How Ultrasonic Cleaners Provide Effective Cleaning Before Plating or Coating

Ultrasonic parts cleaners are the ideal choice for cleaning metal or plastic parts that will be plated or coated. Parts often have contaminants as a result of machining, buffing compound, or shop dirt. Surface parts that are contaminated will encounter problems with adhesion when they’re being coated or plated. Ultrasonic cleaners provide a fast and thorough cleaning of part surfaces, saving time and ensuring complete adhesion. The use of ultrasonic cleaners is completely safe and does not require the use of chemicals to remove dirt or contaminants. The benefits include quicker processing, better throughput, and higher quality results.

How does an ultrasonic parts cleaner work in cleaning parts to be plated or coated? It involves the production of microscopic cavitation bubbles in the cleaning tank. An ultrasonic generator produces a high-frequency electric signal to a transducer, which converts the signal into sound waves as they encounter the cleaning solution.

These sound waves in the cleaning liquid have high-pressure peaks and low-pressure troughs. Cavitation bubbles are formed at low pressure and collapse at high-pressure peaks. The continuous cavitation action results in a mechanical cleaning action and scrubbing effect on the surfaces of the parts to be cleaned. Contaminants and particles are dislodged and carried away by the cleaning solution.

Choosing the appropriate frequency, power and cleaning system configuration is important for effective cleaning before plating or coating. The frequency depends on the structure of the parts as well as the nature of the surface contamination that needs to be removed. Kaijo’s experts work with customers to ensure the right frequency, power and system configuration is used to provide optimum results for their specific cleaning application.

Kaijo’s ultrasonic parts cleaners provide fast and thorough cleaning of parts, ensuring total and effective adhesion of coatings and planting applications. To learn more about how ultrasonic cleaners work, read the complete article “How Ultrasonic Cleaners Provide Effective Cleaning Before Plating or Coating”. Call Kaijo for a free consultation or quote at 408-675-5575 or email info@kaijo-shibuya.com.

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Why Ultrasonic Cleaners Are the Best Alternative to Cleaning with Toxic Solvents

Traditional industrial cleaning methods involve cleaning parts using toxic chemicals and mechanical scrubbing to dissolve and remove surface contaminants and residues. However, the cost of the cleaning chemicals, as well as their handling and disposal, continues to rise. The best alternative to traditional industrial cleaning methods is the use of Industrial ultrasonic cleaners. Ultrasonic cleaning effectively removes surface contaminants from a wide variety of parts made from different materials, but does not require the use of toxic chemicals and intense scrubbing.

How does ultrasonic cleaning equipment work? It uses the scrubbing effect of microscopic cavitation bubbles produced by ultrasonic waves in the cleaning solution. The cavitation bubbles are formed in the low-pressure regions of the ultrasonic sound waves and they collapse in the high-pressure peaks. The continuous formation and collapse of the microscopic bubbles create the powerful cleaning and scrubbing action where they effectively dislodge dirt and contaminants from the surfaces of the parts being cleaned.

Kaijo’s ultrasonic cleaning equipment is a cost-effective alternative to traditional cleaning methods. There is no need to soak the parts or wash them in aggressive cleaning solvents. Since it uses only water and sound waves, ultrasonic cleaning is safe. Plus, ultrasonic cleaning is faster and much more efficient. It can dislodge contaminants without damaging the parts being cleaned when the right frequency and power is applied. For cleaning more stubborn deposits, a mild detergent is sometimes used along with the use of tank heater to heat the cleaning solution.

Ultrasonic cleaning does not also need special storage or handling facilities and does not have regulatory oversight of for waste disposal.

Read our complete article “Why Ultrasonic Cleaners Are the Best Alternative to Cleaning with Toxic Solvents” to learn more about the benefits of using ultrasonic cleaners. Call 408-675-5575, or email info@kaijo-shibuya.com if you would like to discuss how Kaijo’s equipment can be used in your cleaning application.

How to Select an Ultrasonic Tank for Your Industrial Cleaning Application

An ultrasonic cleaning system consists of an ultrasonic generator one or more transducers and the ultrasonic cleaning tank that holds the cleaning solution where the part is cleaned. In a well-designed system, the selected frequency of the generator, system power and tank characteristics all contribute to providing optimum cleaning performance.

The size of the ultrasonic tank is crucial to the ultrasonic cleaning system’s overall cleaning performance. If the ultrasonic cleaning system is a single-use installation, the cleaning tank can be sized to exactly contain the parts to be cleaned. For parts are big, long, or have odd shapes, it’s best to have a custom tank sized to meet the needs of the application. For ultrasonic cleaning systems that are used for many different cleaning applications, the choice of the tank size is critical so as to not limit the cleaning system’s flexibility.

After determining the size of the largest part or items to be cleaned, the minimum tank size needed for the application will be known. For cleaning smaller and/or more delicate parts, a parts basket can be used to hold the parts and prevent them from coming into contact with the vibrating tank on the bottom as well as on the sides. Therefore, the tank should be a bit larger to hold the parts inside the part basket.

The bigger the tank, the more transducers may be required to ensure that the amount of bubbles is generated evenly throughout the cleaning solution. The type of transducer impacts the design of the cleaning tank. They can be bolt-on transducers (fixed onto the tank) or immersible transducers (submerged in the cleaning liquid inside the tank).

Kaijo’s ultrasonic cleaning tanks can be customized for your cleaning application. Read our complete article “How to Select an Ultrasonic Tank for Your Industrial Cleaning Application” to learn more about what Kaijo can do to help you. If you have questions, or would like to schedule a free consultation, call 408–675–5575 or email info@kaijo-shibuya.com.

How Do Ultrasonic Cleaning Transducers Work?

Ultrasonic cleaning transducers convert the high-frequency electric signal of an ultrasonic cleaning system to sound waves within the cleaning solution. Ultrasonic cleaning systems are made up of an ultrasonic generator, a transducer and a tank to hold the cleaning solution. Frequencies in the lower range from 20 kHz to 160 kHz effectively clean heavy hard to clean contamination from a robust part, while higher frequencies up 2 MHz are used for gentle cleaning of delicate components.

Ultrasonic Cleaning Transducer Features

Kaijo’s ultrasonic cleaning transducers have to generate an equal and consistent distribution of sound waves in the cleaning solution while withstanding the vibrations, temperature and the cleaning action of the system. Ultrasonic sound waves create high-energy cavitation bubbles in the cleaning solution, which create a scrubbing and cleaning action, dislodging the dirt and contaminants from the surfaces of the parts immersed in the cleaning solution. The cleaning solution may also contain mild detergent and can also be heated for faster cleaning.

The housing of Kaijo’s ultrasonic cleaning transducer is protected by 316L polished stainless steel so that the transducer is not affected by the cleaning solution and can resist the possible pitting from the cavitation bubbles. They are hermetically sealed and can operate in cleaning solutions of up to 100 degrees centigrade. Lower frequency range transducers are provided with power levels of 600 W or 1200 W, and higher frequency units are available at 1200 W.

There are three types of ultrasonic transducers:

  • Immersible transducers – these are independent units and are the most flexible in their application. They can be placed into different tanks, or different transducers can be placed in the same tank.
  • Bolt-on transducers– they can be semi-permanent placement on a cleaning tank.
  • Mounted transducers– they are integrated into the tank.

If you would like additional information, read the complete article entitled “How Do Ultrasonic Cleaning Transducers Work?” You may also contact Kaijo at 408-657-5575 or email info@kaijo-shibuya.com to discuss what kind of ultrasonic transducer and cleaning system should be used for your application.

Can Kaijo Create a Custom-Built Ultrasonic Cleaner for My Application?

Aside from standard ultrasonic cleaning solutions, there are also industrial ultrasonic cleaners that are custom-built solutions that cater to the clients’ specifications. Kaijo’s extensive knowledge of ultrasonic cleaning technology allows them to analyze cleaning requirements to make needed adjustments to standard equipment for superior cleaning performance.

Industrial ultrasonic cleaners consist of an ultrasonic generator, a cleaning tank, and a transducer. Each of these components can be selected from a line of standard components but custom features can be added and a custom system can be assembled to respond to unusual cleaning conditions or requirements.

Kaijo first looks at the cleaning application and considers the factors affecting the cleaning system. These include the type of parts to be cleaned, nature or level of dirt or contamination to be removed, and whether the system is mainly used for a single cleaning task or whether many different types of cleaning have to be carried out.

Based on these factors, Kaijo decides on the ideal frequencies or frequency ranges as well as the system power. A lower frequency is usually used for removing tough dirt from rugged parts in a single use application, while a higher frequency is ideal for removing light contaminants from delicate parts. Also, the system power must be high enough to evenly fill the cleaning tanks with ultrasonic waves.

Once Kaijo has chosen the frequencies and the power, the company looks at the physical installation, determining the right kind of transducer and tank. Transducers can be immersible or mounted on the tank. Tanks could be existing ones or new ones. The size of tanks and materials used could influence the cleaning process.

Once these characteristics are determined, Kaijo chooses the components from its complete line of ultrasonic cleaning equipment. The company decides whether it’s the standard off the shelf components can be used or if custom components will be required by the client.

The complete article “Can Kaijo Create a Custom-Built Ultrasonic Cleaner for My Application?” provides additional information. If you have questions after reading the article or would like to set up a free consultation to discuss your needs, please call 408-675-5575 or send an email to info@kaijo-shibuya.com.

Why Industrial Cleaners Are Used by Plastic Manufacturers

Manufacturers of plastic products need to clean their equipment between production runs. They also often need to clean the plastic products they manufacture as well.

Also, manufacturing plastic products have various cleanliness standards, depending on the end use of these products. For instance, products that are meant for use in food and medicine must have more stringent cleanliness requirements. Other plastic products used in industry applications may require less strict levels of cleanliness.

More plastic product manufacturers have turned to industrial ultrasonic cleaners from the old traditional cleaning methods that require intense mechanical scrubbing and the use of harsh chemicals.

High performance industrial ultrasonic cleaners can deliver different levels of cleaning action by choosing the right frequency and power. The microscopic cleaning bubbles produced by Ultrasonic cleaners penetrate wherever there is cleaning liquid in the cleaning tank. These bubbles completely and effectively remove contaminants down to the plastic base or tool material.

The benefits that industrial ultrasonic cleaners provide to plastic manufacturers include the following:

  • Reduced costs due to the absence of harsh cleaning chemicals;
  • Reduced labor costs because there’s no more manual scrubbing, scraping, or pressure washing;
  • Increased worker safety because the ultrasonic cleaning process is safe and needs little human supervision;
  • Less time spent on cleaning because the ultrasonic cleaner’s quick one-step cleaning process;
  • Superior cleaning performance as the ultrasonic bubbles penetrate holes and crevices of the surfaces being cleaned;
  • Longer tool and mold life because ultrasonic cleaning does not cause damage to the molds and tools;
  • Better output quality because the ultrasonic cleaning parameters can be selected to specific cleaning application requirements by using appropriate frequencies and power levels.

Kaijo Shibuya, a leader among ultrasonic equipment manufacturers, can provide an ultrasonic cleaning system that meets the requirements of a customer’s application. If you would like additional information, or want a free consultation or quote after reading our complete article “Why Industrial Ultrasonic Cleaners Are Used by Plastic Manufacturers”, call Kaijo’s office at 408-675-5575 or email info@kaijo-shibuya.com.

How to Buy the Right Ultrasonic Cleaner for Your Application – Part 2

The most important things to consider in choosing an ultrasonic cleaning system are the size of the tank, the frequency of the system and the power it can provide. Aside from these the accessories such as a tank temperature heater and holding basket should also be considered when choosing the right system for a cleaning application.

Cleaning tank heater:

Ultrasonic cleaners work by generating tiny cavitation bubbles which clean and scrub surfaces of parts to remove contamination. However, when contaminants on surfaces are hard deposits that are difficult to clean, the cleaning action of the bubbles will take more time. In these cases using a heating, the liquid in the cleaning tank will help to soften or loosen the hardened contamination from the surfaces being cleaned. That’s where the cleaning tank heater enters the picture.

While cleaning tank heaters are a useful option for ultrasonic cleaning systems, they should be designed for the application. Untreated plain water (below 100 degrees centigrade) may be used most of the time but mild cleaning solutions can also be used. If the cleaning solution is considered, the heat settings should be controlled so that solution won’t start boiling. The ultrasonic transducer should also be designed in a way that it will be able to withstand high temperatures.

Using sweep frequencies:
Kaijo’s ultrasonic cleaning systems operate at certain frequencies and are designed to achieve the optimum cleaning results according to the size of the cavitation bubbles and their cleaning intensity. However, a system may experience some unpredictable negative effects. This results in the ultrasonic waves canceling each other and no cleaning occurs. Using sweep frequencies will reduce this effect.

Water resonance system

The water resonance system helps ensure even cleaning action throughout the tank. The water treatment of a water resonance system provides an even distribution of nuclei essential for bubble formation. This allows bubbles to form everywhere within the cleaning solution rather than mostly above the ultrasonic transducer. This provides an even cleaning action on everything placed in the cleaning tank.

If you’re considering the purchase of an ultrasonic cleaner and have questions after reading the complete article “How to Buy the Right Ultrasonic Cleaner for Your Application – Part 2”, contact Kaijo for a free consultation or quote at 408-675-5575 or email info@kaijo-shibuya.com.