Why Ultrasonic Cleaners Provide the Best Green Option for Industrial Cleaning

Ultrasonic cleaning systems offer superior cleaning performance as well as a cleaner environmental footprint. Traditional cleaning involves the use of toxic cleaning chemicals and mechanical scrubbing. The chemicals have to be aggressive to clean the part surfaces completely in a reasonable time. However, some industrial cleaning applications take longer periods to complete. They involve other procedures such as prolonged soaking and the final step of mechanical scrubbing to remove leftover traces of contaminants. Mechanical parts are also labor-intensive and can damage the parts to be cleaned. 



Despite these procedures, some contaminants may remain on the part surfaces, and even more so in harder-to-reach places such as holes and crevices, along cracks and inside tanks and reservoirs. It results in poorly cleaned parts that may contaminate processing. Ultrasonic cleaning systems, on the other hand, do not require chemicals or mechanical brushing. They require only plain water, or plain water and mild detergent to clean the parts quickly and thoroughly.



In an ultrasonic cleaning system, the ultrasonic transducer creates high-frequency sound waves in the cleaning solution and the sound waves, in turn, produce microscopic cavitation bubbles in the low-pressure troughs. The bubbles collapse in the high-pressure peaks of the sound waves, releasing a jet of cleaning solution that strikes the part surface, removing the dirt particles. The cavitation bubbles even pass-through holes, crevices, and complex shapes, cleaning them thoroughly.



Ultrasonic cleaning systems don't require purchasing, storing, handling, and neutralizing chemicals. Thus, the work environment is safer for workers and free of aggressive chemicals that require protective measures.


Discover more about ultrasonic cleaners by reading the complete article, “Why Ultrasonic Cleaners Provide the Best Green Option for Industrial Cleaning.” Contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com to discuss your cleaning requirements. As environmental legislation and worker safety regulations have become stringent, ultrasonic cleaners are the wave of the future. They are environmentally friendly and do not require the use of caustic chemicals. Other benefits of ultrasonic cleaners include low operating costs, low capital costs, lower compliance costs, improved productivity and output, and safer work environment.

The Benefits of Using Ultrasonic Cleaners in Industrial Parts Washing

Industrial ultrasonic cleaning is an excellent alternative to traditional cleaning methods which involve mechanical scrubbing and the use of harsh chemicals and solvents. It delivers excellent cleaning performance that is fast and effective while considerably reducing costs.



The cavitation bubbles produced by the ultrasonic cleaning system delivers a powerful mechanical scrubbing action. The cavitation bubbles quickly and thoroughly remove contaminants from the surfaces of parts made of varying materials and with various shapes and sizes.



Industrial ultrasonic cleaners provide many different benefits that include:



1) Smaller environmental footprint – The use of ultrasonic cleaners reduces the environmental footprint as it uses only water or mild detergents that do not need special handling and disposal.



2) Increased worker safety – Harsh cleaning chemicals require special handling and can result in spills or exposing workers to hazardous fumes. Ultrasonic cleaners do not require the use of chemicals and can do the process automatically, leading to reduced human monitoring and increased safety.



3) Higher throughput – Ultrasonic cleaners operate more quickly compared to traditional cleaning methods. The right ultrasonic frequency, cleaning power, cleaning solution, temperature and detergent needs to be selected to achieve the optimum cleaning speed.



4) Improved cleaning performance – The microscopic cavitation bubbles produced by the ultrasonic cleaners appear everywhere in the cleaning solution, which leads to a thorough cleaning action. The bubbles can even clean hard-to-reach places, including parts that are delicate or have complex shapes.



5) Cost savings – Ultrasonic cleaners are cost-effective because they do not require the purchase, storing, handling and disposal of cleaning chemicals. Instead, ultrasonic cleaners use only water or water with mild detergents. There are also no compliance costs associated with the use and disposal of toxic chemicals.



6) Improved output and part longevity – When parts are cleaned completely through ultrasonic cleaning, they last longer and perform better. Traditional cleaning cannot reach inaccessible places and can leave contaminants behind on the surface, which leads to damage to the parts. Ultrasonic cleaners remove all dirt, even in inaccessible places, leaving the parts completely cleaned and free from contaminants.



For more details read the complete article, “The Benefits of Using Ultrasonic Cleaners in Industrial Parts Washing”. If you have any questions about the use of industrial ultrasonic cleaners for your application, contact Kaijo Shibuya at 408-675-5575 or email info@kaiijo-shibuya.com to schedule a free consultation.

Selecting the Best Frequency for Ultrasonic Cleaning Applications

The success and effectiveness of using industrial ultrasonic cleaners depend on matching the system frequency to the parts to be cleaned, and the type of contaminants being removed. An industrial ultrasonic equipment manufacturer with experience can help companies select the best frequency and ensure their ultrasonic cleaning performance is at an optimal level.
Ultrasonic cleaning depends on the generation of microscopic bubbles in the cleaning solution. The transducers in the ultrasonic cleaning system convert electric high-frequency signals into sound waves that travel through the cleaning bath. These sound waves turn into cavitation bubbles that do the cleaning and scrubbing action on the parts to be cleaned.
Low frequencies - Low frequencies for ultrasonic cleaning are usually below 40 kHz, while typical cleaning frequencies are 26 kHz and 38 kHz. Low-frequency waves produce comparatively large, energetic bubbles that deliver powerful scrubbing action. They deliver high-energy cleaning for robust parts with hard surfaces and for heavy contamination. These frequencies are suitable for metal, glass, or porcelain parts contaminated with oil and grease, uncoated glass components, jewelry coated with production residues, and some medical equipment.
Mid-range frequencies - Mid-range frequencies range from 40 kHz to 200 kHz, with typical frequencies being 78 kHz, 130 kHz, and 160 kHz. Mid-range frequencies produce bubbles that are for cleaning more fragile components, but they can still remove substantial surface dirt. These frequencies are suitable for hard disk drives, solar cells, LCDs, and parts made of ceramic and aluminum.
High frequencies - High frequencies range usually goes beyond 200 kHz, with typical frequencies being 200 kHz, 430 kHz, 950 kHz, and 1/6 MHz. High-frequency waves produce smaller bubbles for cleaning the most fragile and delicate components. The smaller size and the less robust energy of the bubbles ensure that the parts won't be damaged. These frequencies are suitable for cleaning semiconductor components, silicon wafers, LEDs, and delicate medical instruments.
Kaio provides expert help to customers in selecting the right industrial ultrasonic cleaner that meets their specific cleaning application requirements. Learn more by reading the complete article titled "Selecting the Best Frequency for Ultrasonic Cleaning Applications." Contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com for a free consultation or quote.

Is De-Ionized Water Needed for Ultrasonic Cleaning?

The use of de-ionized water can improve the performance of ultrasonic cleaning systems and for rinsing components that have been cleaned. The use of ordinary water is adequate for cleaning lightly contaminated parts or for parts that can withstand robust cleaning. A mild detergent or the application of heat may be needed when cleaning heavily contaminated parts or fragile parts. For parts that cannot withstand mild detergent or heat, the use de-ionized water is the best way to speed up the cleaning process and to ensure even and thorough cleaning.



Ordinary water naturally comes with traces of impurities. To turn ordinary water into de-ionized water, it is first filtered to remove organic matter. Then it is passed through an ion exchange bed. The ion exchange resins attract an remove the dissolved ions which produces very pure water.



De-ionized water helps the performance of ultrasonic cleaning systems in a number of ways. As it doesn't contain contaminants, ultrasonic cleaning applications using de-ionized water and detergents are more effective. The detergents maintain their cleaning power due to the absence of impurities of de-ionized water. Once the detergents are used, the cleaning solution has to be rinsed off after cleaning is done.



If the rinsing is done with de-ionized water, it doesn't leave any residue when dry. Ordinary water, on the other hand, leaves traces of impurities such as salts or organic films on cleaned parts.



Parts such as machined components or metal parts can have metallic dust on the surfaces. The microscopic cavitation bubbles produced by the ultrasonic cleaning systems can dislodge the dust particles and de-ionized water quickly absorbs all the metallic ions which dissolve in the cleaning solution. This type of cleaning application benefits from the use of de-ionized water but the detergents and heating are not needed.



Kaijo offers a free consultation to ensure that their ultrasonic cleaning systems meet a customer’s cleaning requirements.  For more details read the complete blog article, “Is De-Ionized Water Needed for Ultrasonic Cleaning?”  Contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com if you can questions or need a free consultation to discuss your specific ultrasonic cleaning needs.

How Ultrasonic Cleaners Protect Components from Rust

Metal components often suffer from rust and/or corrosion if they are not treated and protected, even stainless steel. To prevent corrosion, metal is treated with various finishing processes such as passivation, which consists of increasing the thickness of the oxide layer.

However, for the metal finishing to be effective, it first needs be completely clean before the process is applied. If the part is not completely clean, the oxide layer may leave gaps, which is possible for the rust to attack through the holes. Using industrial ultrasonic cleaners means the impurities are removed and contamination is not an issue.

When contaminants are present, they can prevent passivation process keeping acid away from the surface of the metal. This keeps the thicker layer of chromium oxide from forming. When the surface of the metal is not cleaned completely, passivation may allow some surface areas to rust and may damage the part itself.

Industrial ultrasonic cleaners are the ideal solution to clean various parts, including metals that are to be treated with anti-corrosion finishing processes. Ultrasonic cleaners remove impurities from the metal part surface to allow the finishing to produce a seamless oxide layer.

Industrial ultrasonic cleaners use high-frequency sound waves in a cleaning tank of water to dislodge particles and contamination from the surfaces of metal parts. In an ultrasonic cleaning system, transducers are immersed in a cleaning tank and produce the sound waves in the liquid. The ultrasonic sound waves create microscopic cavitation bubbles that deliver a scrubbing action when in contact with the surface of the parts which are being cleaned. Dirt, oil, grease and other contaminants are easily removed.

Kaijo provides a full product line of Industrial Ultrasonic cleaning equipment that can be used in a wide range of cleaning applications to effectively remove contamination for parts and components. This is something that traditional cleaning with manual scrubbing or using harsh chemicals cannot easily achieve.

The complete article, “How Ultrasonic Cleaners Protect Components from Rust” goes into further detail. If you have questions or would like to set up a free consultation to discuss your particular needs, contact Kaijo Shibuya by email at info@kaijo-shibuya.com or call 408-675-5575.

Using Ultrasonic Cleaning Manufacturer Solar Panels

Solar panels consist of silicon wafers that have been etched and cleaned before being mounted behind glass sheets. Several of the intermediate steps require cleaning of the silicon wafers and glass sheets.

Unlike traditional cleaning methods that use manual scrubbing or harsh chemicals, ultrasonic cleaning systems remove contaminants and residues quickly and completely, while leaving the underlying silicon wafers or glass sheets unaffected.

Making solar cells involve fabrication steps such as etching the silicon, doping the wafers to create positive and negative charge areas and the depositing of conducting and non-reflecting films. The wafers have to be treated with chemicals; they are rinsed thereafter but these chemicals may remain and can shorten the life span of the solar cells and reduce their efficiency.

Silicon wafers may also have to be masked to produce conducive paths on the solar cells (and the masks have to be removed once the conductive film is deposited). Ultrasonic cleaning removes chemical contamination from the surfaces of the wafers and leaves them ready for subsequent fabrication. It can also remove the masking substance without damaging the thin and delicate conducting paths that have been deposited.

After all, the process steps are completed solar cells have to be assembled into bigger units to create solar panels. These solar cells are mounted on a backing, covered by a sheet of glass and sealed. While the solar cells may have been completely clean, the glass sheets may be contaminated or have residues. These contaminants can hurt solar panel functions and break the seals, allowing moisture to penetrate the panel, corrode the conductors, and block the sunlight that produces solar panel power.

Ultrasonic cleaning systems are an ideal solution for cleaning glass surfaces. Using just a bath of plain water, this cleaning method makes sure that no chemical residues are left on the glass surfaces. Traditional cleaning of silicon wafers and glass sheets require special rinsing to remove traces of contaminants. Moreover, they clean too slowly. It also uses harsh chemicals, whose handling, storage and disposal which can be quite costly.

Ultrasonic cleaning, on the other hand, cleans silicon wafers and glass sheets quickly and thoroughly. It also saves money from spending on harsh cleaning chemicals.

Read the complete article “Using Ultrasonic Cleaning to Manufacture Solar Panels” to learn more. If you have questions or would like to set up a free consultation, contact Kaijo Shibuya at 408-675-5575 or email info@kaijo-shibuya.com.

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.