Why Ultrasonic Cleaning Systems Are Used in the Metal Finishing Industry

Metal finishing involves applying coatings or other kinds of treatments to metal parts surfaces. This is to change the metal part’s characteristics, harden the surfaces, or preventing corrosion. Ultrasonic cleaning systems are able to clean these metal surfaces quickly and completely.

These metal finishes include electroplating, which uses an electrode in applying a thin metal film to metal parts; plating using a chemical process; and plating which involves pressing a foil of metal onto part surfaces at high temperature and pressure.

For these metal finishing processes to be successful, the underlying metal surfaces have to be completely clean. Otherwise, the coatings may not adhere properly if the contaminants (such as grease or oil) remain on the metal surface.

Clean and contamination free surfaces allow for the proper adhesion of metal coatings, that’s why metal parts must be cleaned completely for the coatings and claddings to adhere. Ultrasonic cleaning systems effectively clean metal surfaces quickly and thoroughly.

In ultrasonic cleaning process metal parts to be coated are immersed in a bath of pure water (or water mixed with a mild detergent). A high-powered ultrasonic generator transmits an electrical signal to an ultrasonic transducer that is placed in the bath and produces ultrasonic waves in the liquid at a selected frequency. The sound waves generate tiny cavitation bubbles that produce a strong scrubbing and cleaning action against the metal surfaces in the bath, dislodging particles and removing contaminants.

Other cleaning methods that use chemicals or mechanical cleaning are often used in metal applications. However, the use of ultrasonic cleaning systems and equipment is faster and does not require the use of harsh cleaning chemicals or intense mechanical scrubbing. Since ultrasonic cleaning requires no chemicals costs are reduced and it is more environmentally friendly.

 

Read our complete article, “Why Ultrasonic Cleaning Systems Are Used in the Metal Finishing Industry” to learn more. If you have questions or would like to set up a consultation, contact Kaijo Shibuya at info@kaijo-shibuya.com or call 408-675-5575.

How Ultrasonic Cleaners Provide Green Industrial Cleaning

As chemicals and their safe handing have increased in cost, industrial ultrasonic cleaners provide an ideal alternative that offers substantial savings while reducing negative environmental effects. Ultrasonic cleaners rely on the mechanical scrubbing action of microscopic cavitation bubbles to remove contaminants from the surfaces of the parts being cleaned rather than using harsh chemicals. This cleaning method is completely and does not require the use of harsh or toxic chemicals.

Traditional industrial cleaning methods are costly and time-consuming. In addition, they are generally not environmentally-friendly because they rely on the action of harsh cleaning chemicals to clean parts and components. Various acids or strong solvents are used in the cleaning process, depending on application requirements. After the cleaning application is completed, the chemical wastes need to be neutralized and disposed of in an acceptable manner. Adding to the cost of the traditional industrial cleaning processes are stringent health and safety measures (such as ventilation standards).

The advantages of Industrial ultrasonic cleaners include rapid and effective cleaning and the ability to clean inaccessible places. The use of ultrasonic cleaning also provides a safer, healthier workplace and a more environmentally friendly operation. These aspects provide additional cost advantages.

Since chemicals no longer are required, the extensive chemical handling infrastructure for traditional industrial cleaning methods is eliminated. Toxic and harsh chemicals also have special storage requirements and spills can be expensive. In addition, chemical mixing and delivery to cleaning tanks can are hazardous and the systems that provide this are expensive to set up and maintain. After use, the chemical waste must be neutralized and safely disposed to meet requirements which have become increasingly costly.

Kaijo’s ultrasonic cleaners provide a flexible solution which allows customers to meet the needs of a wide variety of cleaning applications. Using their complete line of ultrasonic cleaning systems and equipment, Kaijo can provide recommendations on a specific system or combination of system components to meet the specific needs of a customer.

The complete article, “How Ultrasonic Cleaners Provide Green Industrial Cleaning” explains more about the benefits of using ultrasonic cleaners. For a free consultation or quote call 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.

How Ultrasonic Cleaning Systems Are Used to Clean Industrial Lenses

Ultrasonic cleaning systems can effectively clean glass lenses, however due to the special characteristics of lenses, selecting the correct ultrasonic frequency, power and bath is critical.

Industrial lenses that are made of pure glass are ideal candidates for ultrasonic cleaning. The ultrasonic generator produces high-frequency electronic signal, and the transducer immersed in the ultrasonic bath converts that signal to ultrasonic waves within the liquid.  The waves within the cleaning bath generate cavitation bubbles in the pressure troughs, and then they collapse in the pressure peaks. The action of the cavitation bubbles produces a powerful scrubbing and cleaning action against the hard surfaces of the lenses, dislodging contaminants from the surface.

While glass itself would not be affected by ultrasonic cleaning systems, it may have been treated with a special coating or surface treatments that can be damaged at certain frequencies, in heated baths or when used with added detergents.

Lower frequencies – Produce larger cavitation bubbles with a more robust cleaning action.

High frequencies – Produce smaller cavitation bubbles with a gentler cleaning action.

The power produced by the ultrasonic system affects the cleaning time. If the power is too low, too few bubbles are generated, and the cleaning process will take longer. The power level should be exactly enough so that it can produce the maximum amount of cavitation bubbles that will allow the quickest and most thorough cleaning action on industrial lenses.

Robust cleaning with the addition of detergents and/or heat will speed up the cleaning process on pure glass lens. However, if the lens has any coating, the same cleaning measures may damage the lens coating. Thus, the required frequency for cleaning coated glass lenses must be high enough to avoid damaging coatings that are softer than pure glass.

The complete article, “How Ultrasonic Cleaning Systems Are Used to Clean Industrial Lenses” goes into more detail. If you would like additional information, or have questions, please contact Kaijo through email at info@kaijo-shibuya.com or call (408) 675-5575.

Using Ultrasonic Cleaners in Disaster Restoration

Items recovered from disasters (like floods, hurricanes, and fires) are often covered with dirt, soot and mold. There are traditional cleaning methods for cleaning recovered items such as wiping, soaking in harsh chemicals or rough mechanical scrubbing. These methods may leave residue or cause damage to these items, while there’s little assurance that they would come out completely cleaned.

Ultrasonic cleaning system is the ideal alternative to the traditional methods in cleaning these items.

This system works by generating ultrasonic waves and the tiny cavitation bubbles in the water (or water mixed with a mild detergent). The bubbles form and collapse in time with the frequency of ultrasonic waves. When these bubbles collapse against the surface of the items being cleaned, they create a strong cleaning and scrubbing action, knocking off and loosening dirt and contaminants from the surface.

One of the greatest advantages of ultrasonic cleaning over traditional cleaning methods is that the former cleans the items thoroughly – even items with complicated shapes and hard-to-reach holes and crevices. It cleans effectively and precisely, without the risk of damage to the items being cleaned.

Choosing the right frequency is the key for successful cleaning. For robust items with hard surfaces, opt for the low frequency (26 to 38 kHz) which produces large, energetic cavitation bubbles for the robust cleaning action. For cleaning delicate items, choose higher frequencies (450 to 950 kHz) which generates smaller bubbles for gentler cleaning.

Adding mild but specific solvents to the cleaning solution is required only for cleaning more stubborn dirt and contaminants. This is to ensure rapid and complete cleaning of the items.

Do you need to restore items after a natural disaster? Read the complete article “Using Ultrasonic Cleaners in Disaster Restoration” to learn how ultrasonic cleaners can help. If you have questions, or would like more information, you may contact Kaijo Shibuya by calling 408-675-5575 or by sending an email to info@kaijo-shibuya.com.

How Ultrasonic Waves Are Produced for Industrial Cleaning Applications

Industrial ultrasonic cleaners deliver cleaning performance that is faster, safer, and more efficient than traditional cleaning methods that use chemicals. Along with being more effective, this method is more environmentally friendly since cleaning doesn’t require the use of harsh chemicals or mechanical scrubbing. Tiny cavitation bubbles generated by the ultrasonic system do the removal of impurities from a variety of parts and components, which range robust metal and ceramics to delicate semiconductors.

The three main components of the ultrasonic cleaning system consist of the ultrasonic generator, the transducer, and the cleaning tank.

The cleaning tank holds the cleaning solution as well as parts to be cleaned. It must be heavy and durable enough to withstand the cleaning action of the ultrasonic waves, and big enough to contain the biggest parts to be cleaned.

How do ultrasonic cleaners work? The ultrasonic generator produces the electric signal which, in turn, generates the ultrasonic waves via the transducer.

The function of the transducer is to handle the frequency and power produced by the generator to create the ultrasonic waves in the cleaning solution. When the ultrasonic waves travel through the cleaning solution, it creates compression peaks and troughs. The tiny cavitation bubbles form in the troughs where there is low pressure and collapse in the peaks because of high pressure.

When the bubbles collapse, each of them releases a small but powerful jet of liquid, which produce an intense cleaning action on the surfaces of the parts being cleaned. This effectively dislodges any contaminants and any other impurities from the surface of the part being cleaned. The microscopic bubbles can clean even intricate shapes and hard-to-access holes and crevices. Result is fast and thorough cleaning.

 

Kaijo Shibuya offers a complete line of industrial ultrasonic cleaning equipment. Read the complete article “How Ultrasonic Waves Are Produced for Industrial Cleaning Applications” to discover how Kaijo Shibuya’s industrial ultrasonic cleaners can be used in your cleaning application. For a free consultation or quote call Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.

Using Ultrasonic Cleaners for Medical Devices

Ultrasonic Cleaning Systems are often utilized to clean medical instruments, devices and implants that have delicate, high-precision designs and complex surface geometries. Medical devices typically have various sorts of contaminants and impurities that include carbon deposits, grease, chemical remnants, fungi and bacteria. Because of that, they often require thorough but also gentle cleaning at the same time – and ultrasonic cleaners are effective in addressing these requirements.

The technology used in ultrasonic cleaning systems employ the power of cavitation. When liquids are subjected to strong forces, they tend to fracture and form microscopic bubbles. When these small bubbles form and collapse (often millions of times every second), they create high temperatures and powerful impact over microscopic areas. These are the forces that are utilized by ultrasonic cleaners.

Ultrasonic cleaning systems use powerful high-frequency sound waves to agitate liquid placed in a cleaning bath or tank. This reaction causes cavitation bubbles to form. When medical tools are placed inside the cleaning bath, these microscopic cavitation bubbles form over the surface. As these bubbles form and collapse over the surface of the medical tools, they dislodge impurities from them, with pinpoint precision.

With an ultrasonic cleaning system, there is no need to use harsh chemicals or scrubbing that can undermine delicate medical devices and implants. Plus, it’s also cost-effective and environmentally safe. Ultrasonic cleaners ensure a powerful, thorough but also gentle and safe cleaning process for delicate medical devices.

Both the CDC (Centers for Disease Control and Prevention) and the WHO (World Health Organization) recommend the use of ultrasonic cleaning technology for medical applications. Ultrasonic cleaners play a vital role to ensuring that medical devices and implants meet high levels of cleanliness.

For further details read the complete article, “Using Ultrasonic Cleaners for Medical Devices”. After reading it, if you have questions, please contact Kaijo Shibuya via email at info@kaijo-shibuya.com or by calling 408-675-5575.

How Medical 3D Printing Benefits from Ultrasonic Cleaning

Hospitals, medical research centers and facilities produce 3D printed models of human body parts or internal organs to create prosthetics for the purposes of surgical procedure, diagnosis, or for educational purposes. Industrial ultrasonic cleaners are now being used to ensure that parts manufactured for medical use are ready for use.

3D-printed models of human body parts and organs are made with build material. The support material, on the other hand, holds the build material until the latter has hardened and self-supporting, and then the support material must be removed to ensure model accuracy. This is where industrial ultrasonic cleaners are used to provide precise cleaning without damaging the material being cleaned.

The ultrasonic cleaning system uses a generator that produces an ultrasonic electrical signal. The transducer, then, converts this signal into ultrasonic waves that travel through the cleaning solution inside the tank. Microscopic cavitation bubbles form from the waves, and then collapse in the pressure peaks.

The cavitation bubbles encounter the support material and effectively dislodge it from the build material. The great thing about ultrasonic cleaning is that it doesn’t cause any damage to the build material that is being cleaned.

Depending on the 3D model being cleaned, Kaijo’s industrial ultrasonic cleaners can operate at frequencies delivering the precise cleaning strength. Lower frequencies (26 kHz or 38 kHz) produce larger cavitation bubbles which perform a more robust cleaning action on typical 3D models. For more cleaning delicate models or models with fragile material, higher frequencies (450 kHz or 950 kHz) are used to produce smaller bubbles which deliver a gentler cleaning action.

Medical 3D models benefit from ultrasonic cleaning. First, it does rapid and thorough cleaning of support material. Second, it is free from human errors. Third, no harsh chemicals or scrubbing is involved. And fourth, disposal of wastes doesn’t require additional measures.

Kaijo can help hospitals and medical facilities realize the benefits of using ultrasonic technology with 3D printing. For more details read the entire article, “How Medical 3D Printing Benefits from Ultrasonic Cleaning”. For a free consultation or quote call Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.

Why Use Ultrasonic Cleaning Systems with a Heater?

Ultrasonic cleaning systems can remove a wide variety of contaminants from the surfaces of parts that need to be cleaned, however removing certain kinds of contaminants require more time than other cleaning applications.

The performance of an ultrasonic cleaning system depends on the parts to be cleaned and the type of the contaminants that have to be removed. For instance, robust parts like automotive components can be typically cleaned in plain water, using the strong cleaning action of the lower frequencies (which produce larger and more energetic bubbles for more robust cleaning). More delicate and fragile parts like semiconductor wafers are usually cleaned using higher frequencies (which produce smaller and less energetic cavitation bubbles for delicate cleaning).

But sometimes, cavitation bubbles alone are not enough to remove tough deposits such as oil-based dirt and grease. That’s where additional measures like a mild detergent and heat come into the picture.

In some cases, a combination of a mild detergent and heat can be tailored to a particular object, and the proper selection can help in improving the ultrasonic cleaning system‘s performance significantly. The detergent increases the solubility of the contaminants while heat softens them. The heat increases the effectiveness of the detergent. These measures will help in removing these contaminants quickly and completely.

Kaijo’s ultrasonic cleaning systems consist of ultrasonic generators (which produce the ultrasonic signal and are selected depending on the frequency needed for the cleaning application), transducers (which should be matched to work with the selected generator), and a tank (which holds the bath and the objects to be cleaned in it).

For cleaning applications requiring heat, both the transducer and the tank should be designed for a heated cleaning solution. Typical temperatures range from 80 degrees Centigrade (or 176 degrees Fahrenheit). Kaijo’s ultrasonic transducers and tanks can accommodate heating requirements up to 100 degrees centigrade (212 degrees Fahrenheit) and the company will work with customers to select right equipment and systems from their full line of products.

Learn more about Kaijo’s ultrasonic cleaning systems by reading our entire article titled “Why Use Ultrasonic Cleaning Systems with a Heater?” For more details contact Kaijo either by email at info@kaijo-shibuya.com or call use a 408-675-5575.

How Ultrasonic Cleaning Systems Promote Profitability

Having an effective cleaning process is essential to many industries. In recent years many companies have made the switch from degreasing and other conventional cleaning processes to a more cost-effective cleaning approach.

The chemicals involved in the conventional cleaning process and are expensive to buy and also need to be safely stored. Another consideration for choosing a new cleaning method is the protection of workers who use these chemicals, plus the safe disposal of toxic waste adds further expense. Other industries need to find alternative cleaning alternatives due to environmental concerns.

In industries that require cleaning of industrial parts and equipment, ultrasonic cleaning systems have emerged as a preferred alternative to traditional cleaning methods. These systems utilize ultrasonic energy to clean contaminated tools or parts.

Ultrasonic energy works rather simply – when dense, elastic media such as water is subjected to high-frequency energy, it expands and contracts quickly as to cause millions of microscopic fractures or tears. The microscopic bubbles that are created form and collapse so quickly that they create a great force. When these bubbles touch close to the surface of an object, the force can knock the contaminants off the surface.

Ultrasonic cleaners consist of a tank that is usually filled with water. A transducer can generate high-energy ultrasonic frequencies between 20 to 200 kHz. When contaminated items are a placed in a bath inside the tank, the ultrasonic waves from the transducer generate millions of tiny cavitation bubbles which do the cleaning action. Depending on the frequency chosen, ultrasonic cleaning systems can do effective cleaning on all parts that range from machinery tools to delicate medical equipment.

Ultrasonic cleaning systems are cost-effective but are also a fast, powerful and safe choice for even the most challenging cleaning applications. It needs little supervision and does not require cleaning with chemicals or the need toxic waste disposal. Since there are very few moving parts ultrasonic cleaners require little maintenance as well.

Read the complete article titled “How Ultrasonic Cleaning Systems Promote Profitability” for more details. If you have questions or need additional information, call Kaijo at 408 675-5575 or email info@kaijo-shibuya.com.