaning process. Combining these special features in an ultrasonic cleaner adapted to the task helps obtain the best cleaning performance possible.

The advantages of and benefits of using ultrasonic cleaners include:

• Rapid cleaning
• Reduced manpower costs
• Reduced operating costs
• Increased workplace safety
• Reduced environmental impact

These advantages translate to:

• Lower overall costs
• Greater employee satisfaction
• Improved output
• Higher productivity

Learn more about our automotive ultrasonic cleaners by reading the complete article “Why Ultrasonic Cleaners Are Essential for the Automotive Industry.” If you have questions or would like to set up a free consultation to discuss your specific needs, call 408-675-5575 or send an email to info@kaijo-shibuya.com.

Does Ultrasonic Cleaning Work with Plastics?

Ultrasonic cleaning systems work best on parts with hard surfaces, such as those made of metal. But can it also clean parts made of plastic?

Most plastic parts have comparatively soft surfaces, and many have other characteristics that make them less suitable for ultrasonic cleaning. Parts made of light, soft plastic with simple shapes can often be cleaned better manually. But for parts with complex shapes with openings and dead-end holes, ultrasonic cleaning may still be the best solution.

The success of cleaning plastic parts using ultrasonic cleaners depends on the kind and condition of plastic.

• Plastic rigidity – If the plastic is soft and flexible (such as low-density polyethylene), the plastic material will flex with the ultrasonic waves and absorb some of the cleaning power, therefore reducing cleaning performance.
• Plastic density – Low-density plastics may float in the cleaning solution, which leaves some surfaces exposed and not cleaned. A basket is needed to hold them when cleaning such parts.
• Surface hardens – When parts surfaces are soft, the ultrasonic cleaner has to operate at a higher frequency to reduce cleaning intensity and avoid surface pitting. The reduced cleaning intensity required to clean soft plastic parts makes cleaning time a bit longer than required and reduces cleaning effectiveness.
• Degree contamination – The reduced cleaning intensity due to the higher ultrasonic frequency means light contamination can be removed quickly. Heavy contamination will take longer.
• Plastic composition – To speed up ultrasonic cleaning at higher frequencies, the cleaning solution may be heated or added with mild detergents to remove specific contaminants.

Even if some plastic parts are not ideally suited for ultrasonic cleaning, their shape may require an ultrasonic cleaning solution to get the parts completely clean.

For a specific plastic part cleaning application and a corresponding contaminant, the manufacturer of ultrasonic cleaning systems can often design an effective solution. They can determine which frequencies will be the most suitable and effective and can recommend other cleaning agents (such as heating or adding mild solvents) based on their experience.

Kaijo Shibuya is one of the leading ultrasonic cleaner manufacturers and they work closely with customers to ensure their ultrasonic cleaning needs are met. Their complete article, “Does Ultrasonic Cleaning Work with Plastics?”, goes into further detail. Call them at 408-675-5575 or send an email to info@kaijo-shibuya.com if you have questions or would like to set up a free consultation to discuss your ultrasonic cleaning needs.

Why Medical Manufacturers Are Using Ultrasonic Cleaners

New technologies have made medical devices and equipment harder to clean, that’s why medical manufacturers must explore better ways to clean and sterilize them.

Certain cleaning methods may compromise the functionality of medical devices, and even damage them. High-pressure cleaning and autoclave sterilizing can’t be used for devices with electronics or other temperature-sensitive components. Manual scrubbing may remove heavy contamination but may also scratch fragile optical parts and surfaces with delicate coatings.

Medical manufacturers need effective but gentle and low-temperature cleaning methods that can sterilize as well. And this is where medical ultrasonic cleaners become the better alternative to traditional cleaning methods.

They operate at room temperature and can easily clean medical devices with complex shapes or hard-to-reach areas.

Ultrasonic cleaners work by generating microscopic cavitation bubbles in the cleaning solution. The bubbles form and burst in time with the ultrasonic frequency being applied. When they burst, they create tiny, intense jets of liquid that impact the surfaces of the parts to be cleaned and dislodge contaminants.

Since the cavitation bubbles are present wherever the cleaning solution can penetrate, medical ultrasonic cleaners can clean devices with complex shapes, openings, dead-end holes, rough areas, and interior spaces that are normally hard to clean with manual scrubbing. Devices with light contamination can be cleaned as little as ten minutes.

The choice of frequency is a key element for achieving optimal cleaning performance. Low frequency ultrasonic cleaners produce comparatively large cavitation bubbles that deliver an intense cleaning action. Higher frequencies, on the other hand, produce smaller bubbles and cleaning action is gentler. The cleaning intensity of ultrasonic cleaners can be adjusted from robust cleaning for certain devices, such as implants, to gentle cleaning action for delicate instruments. When a disinfectant is added to the cleaning solution, it renders the clean parts sterile.

To achieve a successful ultrasonic cleaning, an experienced ultrasonic cleaner manufacturer can advise customers on the right frequency for their cleaning application while also addressing cleaning tank size and system power. When the medical ultrasonic cleaner is matched correctly to the cleaning application, the cleaning performance is excellent.

Read Kaijo’s complete article, “Why Medical Manufacturers are Using Ultrasonic Cleaners”, for further information. If you have questions or would like to set up a free consultation to discuss your ultrasonic cleaning needs, contact Kaijo by email at info@kaijo-shibuya.com or by calling 408-675-5575.

What Is the Difference Between Cleaning Solvents and Detergents?

https://www.kaijo-shibuya.com/whats-the-difference-between-cleaning-with-solvents-and-detergents

When industrial parts have to be cleaned, the use of ultrasonic cleaners with detergents offers several advantages over the more traditional methods of using solvent baths.

When used by themselves, detergents are not strong enough to remove tough contaminants, whereas powerful solvents that are matched to the material to be removed can dissolve even the heaviest contaminants.

However, you will be surprised to discover that using detergents in ultrasonic cleaners can actually outperform solvents and work well with all types of industrial parts, which can result in cleaner parts and reduced operating costs. They’re a better alternative to solvent-based cleaning methods.

Detergents and solvents clean in different ways. While water can dissolve many substances, plain water alone cannot get rid of compound substances, such as grease and oil. Detergents form a bridge between the water molecules and oily particles by surrounding the contaminating particles, allowing them to be rinsed away.

Solvents clean by dissolving contaminants. Some solvents can dissolve specific substances while others dissolve a whole range of various compounds. The right solvent must be used to remove the contaminants from the part surface and put it into solution, to clean the parts effectively. The solution that contains the contaminant must then be disposed of.

Solvents are chemicals that are typically aggressive, flammable, and give off noxious fumes. They can be costly when used in large soaking baths. They are also harmful to the environment, that’s why they should be treated first before disposal.

Detergents, by contrast, are safe and inexpensive. Most of them are biodegradable, and thus, environmentally friendly. Unlike solvents, detergents are non-flammable and non-toxic. They also don’t generate fumes. When used with ultrasonic cleaners, detergents can clean quickly and effectively without leaving a residue or damaging the parts to be cleaned.

Here are the benefits of using detergents with ultrasonic cleaners:

• A cleaner, more employee-friendly workplace.
• A safer workplace.
• No need for special fire protection.
• Reduced cleaning costs.
• Reduced environmental footprint.
• Improved manufacturing output.

Automotive ultrasonic cleaning is a challenging application, but Kaijo’s ultrasonic cleaners are up to the task.

Read our complete article, What Is the Difference Between Cleaning Solvents and Detergents?, to learn more. You may contact Kaijo via email at info@kaijo-shibuya or call 408-675-5575 to set up a free consultation or discuss your specific ultrasonic cleaner needs.

Kaijo Exhibiting at MD&M Trade Show August 10-12, 2021 Booth #2385

Visit us at Booth #2385 at the MD&M (Medical Design and Manufacturing) West trade show in Anaheim, CA on August 10-21, 2021.

Key discussions will include the importance of using the proper frequency for different medical cleaning applications, as well as Phenix Hyper and Phenix+ ultrasonic cleaners that are ideal for cleaning all types of delicate medical parts, tools, and devices.

Medical devices are often delicate and have to be cleaned to meet high standards. Many of these devices cannot be exposed to conventional mechanical scrubbing, heat, and chemicals that will compromise their functionality and damage them.

Ultrasonic cleaners are perfect for medical industry applications because they provide gentle cleaning and complete removal of contaminants.

In order for an ultrasonic cleaner to clean most effectively, the right frequency needs to be used based on the application. Ultrasonic systems can be adjusted and configured to match the cleaning requirements of medical devices and components so that all surface contaminants are cleaned quickly and completely.

Selecting the right frequency is not important – it is also critical. That’s because using the wrong frequency can damage the parts and components. Using the right frequency, on the other hand, can provide rapid and thorough cleaning of the components, removing all contaminants from the surface of the parts and components being cleaned.

Lower frequencies – They’reusually 40 kHz and below. Typical cleaning frequencies used include 26 kHz and 38 kHz to provide robust cleaning for hard metals, glass, and porcelain parts.

Mid-range frequencies – They range from 40 kHz to 160 kHz. Typical frequencies used include 78 kHz, 100 kHz, 130 kHz, and 160 kHz for cleaning softer and more delicate materials, soft metals, aluminum, and ceramic parts.

Higher frequencies – They range from 200 kHz up to 1+ MHz. Typical frequencies used include 200 kHz, 430 kHz, 950 kHz, and 1.6 MHz for delivering very gentle cleaning parts with incredibly soft surfaces, delicate coating, and micro-structures.

Kaijo’s ultrasonic cleaners for medical cleaning applications

• Kaijo-Shibuya Phenix+ – It has self-regulation features for ease of use, and remote-control operation and monitoring for ease of integration.
• Kaijo-Shibuya Phenix Hyper – The Hyper Mode achieves 3-D cleaning of complex-shaped objects to ensure all surfaces with irregular shapes are thoroughly cleaned.

A leader among ultrasonic cleaner manufacturers for over 70 years, Kaijo Corporation provides powerful and precise cleaning of parts and components.

Read our complete article, Kaijo Highlighting Its Ultrasonic Cleaning Systems for Medical Applications at MD&M West August 10-12, 2021, to learn more. If you would like to discuss your ultrasonic cleaner needs prior to the MD&M event, call Kaijo at 408-675-5575 or send an email to info@kaijo-shibuya.com to set up a free consultation.

Guidelines for Using Ultrasonic Cleaners to Clean Surgical Instruments

Ultrasonic cleaners can deliver excellent cleaning and sterilizing to all types of surgical tools and instruments, which are normally difficult to clean using traditional cleaning methods.

Some instruments, such as laparoscopes used in minimally invasive surgery, may have heat-sensitive components, and can’t be sterilized in an autoclave. Some instruments have complex shapes with areas impossible to reach within manual cleaning. Using ultrasonic cleaners also reduces the risk to medical personnel of handling sharp tools.

Ultrasonic cleaners for medical instruments are deemed effective for cleaning, and as a result, a growing number of medical facilities have begun using them. Despite that, specific guidelines should be followed to ensure a safe and effective operation.

1) Although ultrasonic cleaners are highly effective in cleaning and sterilizing surgical tools, regular medical procedures should still be followed. For example, the tools should be rinsed right after use or kept moist to prevent blood, other bodily fluids, or other material from drying out, as dried contaminants are harder to clean out.

2) The manufacturer’s recommendations and the IFU should always be followed.

3) Effective cleaning depends on using the correct ultrasonic frequency. Cleaners used with only one type of instrument or application may have fixed frequency, while general-purpose cleaners can typically be operated at several frequencies, depending on what’s being cleaned.

4) Sterilization depends on using the right disinfectant and the right quantity. The IFU sometimes specify disinfectants to be used and the applicable research may be available for specific cases. Medical personnel should verify the type and concentration of the cleaning solution.

5) When operating properly, medical ultrasonic cleaners deliver stainless steel instruments that are shiny and completely clean while other parts will be visibly free of contaminants.

6) Besides the general instructions for the use of ultrasonic cleaners for surgical instruments, medical facilities should prepare specific use-based policies and procedures for cleaning different types of instruments with ultrasonic technology. Kaijo works closely with all of the customers to ensure their ultrasonic cleaner requirements are met. You can learn more by reading the complete article, Guidelines for Using Ultrasonic Cleaners to Clean Surgical Instruments, and then by contacting Kaijo to ask questions or to set up a free consultation. You can reach Kaijo Shibuya by either calling 408-675-5575 or by emailing them at info@kaijo-shibuya.com.

Using Ultrasonic Cleaners to Provide an Effective Sterilization Process

Medical devices, instruments, and equipment designed for repeated use have to be cleaned and sterilized after each patient.

Traditional cleaning usually consists of manual scrubbing and wiping together with steam cleaning. Sterilization then takes place at high temperatures in an autoclave. However, more modern medical devices and tools usually include electronics and other temperature-sensitive components. They may also have interior crevices and complex shapes that are hard to clean. Some devices are fragile and may be damaged by manual cleaning or have delicate coatings that are easily scratched when scrubbed.

Ultrasonic cleaners for medical instruments are the better alternative to traditional cleaning methods. Read the article “Why the Sterilization Process Requires an Ultrasonic Cleaner” by Medicanix. They explain how ultrasonic cleaners clean these instruments effectively while avoiding issues with heat and handling.

But ultrasonic cleaners for medical instruments, by themselves, do not sterilize the parts to be cleaned. Adding disinfectant to the cleaning solution can result in sterile parts. The key to a successful cleaning is using the right ultrasonic cleaner for a specific cleaning application and the right amount of disinfectant for parts that are sterile and completely clean.

Ultrasonic cleaners can gently remove contamination without using heat (depending on the parts to be cleaned). They work by using microscopic cavitation bubbles in the cleaning solution to dislodge contaminants from the underlying surfaces. Ultrasonic waves in the cleaning solution generate the bubbles, which form and collapse in time with the ultrasonic frequency. When they collapse, the bubbles release tiny jets of cleaning solution that hit the parts to be cleaned and wash away the contaminants.

This process takes place wherever cleaning solution is present, even on complex shapes and inside interior crevices, inside tubes, along hinges, and in dead-end holes.

One of the great things about ultrasonic cleaners for medical applications and tools is they can clean gently at room temperature. The cleaning intensity can also be adjusted to match the fragility of the medical parts to be cleaned and temperature-sensitive electronics don’t suffer heat damage.

With ultrasonic cleaners, there’s no need for scrubbing or heating, both of which would otherwise damage fragile and heat-sensitive medical tools and devices. Kaijo’s experience building ultrasonic cleaners, along with their in-house expertise, makes them the best choice for working with medical facilities for their ultrasonic cleaner needs.

Our complete article, Using Ultrasonic Cleaners to Provide an Effective Sterilization Process, explains further. After reading the article, contact Kaijo by email at info@kaijo-shibuya.com or by calling 408-675-5575 if you have questions or would like to set up a free consultation to discuss your ultrasonic cleaner requirements.

Why Ultrasonic Cleaners Are Essential to Medical Manufacturers

Modern medical equipment incorporates sensitive components such as electronics, sensors, and optical fiber. Because of the way they are constructed, traditional cleaning and sterilizing methods can’t often be used in cleaning them.

Manual scrubbing can remove heavy contamination but can cause scratches to certain devices such as sensors, optical devices, and other fragile equipment. Some electronics are sensitive to heat, and therefore cannot stand high temperatures from hot steam. Devices with complicated shapes, hinges, threaded holes, and interior surfaces are hard to clean by traditional cleaning methods alone.

Ultrasonic cleaners provide the best alternative to traditional cleaning methods to remove contaminants without using chemicals, manual scrubbing, or high temperatures. They can do effective cleaning performance for both robust parts and delicate parts, as long as the configurations are adjusted accordingly.

Medical ultrasonic cleaners work by creating microscopic bubbles in the cleaning solution. As the ultrasonic sound waves pass through the cleaning tank, the bubbles form and burst in tune with the ultrasonic frequency. When the bubble bursts, it produces a tiny but powerful jet that can dislodge contaminants from the surface of the part to be cleaned.

The ultrasonic cleaning system has to have enough power to fill the cleaning tank with ultrasonic waves. Ultrasonic cleaners can be configured to deliver strong cleaning performance for durable and robust parts or gentle cleaning to fragile parts. Low frequencies create comparatively large bubbles and deliver a powerful cleaning action. High frequencies, on the other hand, produce smaller bubbles and weaker jets, providing a gentler cleaning action. Choosing the right frequency matches the cleaning power to the medical equipment to be cleaned.

Ultrasonic cleaners can clean parts and devices with complex shapes, interior holes or along crevices. While medical ultrasonic cleaners do not sterilize, adding a disinfectant to the cleaning solution renders the clean parts sterile. As modern medical equipment gets more difficult to clean, ultrasonic cleaners are the ideal solution for the manufacturers of medical equipment. Learn more about Kaijo’s ultrasonic cleaning systems by reading the complete article, Why Ultrasonic Cleaners Are Essential to Medical Manufacturers. Call Kaijo Shibuya at 408-675-5575 to set up a free consultation to discuss your cleaning requirements or email info@kaijo-shibuya.com.

Incorporating Megasonic Cleaners into Large Processing Systems

Environmental regulations impose restrictions on the use of aggressive chemicals commonly used in large processing systems, resulting in more stringent production part cleaning requirements.

Manufacturing lines often include cleaning steps to prepare parts for subsequent processing. Cleaning may include manual scrubbing, pressure washing, and soaking the parts in hot chemical baths. However manual scrubbing and pressure washing don’t guarantee thorough cleaning and may even damage the most fragile parts. Some parts used in modern products may be temperature-sensitive that could be damaged by hot chemical baths.

Semiconductor manufacturers use large processing systems in processing silicon wafers. Wafers have to be cleaned between process steps to reduce possible particle contamination that will affect the quality of devices produced. Cleaning silicon wafers are usually carried out using baths that contain harsh and aggressive chemicals.

Megasonic cleaning systems make an ideal alternative for removing contaminants from surfaces of parts that are being cleaned without manual scrubbing or the use of harsh chemicals.

In megasonic cleaning, the process can take place at room temperature and is completely safe, requiring no additional operator safety measures. No special support equipment is needed, and the cleaners work without the need for constant operator monitoring.

Megasonic cleaning systems clean parts by using very high frequency sound waves. These sound waves create microscopic cavitation bubbles when the sound waves pass through the cleaning solution. The scrubbing action of the bubbles, as they form and burst, dislodges contaminants, and allows them to be rinsed away. This cleaning mechanism is especially effective for stubborn microscopic particles that can cause semiconductor component defects. Incorporating the megasonic cleaning method produces silicon wafers that have fewer contaminating particles.

For manufacturers that want to reduce the use of expensive and toxic cleaning chemicals while improving the performance of their cleaning stations, megasonic cleaners can also be incorporated into larger processing systems to provide an effective solution.

One area that that megasonic cleaners are incorporated into large processing systems is in wet bench chemical stations used by semiconductor manufacturers. Incorporating megasonic cleaning systems into the semiconductor production line reduces chemical use and improves cleaning performance. Megasonic cleaners work mechanically to remove contaminants from surfaces of silicon wafers.

For more details read the complete article, Incorporating Megasonic Cleaners into Large Processing Systems. Contact Kaijo Shibuya at 808-675-5575 to set up a free consultation or  email info@kaijo-shibuya.com.