When Are High Frequency Ultrasonic Cleaners Needed?

High frequency ultrasonic cleaners are needed when the parts to be cleaned are delicate and easily damaged.

How ultrasonic cleaners clean parts?
Ultrasonic cleaning systems use the scrubbing action of microscopic cavitation bubbles to clean dirt and contaminants from the surface of the parts being cleaned.

The ultrasonic frequency generator produces an electrical signal that the ultrasonic transducer converts to sound waves in the cleaning solution. Cavitation bubbles form in the troughs of the sound waves and collapse in the peaks. When they collapse, the bubbles create many tiny high-energy jets of cleaning solution. If the bubbles are near the surface of the parts being cleaned, the jets hit part the surface and dislodge any contaminants that are present there.

How can cavitation bubbles damage parts?

Selecting the right frequency is one of the keys to achieve the optimal cleaning performance.

Low frequency systems generate larger bubbles that deliver robust cleaning. These bubbles are so powerful that they can effectively remove heavy contaminants, but they can also cause damage to parts made of delicate materials.

High-energy jets produced from low frequency systems can also cause damage to parts with complicated structures such as printed circuit boards. They can also strip away protective coating of plating parts of some materials such as coated lenses, hard disk media or flat panel glass.

High-frequency jets are the key

High-frequency ultrasonic cleaners (over 100 kHz) generate smaller bubbles that deliver gentle cleaning. These bubbles form weaker jets. These jets don’t clean as fast as the jets of the lower frequency systems, but they are also too weak to cause damage to delicate parts.

High-frequency bubbles are ideal for cleaning delicate parts and components. They are gentle enough not to cause pitting to soft parts or strip away the coatings, but they have adequate power to remove contaminants that negatively impact the coated parts. The gentle cleaning action of the high-frequency bubbles will maintain the integrity of delicate parts being cleaned.

If you would like additional information, please read the complete article “When Are High Frequency Ultrasonic Cleaners Needed?” Contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com to set up a free consultation to discuss your specific cleaning requirements.

How Ultrasonic Part Cleaners Keep Employees Safe

Ultrasonic cleaning allows workers place the parts in a water-based solution and leave them there for a short period until they are clean. This is in sharp contrast to traditional cleaning methods that require extensive handling of parts, soaking them in harsh chemicals and scrubbing them.

Ultrasonic part cleaners keep the workers safe in many ways:

1) Less handling of parts reduces accidents
Traditional cleaning of parts is labor-intensive. Some parts have complex shapes that may require manual scrubbing. The handling of heavy parts and parts with sharp edges and corners can result in strain, cuts and bruises. Ultrasonic part cleaners minimize handling of parts, thus reducing the risk of accidents and injury.

2) Less use of sharp cleaning tools
Manual cleaning and brushing of contaminated parts consists of using wire brushes and scrapers which can penetrate or cut through protective gloves, thus injuring employees. Ultrasonic part cleaners can clean parts without the use of sharp cleaning tools.

3) Minimized use of harsh chemicals
Traditional cleaning also consists of using harsh chemicals. But storage, handling, use during cleaning of the parts and disposal of these toxic chemicals can present safety hazards to both humans and the environment. Ultrasonic cleaning requires no special solvents beyond mild detergents in a water solution for heavy contamination with grease or oily deposits. Moreover, these detergents are not hazardous and require no special disposal after use.

Ultrasonic parts cleaners are the ideal alternatives to traditional cleaning of parts that require manual scrubbing or using toxic cleaning chemicals. Moreover, they clean the parts quickly, thoroughly and effectively while keeping the workers and the work environment safe.  Employees simply place the parts to be cleaned in ultrasonic cleaning tanks turn on the system to run for a specified time.

For more details read the completed article titled “How Ultrasonic Part Cleaners Keep Employees Safe”. If you want a free consultation or quote, please contact Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.

Why Ultrasonic Cleaners Are Used in the Medical Industry

why-ultrasonic-cleaners-are-used-in-the-medical-industrySince medical devices are often delicate and have high cleaning standards, industrial ultrasonic cleaners provide an ideal solution, offering gentle cleaning and complete removal of contaminants.

Medical devices that include surgical instruments and medical implants are used inside the body and are subject to extremely high standards of cleanliness and sterility. In addition, medical devices have complex structures that mean intricate surfaces, tiny crevices, dead-end holes and even inside slots and threaded holes.

Many medical devices cannot be exposed to heat, harsh cleaning chemicals and intense scrubbing which are typically used in traditional cleaning methods. Not only these methods costly and cause potential damage to medical devices, but they also do not guarantee that they provide complete cleaning.

Industrial ultrasonic cleaners rely on sound waves, which produce microscopic cavitation bubbles in the cleaning solution. The formation and collapse of these bubbles agitate the cleaning solution near the medical device surfaces to dislodge any dirt or contamination that may be present.

Low ultrasonic frequencies produce comparatively large bubbles with an intense cleaning action for rugged devices. High ultrasonic frequencies, on the other hand, produce smaller bubbles with a gentle cleaning action which is the frequency used to clean delicate parts such as medical devices.

No matter how complex medical devices are, once they are immersed in the cleaning solution, the microscopic cavitation bubbles are formed inside the tiniest crevices and dislodge any contaminants, cleaning down to the original surface. A complete cleaning is extremely important, especially for implants. If these implants still have leftover contaminants due to improper and incomplete cleaning, it could result in the rejection of the implants.

While industrial ultrasonic cleaning systems effectively remove contaminants, they do not, by themselves, kill or eliminate bacteria. Thus, adding a sterilizing solvent to the cleaning solution helps the cleaning action process and the action of the cleaning bubbles heightens the sterilizing effect as well.

For more information read the complete article, “Why Ultrasonic Cleaners Are Used in Medical Industry”. Contact Kaijo for a free consultation or quote by email info@kaijo-shibuya.com or call 408–675–5575 to discuss your cleaning requirements.

Selecting the Right Ultrasonic Tank and Transducer for Your Application

An ultrasonic cleaning system consists of several different components:

  • Ultrasonic generator – Produces the electric ultrasonic frequency;
  • Transducer – Converts the electric signal to sound waves; and
  • Tank – Holds the cleaning solution and the parts to be cleaned.

Choosing the right ultrasonic cleaning tank and transducer for your specific application helps ensure that the ultrasonic cleaning system works as expected and satisfies the requirements of your cleaning application.

When selecting the right tank, you need to consider several characteristics:

  • Size – the tank must be large enough to hold the cleaning solution and the parts to be cleaned and not over-sized which results in inefficient operation.
  • Basket – the basket holds the smaller parts, so that they won’t be damaged against the tank’s bottom and walls from the vibration caused by the ultrasonic frequency.
  • Heating – some cleaning applications will benefit from a tank that can distribute heat in the cleaning solution.
  • Thickness of tank material – the thickness of the tank enhances the sound distribution and prevents cracking.

Ultrasonic cleaning transducers are sealed metal containers that can be either immersible, bolt-on, or directly mounted types:

  • Immersible ultrasonic transducers – are the most flexible type of transducers because they can be moved and placed in any tank. It is waterproof and are attached to a cable, which is then plugged into the ultrasonic generator. It can be suspended in the cleaning solution to produce the ultrasonic sound waves.
  • Bolt-on transducers – are fixed to the bottom or sides of the cleaning tank. Bolt-on transducers can be exchanged but they are not as flexible as immersible transducers.
  • Mounted transducer – it is fixed to the bottom or sides of the cleaning tank. Mounted transducers often come with turnkey systems and are integrated into the ultrasonic cleaning system.

It is also important to choose the right ultrasonic cleaning tank and transducer combination. Kaijo provides expert advice for ultrasonic cleaning installations to ensure your system delivers the performance you expect.

Read the complete article “Selecting the Right Ultrasonic Tank and Transducer for Your Application” to learn more. Contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com if you have questions or want a free consultation on choosing the right ultrasonic system for your needs.

How Ultrasonic Cleaning Systems Eliminate Manufacturing Production Delays

Incomplete cleaning of tools and parts used in manufacturing production lines, such as cleaning injection molds, can result to slow operation, down times and overall operation and production delays.

The use of ultrasonic cleaning systems ensures that cleaning injection molds and related parts are completely and properly cleaned. It also reduces the time needed for finding and solving cleaning problems that are usually encountered with conventional cleaning methods.

The use of ultrasonic cleaning technology allows even hard to clean part surfaces and textures to be completely and effectively cleaned. The ultrasonic waves result in the formation and collapse of the cavitation bubbles in the cleaning solution. This action of cleaning bubbles helps in dislodging contamination and other undesirable particles from the surfaces of the parts that are being cleaned. The cavitation bubbles can even clean intricate shapes and hard-to-reach places of the parts being cleaned.

To achieve the optimum cleaning performance in an ultrasonic cleaning system, the right tank size, power and frequency levels should be selected carefully.

The ultrasonic cleaning system is so effective that it doesn’t need aggressive cleaning chemicals or use mechanical scrubbing action. Operator safety is greatly enhanced and costs for the use, handling, storage and disposal of chemicals are eliminated. With the elimination of chemicals, the ultrasonic cleaning system is also environmentally compliant.

For more details read the complete article “How Ultrasonic Cleaning Systems Eliminate Manufacturing Production Delays” to learn how Kaijo can help you. For a free consultation or quote call 408-675-5575 or email to info@kaijo-shibuya.com. Ultrasonic cleaning systems are an ideal solution for quick, thorough and efficient cleaning of industrial and manufacturing parts, such as injection molds. Using a proactive cleaning process, you won’t have to encounter down times and unnecessary production delays any longer.

What Are the Advantages of Turn-Key Ultrasonic Cleaning Systems?

An ultrasonic cleaning system contains three essential components: the ultrasonic generator, the transducer, and the cleaning tank.

These components can be purchased together in a complete turn-key system or purchased separately. If components are purchased separately customers need to make sure that the components and specifications match otherwise the system will not perform or provide less than ideal results.

Turn-key ultrasonic cleaning systems from reputable manufacturers are built with components that have the required characteristics. The system design ensures that the selected components are matched correctly and together deliver the best performance.

Aside from the frequency, power and tank size, the type of controls, the tank material and the operating temperature should be considered. 

  • General-purpose cleaning or cleaning rugged components – low frequency (26 kHz or 38 kHz)
  • Cleaning delicate parts – high frequency (130 kHz or 160 kHz)

The size of the tank should and a number of transducers needed must be determined. Tanks need to be large enough to hold the biggest or longest parts to be cleaned. The tank material also needs to be impervious to withstand any cleaning solutions used as well as the high temperatures (if heating is needed).

Control systems should be run in either fixed mode or sweep mode to produce even distribution of the ultrasonic waves. The system controls also adjust the power.

Citing the time-consuming and expensive nature of the application of these design configurations, any mistakes will adversely affect the ultrasonic cleaner’s performance and may even damage the parts that are being cleaned.

Kajio’s Phenix III is a turn-key ultrasonic cleaning system will eliminate those potential problems. It delivers general ultrasonic cleaning for a variety of industrial parts in a reliable and cost-effective manner. It is easy to use and offers flexibility in operations.

It offers various standard tank sizes to accommodate different powers and frequencies. Custom sized tanks are also available. The 3mm-thick stainless-steel tank can withstand high temperatures (up to 100 degrees centigrade) and common detergents, therefore delivering superior cleaning performance. The transducers and the tank can also withstand high-temperature operation.

The Phenix III is available in 26 kHz and 38 kHz models as well as 600w and 1200w models. It can operate in either fixed or sweep mode.

For additional flexibility, the single-phase 50/60 Hz AC power supply is selectable for 200V, 208V, 230V or 240V. The unit draws 6A for the 600 W model and 10 A for the 1200 W model.

To learn more about Kaijo’s Turn-Key ultrasonic cleaning system, read the complete article “What Are the Advantages or Turn-Key Ultrasonic Cleaning Systems?” For a free consultation or quote email info@kaijo-shibuya.com or call 408-675-5575 to discuss your requirements.

Top 5 Things to Consider When Buying an Ultrasonic Cleaner

top-5-things-to-consider-when-buying-an-ultrasonic-cleaner Industrial ultrasonic cleaners have become the preferred choice for many manufacturing and research facilities. They provide a more effective solution for a lot of cleaning applications and they clean more quickly than traditional cleaning methods that involve hard manual scrubbing and the use of caustic cleaning chemicals.

The key to buying the right ultrasonic cleaner is looking at the right characteristics and features:

1) Ultrasonic cleaner frequency
The ideal frequency of an ultrasonic cleaner determines the level and size of cavitation bubbles which produce the cleaning action in the cleaning solution. Low frequencies result in bigger bubbles which are ideal for robust cleaning of parts with hard surfaces. Higher frequencies produce smaller bubbles that are ideal for gentle cleaning of soft and delicate parts.

2) Ultrasonic cleaning tank size
The ultrasonic tank contains the cleaning solution where you immerse the parts to be cleaned. The cleaning system tank size is important in relation to the size of the parts to be cleaned. These parts must fit adequately into the tank.

If many different parts must be cleaned, a basket may be needed. Baskets keep the small parts clear of the tank bottom and sides because the vibrations against the tank walls during cleaning may damage the parts.

3) Ultrasonic cleaner power
Power is also an important factor when choosing an ultrasonic cleaner. Turnkey systems automatically have the right power levels for the ultrasonic system, however, if the ultrasonic generator, transducer, and cleaning tanks are purchased separately, adequate power needs to be generated based on the size of the tank. The ultrasonic power rating, as well as the configuration of transducers, can affect cleaning performance.

4) Cleaning with mild soaps and detergents
Industrial ultrasonic cleaners usually clean with deionized (DI) water alone, however, mild soaps and detergents may be required to remove more stubborn contaminants and to facilitate cleaning. For contaminants that are harder to clean, a solvent specific to the contaminant will often speed up cleaning and improve cleaning performance.

5) Using heat to improve cleaning performance
Sometimes the application of heat is used in ultrasonic cleaning to soften and remove heavy contamination to speed up cleaning. If heating is to be used, the tank and the transducer must be able to operate in temperatures up to 100 degrees Celsius. The tank must be fitted with the heater and the parts to be cleaned should also be able to withstand the high temperatures. Depending upon the contaminants to be cleaned, the cleaning process may take more time.

For more details read the complete article “Top 5 Things to Consider When Buying an Ultrasonic Cleaner”. For a free consultation or quote contact Kaijo at 408–675–5575 or email to info@kaijo-shibuya.com.