How Utility Companies Cut Grease, Grime and Costs with Ultrasonic Cleaners

The large compressors are usually used by utility companies to move natural gas through pipelines into storage. The compressors themselves, as well as the engines that drive them, are exposed to a lot of grease, grime and deposits and thus require extensive cleaning and maintenance.

Many utility companies use conventional methods of cleaning those heavily and hardened grease- and oil-based components. However, industrial ultrasonic cleaners now offer a better alternative solution to traditional cleaning methods. They use powerful ultrasonic generators and transducers to generate microscopic bubbles in the cleaning solution. These bubbles act as “scrubbers” which cleans parts quickly and thoroughly.

Traditional cleaning methods use strong cleaning chemicals which may corrode or damage the surface of the parts being cleaned. Using industrial ultrasonic cleaners on the other hand only requires a gentle water-based cleaning solution to clean parts. A mild detergent may also added, and/or the solution can be heated if needed for cleaning off grease and oil-based materials.

Unlike manual scrubbing, microscopic bubbles generated by ultrasonic cleaners can reach inaccessible interior surfaces (such as holes, bolt threads and deep crevices) of the parts being cleaned. The result? When a part is submerged in the ultrasonic tank all surfaces are cleaned equally and completely.

Using industrial ultrasonic cleaners will significantly reduce the need to soak soiled materials in a harsh cleaning solution. Not only will ultrasonic cleaning system will save you time, it will also save you money as well. When machine parts are cleaned down to the bare metal throughout, maintenance is more effective, easier to carry out and provides improved reliability for the compressors and engines. Parts that are completely clean will usually have a longer life and extend the lifetime of the corresponding machines. Overall facility operating performance will be more cost-effective and energy-efficient.

Kaijo can help utilities realize the benefits of using ultrasonic technology. For more details read the entire article, “How Utility Companies Cut Grease, Grime and Costs with Ultrasonic Cleaners”. For a free consultation or quote call Kaijo at 408-675-5575 or email info@kaijo-shibuya.com.  

The Power behind Ultrasonic Cleaning Systems

Ultrasonic cleaning systems offer an ideal alternative to the traditional cleaning methods, which apply substances or physical contact such as using harsh chemicals or mechanical scrubbing.

But an ultrasonic cleaning system, as the name implies, uses sound rather than substance or scrubbing. It utilizes the principle of cavitation in cleaning contaminated tools and parts.

The principle of cavitation refers to a phenomenon in which disturbances in liquids lead to the creation of short-lived cavities bubbles of gas or vacuum. When the bubbles reach high levels of energy, the bubbles implode and generate a considerable amount of force. The impact created by the imploding bubbles powers the ultrasonic cleaning method.

An ultrasonic cleaning system consists of a tank fitted with a special loudspeaker (transducer) which generates the high-energy ultrasonic waves. As the waves pass through a liquid of water, they reach a desired level of disturbance which leads to the formation of millions of tiny bubbles. As these bubbles form and implode many times each second, they create the cavitation energy needed to dislodge dirt, grease, and grime of the article immersed in the cleaning tank. Despite being tough and effective in removing dirt because of the cavitation energy, these bubbles otherwise will not damage even the most delicate tools.

Kajjo’s ultrasonic cleaning systems offer versatile cleaning ability which are also cost-effective and energy-efficient. A unit has a transducer which produces ultrasonic energy that range from 20 kHz to 1.5 MHz.  These systems employ piezoelectric transducer technology which promises – and delivers – superior cleaning performance over a wider range than other technologies. Piezoelectric transducer technology is far more suitable for ultrasonic cleaning because it has the ability to create ultrasonic sound energy at very high frequencies.

For more information read the complete article titled “The Power behind Ultrasonic Cleaning Systems”. If you would like to learn how ultrasonic cleaning can be effectively used for your application, contact Kaijo for a free consultation or quote at 408-675-5575 or email info@kaijo-shibuya.com.

Using Ultrasonic Cleaning for Fuel Injectors

There are traditional methods of cleaning fuel injectors such as soaking them in harsh chemicals, forcing solvents through the injector at high pressure, or removing the deposits manually. These traditional cleaning methods do not guarantee the complete removal of deposits, and they may even damage the injector.

Ultrasonic cleaning systems, on the other hand, do not involve the use of harsh solvents or slow, manual cleaning. Furthermore, it is an excellent alternative that doesn't suffer from the same drawbacks and it cleans items -- even fuel injectors heavy with deposits -- quickly and thoroughly.

A fuel injector is placed in a cleaning tank that has an ultrasonic transducer installed at the bottom or on the walls (a portable transducer can also be used in the cleaning solution).

The ultrasonic transducer is powered by an ultrasonic generator that supplies the high-frequency electrical signal (the normal signal is usually 30 kHz). The ultrasonic cleaning system transducer generates ultrasonic waves in the cleaning solution, causing them to produce cavitation bubbles. These bubbles act as cleaning agents for hard metal surfaces like those of fuel injectors. When the bubbles collapse, they dislodge contaminants and deposits from the surface of fuel injectors.

The bubbles travel wherever the cleaning solution is present, so ultrasonic cleaning works outside, inside and in every part of fuel injectors. It even cleans hard-to-reach places, something that traditional cleaning cannot do. As a result, the deposits are removed from inside fuel injector holes, from threads, and from couplings. All foreign material is removed and cleaned down to the bare metal. Ultrasonic cleaning is also fast, taking from 10 to 20 minutes for the cleaning cycle.

If you would like to learn more about the Kaijo’s ultrasonic cleaning systems and how they are effective for cleaning fuel injectors, read our complete article “Using Ultrasonic Cleaning for Fuel Injectors.” You may also call us at 408-675-5575 if you have questions or would like addiitional information.

3 Big Cost Savings Benefits of Using Ultrasonic Cleaners vs. Spray Washers

If there's one thing that business and facilities owners want when they're considering a cleaning solution, it should be cost-effective.

Ultrasonic cleaners provide an excellent cleaning alternative to other traditional methods of cleaning, like spray washers. Ultrasonic cleaners can clean anything from delicate medical parts to machine parts, and everything in between.

But there are also other ways that business owners can benefit from using ultrasonic cleaners as opposed to spray washers, in relation to the cost:

1. Save on materials
Spray washers rely on large amounts of chemicals to clean stains and require operators to use protective equipment. These concerns are non-existent with ultrasonic cleaners. Cleaning with high-frequency pressure waves does not require chemical action to loosen stains. While it requires a mild detergent to help loosen the most stubborn stains, it is otherwise inexpensive when compared to the number of chemicals used in spray washers.

2. Save on labor costs
The ultrasonic waves generated by these cleaners do not need to be directly aimed at surfaces to be cleaned. The microscopic bubbles travel in every nook and cranny of the tools and parts being cleaned, assuring thorough cleaning. With ultrasonic cleaning, the parts become cleaner with less effort.

3. Save on maintenance
Spray washers may require lots of energy to operate. It has moving parts as well that require expensive maintenance -- if they cannot be maintained regularly, they would eventually lose their usefulness. Customized ultrasonic cleaners do not require much maintenance -- they don't come with moving parts -- all you have is a transducer and a bath of liquid. With very little maintenance, ultrasonic cleaning systems are guaranteed to last a lifetime.

Our complete article “3 Big Cost Savings Benefits of Using Ultrasonic Cleaners vs. Spray Washers” explains in more detail. After you read the article, if you have questions, contact us by calling 408-675-5575 or email us at info@kaijo-shibuya.com.

Cleaning Brass and Stainless Steel Using Ultrasonic Parts Cleaners

Ultrasonic parts cleaners use transducers and ultrasonic frequency generators to produce microscopic bubbles in water (or a mild cleaning solution). These tiny bubbles act as “scrubbers” that are highly effective in lifting away dirt and impurities from the parts being cleaned.

Ultrasonic parts cleaners are an excellent alternative to the traditional cleaning methods that use intense scrubbing and harsh cleaning chemicals that can leave deposits or cause damage to these parts.

Tools that are made of brass and stainless steel can also be cleaned using ultrasonic parts cleaners. These are considered “robust” parts. Ultrasonic cleaners operating at the lower ultrasonic frequency ranges are the most effective for cleaning such parts. Ultrasonic generators for 26 kHz or 38 kHz create large, energetic bubbles that form and collapse in time with the cleaning frequency. When these bubbles collapse at the surface of the brass or stainless steel, they release bursts of energy that dislodge dirt and impurities, while never causing damage to the solid metal surface.

For parts covered in heavy dirt like oil and grease, the effectiveness of ultrasonic cleaners can be improved by adding only a mild detergent to the water bath and by slightly heating the cleaning solution. The heat will help melt the oil and grease away from the surface while the detergent dissolves them. The ultrasonic bubbles penetrate wherever there is cleaning solution, leaving the brass and stainless steel parts thoroughly cleaned. Ultrasonic cleaners also make cleaning these parts quick and efficient as well.

If you have questions about how Kaijo’s ultrasonic parts cleaners can be used to clean your brass and stainless steel parts, read the complete article entitled “Cleaning Brass and Stainless Steel Using Ultrasonic Parts Cleaners”. You may also contact Kaijo by phone at 408-675-5575 or by emailing at 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.