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.

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 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.

Should De-Ionized Water Be Used with an Ultrasonic Cleaning System?

De-ionized (DI) water is plain water that lacks ions or particles because of the purification process. It is used to remove contaminants like metals and salts (ions).

Should DI water be used with an ultrasonic cleaning system? The answer is yes, depending on the parts being cleaned or the degree of their contamination. When DI water is used in the ultrasonic cleaning system, it can improve the cleaning performance. Such cleaning performance is especially important for parts that cannot tolerate detergents, solvents or other cleaning solution.

Ultrasonic cleaning systems can also use plain water – a mild detergent can be added to enhance the cleaning process. However, delicate tools and parts could not tolerate these detergents, that’s why cleaning them with DI water is often recommended. For parts contaminated with heavy, stubborn dirt and grease, a mild detergent or cleaning solvent (that do not cause damage to the parts themselves) can be added to the DI water for more effective and quick cleaning.

When an ultrasonic cleaning system has removed dirt from the parts to be cleaned, the cleaning solution is drained away but they still must undergo thorough rinsing. Plain water has dissolved minerals the parts and other impurities so that rinsing can leave a deposit. When the parts are dried, spots or films left over from the evaporated plain water can remain in these parts – even the tiniest spot or impurity left over can lead to the malfunction of these parts. That’s why the use of DI water is often recommended for rinsing them since it contains no impurities, leaving these parts spotless and clean.

Learn more about using de-ionized water for ultrasonic cleaning by reading the complete article entitled “Should De-Ionized Water Be Used with an Ultrasonic Cleaning System?”. You may also send an email to info@kaijo-shibuya.com if you have questions or want a free consultation.

Why Ultrasonic Cleaning Systems Are Used by Aerospace Manufacturers

Aerospace industry manufacturers need to provide high-precision parts and also maintain and repair parts in production that are used in complex engines and machinery. Production parts and parts from maintenance and repair operations are usually contaminated by grease, dirt, soot, and lubricants as a result of the normal operation.

These parts and tools are traditionally cleaned by either manually washing or scrubbing, or by using harsh solvents. But there’s a better alternative to the traditional cleaning methods – the use of ultrasonic cleaning systems, which saves both time and money along with providing an environmentally friendly process that cleans parts fast and efficiently.  

Ultrasonic cleaning systems are made up of an ultrasonic generator, transducer and a cleaning tank. The ultrasonic generator is the “heart” of an ultrasonic cleaning system. The Ultrasonic transducers are installed inside the cleaning tank and convert electric signals from the generator into sound waves in the cleaning solution of the tank. These sound waves create microscopic bubbles that do the cleaning and scrubbing action, lifting away contaminants from the surfaces of the items (such as tools) in the cleaning solution. It leaves the items completely cleaned with no particles left over.

More aerospace manufacturers have transitioned to using ultrasonic cleaning systems from old traditional cleaning methods, for a number of reasons:

·         The cleaning of parts is more effective, efficient and thorough – the microscopic cleaning bubbles have the ability to penetrate and clean even in crevices, holes, and other more complicated and harder-to-reach areas of the tools being cleaned.

·         The cleaning fluid may consist of plain water or only a mild cleaning solution. No harsh and toxic cleaning chemicals needed.

·         It is faster.

·         It doesn’t require manual or mechanical scrubbing.

·         It is cost-effective.

·         It is safer to use compared to using harsh chemicals.

·         The frequencies of the signal can be adjusted to allow appropriate cleaning of robust or delicate tools and items.

If you have questions about how the Kaijo’s Ultrasonic cleaning systems can be used in your application, read the complete article entitled “Why Ultrasonic Cleaning Systems Are Used by Aerospace Manufacturers”. You may also contact Kaijo by phone at 408-675-5575 or by emailing at info@kaijo-shibuya.com.

Kaijo’s New Phenix Hyper Ultrasonic Generator Provides Optimum Cleaning Results

Kaijo’s new Phenix Hyper cleaning generator, along with the Hyper immersible transducer, deliver improved cleaning performance using the latest ultrasonic technology.

The generator features the usual ultrasonic controls, operates at 78 kHz and can deliver up to 1200 W output power. Kaijo’s Phenix Hyper ultrasonic cleaning generator can be used with the standard sweep frequency mode but also features the new Hyper mode which allows more effective cleaning that provides a uniform ultrasonic pattern that totally fills the process tank.

It has a user-friendly operator interface and has various alarm, display, and interlock functions which guarantee reliable and safe operation.

The Hyper immersible transducer is designed to work specifically with the Phenix Hyper generator. This high-polish stainless steel transducer is ideal for immersion in cleaning solutions (such as mild detergents) up to 80 degrees C.

This new system also represents a user-friendly turn-key solution for applications with an existing tank.

The Phenix Hyper Ultrasonic Generator together with the Hyper immersible transducer provide improved and more effective cleaning, ease of operation and reliable performance. This new system addresses problems pertaining to poor or incomplete cleaning and reduces surface damage to cleaned parts. Parts made from metal, glass and ceramics can be cleaned effectively on all sides, even if they have complex shapes with hard-to-reach places. The Hyper ultrasonic cleaning technology works wherever the cleaning solution can penetrate by removing fine contaminants quickly and completely throughout the cleaning tank.

Learn more about the new Phenix Hyper Ultrasonic Generator by reading the complete article entitled “Kaijo’s New Phenix Hyper Ultrasonic Generator Provides Optimum Cleaning Results”. You may also send an email to info@kaijo-shibuya.com if you have questions or want a free consultation.

Time Vs. Money: How an Ultrasonic Cleaning System Saves Both

Ultrasonic cleaning systems can clean parts and components quickly and thoroughly and provide a superior option compared to traditional methods that use harsh chemicals and mechanical brushing. Plus, these systems help reduce cleaning costs considerably, they also save time and increase the efficiency of many production lines or manufacturing processes.

Ultrasonic cleaning process works by placing the items to be cleaned in a cleaning liquid of a cleaning tank. The sound waves generate cavitation bubbles in the cleaning liquid. These microscopic bubbles dislodge contaminants from the surfaces of the items being cleaned.

Ultrasonic cleaning saves time because the items do not need to be soaked in the cleaning liquid in order to soften the dirt. Subsequent manual scrubbing with pressure sprays is also no longer needed. In ultrasonic cleaning, the bubbles do the cleaning and scrubbing action, and they could clean even the more complicated parts, shapes, holes, and crevices of the items, resulting in quick but thorough cleaning.

The cost savings come from various sources. Because of the high performance of the ultrasonic systems, the need for water and power are reduced and the use of harsh chemicals is eliminated. Depending on the cleaning chemicals previously used, various chemical handling equipment and processing may no longer be needed.

High performance ultrasonic cleaning systems save on power usage since a typical system uses up to 1200 Watts, lower than the power used by conventional cleaning systems. Water use is also reduced because only one tank is needed for cleaning. These reductions translate into bigger savings.

You can learn more about Kaijo’s ultrasonic cleaning systems by reading the complete article titled “Time Vs. Money: How an Ultrasonic Cleaning System Saves Both.” Contact Kaijo for a free consultation or quote at info@kaijo-shibuya.com or call 408-675-5575.

7 Reasons to Clean Using the Power of Ultrasonic Cleaning Systems

There are various reasons why manufacturers and companies need to use the power of the ultrasonic cleaning system in cleaning parts and equipment.

1. Ultrasonic cleaning systems deliver improved cleaning performance
Ultrasonic transducers generate cavitation bubbles which do the cleaning. These bubbles have the ability to clean and scrub through holes, around corners, and in crevices to thoroughly clean tools and instruments. The intensity of the bubbles' cleaning action for a particular cleaning task can be adjusted by modifying the frequency and power.

2. Parts and equipment are cleaned faster
Cleaning parts and equipment with the power of the ultrasonic cleaning system are faster, less laborious and less time-consuming compared to cleaning with chemicals.

3. Ultrasonic cleaning removes contaminants without damaging parts and equipment to be cleaned.
Ultrasonic cleaning doesn't clean by blasting, scrubbing, or using harsh chemicals which can damage the parts and equipment.

4. Ultrasonic cleaning systems are environmentally-friendly
Ultrasonic cleaning doesn't use harsh cleaning chemicals which contribute to the pollution to the environment.

5. Ultrasonic cleaning is safer for workers
Ultrasonic cleaning technology doesn't use materials and cleaning techniques that are dangerous. It minimizes operator errors that can otherwise lead to accidents and other severe consequences.

6. Ultrasonic cleaners have a higher capacity than conventional systems
Cleaning is rapid and thorough, almost without experiencing down time. Put the materials to be cleaned inside the tank, and the ultrasonic cleaning technology will do its job right away.

7. Ultrasonic systems are versatile and can handle a variety of applications.
Ultrasonic cleaning systems can handle a variety of cleaning tasks required for manufacturing companies and plants using heavy equipment.

Contact Kaijo Shibuya if you would like to learn more about how an ultrasonic cleaning system is right for your applications. Reading our complete article “7 Reasons to Clean Using the Power of Ultrasonic Cleaning Systems” may also provide the answers you need.

Why a Mini Ultrasonic Generator System May Be the Best Choice for Your Device Cleaning Requirements

Ultrasonic cleaning is a fast, effective, practical, and environmentally-friendly alternative to cleaning objects using harsh chemicals and scrubbing. An ultrasonic generator with low ultrasonic frequency can produce large cavitation bubbles which clean stains and impurities with robust action while a high-frequency cleaning produces smaller cavitation bubbles and less intense cleaning action, ideal for gentler cleaning tasks.

Kaijo's Quava Mini ultrasonic generator is able to clean small parts using a wide frequency range depending on the cleaning task, making it ideal for all-purpose cleaning. The Quava Mini can be used by facilities that either clean a variety of components or have specific cleaning requirements.

The Quava Mini ultrasonic generator is available in two models. The low frequency provides either 26/78/130 kHz or 38/100/160 kHz at up to 50 W while the high frequency model produces 200/430/950 kHz or 1.6 MHz at up to 100 W. For a complete range of low and high frequencies an installation requires either the low range generator with two multi-frequency transducers or the high range generator with four multi-frequency transducers.

The Quava Mini has an LED display for precise control of the power brought to the transducer. Power can be different in steps of 0.1 W for precise control of cleaning power. For the low-frequency model, several frequencies can be adjusted without changing the system configuration. For the high-frequency model, the transducer is changed to meet the selected frequency. A low frequency produces large cavitation bubbles for a more intense cleaning action while a high frequency produces smaller bubbles for gentler cleaning. By increasing the power delivered to the transducer more bubbles are produced at a given frequency.

You can learn more about Kaijo’s Mini ultrasonic generator and cleaning system by reading the main article on Kaijo’s site titled “Why a Mini Ultrasonic Generator System May Be the Best Choice for Your Device Cleaning Requirements”.