Choosing the Right Industrial Ultrasonic Cleaner Features and Options

Industrial ultrasonic cleaners can represent a sizeable investment.  Here we define these units, what to look for when purchasing, and offer equipment options to help you make the right selection.  Included are examples of industrial ultrasonic cleaner applications.

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Industrial Ultrasonic Cleaner Defined

Industrial ultrasonic cleaners are heavy-duty cleaning systems designed for continuous operation and the effective removal of contaminants from large or numerous parts. The job to be done – not the size of the cleaner or items being cleaned – defines these products.

That’s why industrial units are available in benchtop and floor mounted configurations.

Heavy-duty ultrasonic parts washing usually means long-term (multi-hour) continuous cleaning operation.  This calls for capabilities such as heavier gauge stainless steel cleaning tanks, automatic time and temperature safety shutoffs, and other features/benefits described here. 

Key Industrial Ultrasonic Cleaner Features to Consider

Tank Capacity

Cleaning tanks are specified by dimensions (length, width, depth) and cleaning solution capacity. Key points to consider when selecting tank capacity:

• Parts must be fully immersed in cleaning solutions
• Parts should not contact each other or the tank
• Cleaning baskets, used in most applications, are smaller than tank dimensions
• Dividers and trays offer options for part separation in baskets

Large and/or heavy parts can be suspended in the tank or rest on specially constructed supports on tank bottoms offered on certain industrial units. 

Ultrasonic Frequency

Ultrasonic cleaning occurs when billions of microscopic vacuum bubbles implode against surfaces being cleaned to blast loose and carry away contaminants. 

• Lower frequencies such as 25 kHz produce larger bubbles.  When these bubbles implode they release strong cleaning energy.  For removing caked on grease, lapping abrasives or polishing pastes use a low frequency. 
• Higher frequencies such as 37, 45 and 80 kHz produce progressively smaller bubbles.  These are better for delicate, highly finished parts and those with complex surfaces, blind holes, cracks and crevices.
• Dual-frequency units allow you to broaden service offerings.   

For more information please check ultrasonic cleaners and how they work.

Industrial Ultrasonic Cleaner Operating Features

Unit size and operating frequency are two critical specification criteria.  Other features that may be important in helping you do the job most efficiently include:

• Temperature controls let you set cleaning solution temperature to the level recommended by the cleaning solution manufacturer.
• Timers control the duration of the cleaning cycle.  Some units are designed to start cleaning when the selected temperature is reached and shut down at the end of the cycle.
• Degas mode speeds the removal of trapped air in fresh cleaning solutions.  An alternative is allowing the equipment operate for a period of time without a load.    
• Sweep provides a slight ± fluctuation in the ultrasonic frequency and serves to even out the cleaning action to avoid “hot spots” or possibly damaging cavitation action, “dead zones” or no cleaning action, and harmonic vibrations that can damage delicate parts such as PCBs.  
• Pulse mode boosts ultrasonic power up to 20% to remove stubborn contaminants. 
• Dynamic mode optimizes cleaning results by automatically combining the sweep mode for uniform cleaning with the pulse mode that removes stubborn contaminants.
• Eco Mode provides gentle cleaning and a quieter operation, achieving a lower intensity cleaning cycle with sweep frequency.
• Adjustable Power lets you set the cleaning parameters to the job at hand. 

Benchtop Industrial Ultrasonic Equipment from Tovatech

Should your parts be heavily contaminated and require long-term cycles a suggestion is a 37 kHz Elmasonic xtra TT unit.

• Operates up to 8 hours a day
• Permanent Sweep mode for uniform cleaning
• Switchable Dynamic mode to increase cleaning intensity

The Elmasonic Xtra series of 37 kHz industrial benchtop ultrasonic cleaners is perfect for production lines, workshops and service bays.

• Extra powerful cleaning mode with consistent, uniform cleaning results
• Energy-saving Eco mode for gentle cleaning of less-soiled parts
• Set bath temperature from 30 to 80⁰C
• Timed cleaning to 30 minutes, continuous to 6 hours
• Welded stainless steel tanks carry a 3-year warranty

Floor-Mounted Mobile Ultrasonic Cleaners from Tovatech

When cleaning a variety of materials consider a dual-frequency ultrasonic cleaner.  An example is the Elmasonic X-tra ST line.

• Powerful or gentle dual frequency cleaning 25/45 kHz
• Heavy duty tanks operate to 8 hours a day
• Timer, drain, and heater up to 80° C
• Seven tank sizes from 8 to 67 gallons
• On lockable casters for portability
• In stock for quick delivery

The X-tra ST line offers optional accessories to pre- and post-rinse products and filter cleaning solutions, both contributing to longer cleaning solution effectiveness.

SHIRACLEAN industrial units available in 7 capacities from 25 to 204 gallons are designed for machine shops, equipment maintenance, solder flux removal, printing, electronics, 3-D mold support and a variety of laboratory applications.

• Filtration to prolong solution lifetime
• Weirs and spray bars to remove oils and other floating contaminants
• 40 kHz with Sweep
• Timer, heater, drain

Customized Ultrasonic Cleaners for Industrial Applications

If standard equipment offerings do not satisfy your needs customized units can be constructed to meet your specific requirements.  Tovatech scientists are ready to work with you to specify exactly what you need.

• Systems built to your specifications
• Pricing comparable to standard units
• Ideal for parts too large or numerous for off-the-shelf tanks
• High quality equipment with 2-year warranty and excellent technical support
• Optional features available to meet your needs

Ultrasonic Cleaning with Volatile Solvents

Ultrasonic cleaning using volatile solvents such as IPA, acetone and toluene require precautions including meeting local and national regulations to avoid fire and explosions. The SOL XP series of explosion-proof ultrasonic cleaners in 6 tank sizes to 33 gallons help you meet these requirements.

If you want to learn more, please visit our website RedCrown.

Typical Applications for Industrial Ultrasonic Cleaners

The extent and type of contamination (i.e. dirt, gunk, greases and oils) to be removed may require longer cleaning cycles, pointing to the selection of a heavy-duty ultrasonic cleaner.  The following examples provide you with greater detail on when and how these units are used. 

• Automotive and power train cleaning and degreasing
• Cleaning costly plastic injection molds to maintain quality output
• Ultrasonic passivation for stainless steel to meet ASTM A967 standards
• Safely remove 3-D printing mold support
• Degreasing heavy parts
• Nondestructive testing of aircraft engine parts
• Cleaning new and reconditioned filters using flammable solvents

Solutions and Frequently Asked Questions

Ultrasonic cleaning solution formulations are available to handle a broad range of cleaning challenges.  Selecting the correct formulation can make the difference between OK or perfect results.  Check our post on specifying ultrasonic cleaning solutions.

Another useful resource is our answers to ultrasonic cleaner frequently asked questions.

Equipment Investment Considerations & Pricing Guide

Cost-benefit analyses are important to any investment in plant and equipment.  When it comes to ultrasonic cleaning industrial parts – or any part for that matter – time saved to achieve desired results is an important consideration. 

As a start, download our Pricing Guide offer to get an idea of costs involved. 

But before making your final decision we encourage you to call or chat with the scientists at Tovatech. We are ready to help you select the best industrial ultrasonic cleaner for your requirements, whether benchtop or floor mounted.

In any industrial setting, for any industrial process, it is essential to keep industrial parts clean. Clean parts help keep machinery running smoothly; they help to mitigate any process flaws or errors; they protects sensitive industrial parts and components from damage, corrosion or contamination; and they help to promote quality in nearly every facet of an industrial operation.

When it comes to industrial parts cleaning, there are several cleaning methods to consider. In our last blog post Industrial Parts Cleaning 101: Understanding Methods, Costs, Pros and Cons, we presented a comprehensive review of industrial cleaning methods and processes. Now, we’d like to focus in on industrial parts cleaning process in particular: ultrasonic cleaning. In this post, we will cover the following:

• How ultrasonic cleaning technology works;
• Types of ultrasonic cleaners/units;
• Considerations when choosing the right unit/size for your application;
• Types of cleaning solutions;
• Cleaning and maintenance—how to clean the cleaner

Just as a quick recap, here are some of the key benefits of ultrasonic cleaning for industrial parts cleaning applications:

• Used for a wide range of workpiece shapes, sizes and materials
• The ultrasonic cleaning process gently moves parts to assist with cleaning; this mitigates the risk of damage to industrial parts during cleaning
• May not require the part to be disassembled prior to cleaning. Lower labor costs equal increased profits.
• Water, soap and green-friendly solvents are environmentally safe. Ultrasonic cleaning reduces/replaces hazardous cleaning solvents
• Short cycle times save time, money and increase plant efficiency

How ultrasonic cleaning technology works

Ultrasonic cleaning uses cavitation bubbles induced by high-frequency pressure (sound) waves to agitate a liquid. The agitation produces high forces on contaminants adhering to substrates like metals, plastics, glass, rubber and ceramics. This action also penetrates blind holes, cracks and recesses. The intention is to thoroughly remove all traces of contamination tightly adhering or embedded onto solid surfaces. Water or solvents can be used, depending on the type of contamination and the part.

VIDEO: HOW ULTRASONIC CLEANING TECHNOLOGY WORKS.

Types of Ultrasonic Cleaners

Table-Top Ultrasonic Cleaners
Table-top units are small, feature single tanks (usually a half-gallon to eight gallons) and can sit on a table, on a shelf or on a workbench. They’re also portable, and they’re ideal for small and light-duty applications. UltraSonic LLC offers two table-top ultrasonic cleaners: The Ultra (2.6 gallons / 9.8 liters); and the Ultra (5.2 gallons / 19.7 liters).

Medium-Capacity Ultrasonic Cleaners
Medium-capacity ultrasonic industrial cleaners are ideal for a variety of industrial, automotive, aerospace and engineering industries. UltraSonic LLC offers the following medium-capacity ultrasonic cleaners: A (10 gallon); FA (30 gallon);

Large-Capacity Industrial Ultrasonic Cleaners
Large-capacity ultrasonic industrial cleaning units are designed to handle large and heavy duty equipment and parts, including a variety of industrial parts, automotive and aerospace parts.  These units typically feature rinse and dry stations and other features. UltraSonic offers the following large-capacity ultrasonic cleaners: FA (65 gallon); FLT (115 gallon); and FLT (210 gallon).

Considerations when choosing the right unit/size for your application

• Parts: The parts you need to clean – and their particular characteristics, from shape and size to durability and composition – can dictate what unit and size is best suited to do the job.
• Power: Most ultrasonic generators are single-phase 120 Volt AC or single-phase 240 Volt. You should check with the manufacturer for specific supply voltage and frequency specifications for your ultrasonic cleaner.
• Portability: Do you anticipate that you’ll need to move your ultrasonic cleaning machine to different locations in your facility? If so, you may want to consider a cleaning machine with casters for easy movement. UltraSonic LLC’s FA cleaning machine is a 30-gallon cleaner with attached casters.
• Contaminants: When you’re cleaning oils, water-based coolants and light dirt from industrial parts, a unit with side-mounted or bottom-mounted transducers should be adequate, since oil floats, and minimal dirt will settle on the bottom of the tank.

For heavily soiled items, it’s best to choose a unit with side-mounted transducers, since the large volume of dirt, carbon and grime that falls to the bottom of the tank during cleaning could sit atop transducers in a bottom-mounted unit and muffle the sound, thus limiting the cleaning power.

• Multi-stage options: Ultrasonic industrial parts cleaning machines generally come in one-, two- and three-stage systems. The part or part you need to clean, as well as the filtration that’s necessary to get the job done, and the extent to which hot drying is necessary, usually determines which one is right for you.
• Location and environment: Within a facility and outside of it, location and environment are important factors in determining where ultrasonic cleaners should be located in a facility, and what, if any, special equipment is necessary to protect them from atmospheric and temperature elements.

Types of cleaning solutions

UltraSonic LLC offers the following cleaning solutions:

• UltraSonic Ultra Soap Multi-Purpose Cleaner
• UltraSonic Ultra Soap Carbon Cleaner
• UltraSonic Ultra Soap Moderate-Duty Cleaner

Cleaning and maintenance – how to clean the cleaner

Ultrasonic cleaning machines require regular care and maintenance in order to ensure that they run efficiency, effectively and do so over a long period of time. Every industrial environment is unique, so specific cleaning and maintenance programs should be developed based on manufacturer recommendations. Consult with the manufacturer that produced your ultrasonic cleaning machine for recommendations and tips.