How Accessories Amp Up Ultrasonic Cleaner Performance
Tovatech’s PhD’s explain how accessory selections, starting with new modular basket designs, increase industrial and laboratory ultrasonic cleaning and processing efficiencies. Here we offer suggested solutions to ultrasonic cleaning problems brought to our attention.
Modular Baskets Provide Unprecedented Parts Positioning Flexibility.
Ultrasonic energy in industrial cleaning and for laboratory tasks works best when items to be cleaned or processed are properly positioned in the ultrasonic bath. Baskets are essential to successful cycles. That is because baskets position items – without crowding – at the proper level in the bath to receive optimum cleaning or processing energy delivered by the ultrasonic cleaner.
Problem: For best cleaning results parts should be positioned to allow contaminants to fall away from surfaces. This can be a challenge, for example, when cleaning tubular or complex-shaped products, or parts better placed vertically than lying horizontally in the basket. In many instances, operators find it necessary to remove the basket and carefully reposition parts to assure a thorough cleaning job.
Solution: Stainless steel modular basket systems designed to fit Elmasonic benchtop ultrasonic cleaners solve parts positioning challenges. Distinguished by a unique basket design, the system allows operators to create levels, dividers, and employ parts holders, pins, hangers, combs, clamps and stands to accommodate virtually any part for cleaning or sample for processing.
Damage-Free Lab Sieve Cleaning
Problem: Cleaning fine mesh particle analysis lab sieves becomes more difficult as mesh size decreases, making it more likely that particles become trapped in fine sieve openings. These screens are easily damaged when cleaning is attempted manually using brushes.
Solution: For simultaneously cleaning multiple sieves, we recommend combining the Elmasonic EP300H ultrasonic cleaner with the Elma SRH 4/200 sieve rotation holder accessory.
The electrically powered SRH 4/200 is positioned atop the ultrasonic cleaner and holds up to 4, 200-mm (8 inch) lab sieves. These are clamped in a slightly canted position and rotated into and out of the ultrasonic cleaning solution. Because the screens are canted, particles fall to the bottom of the cleaning tank.
The rotation feature of the SRH 4/200 also serves as a rinsing action, further contributing to thorough cleaning.
Cleaning one sieve at a time and other lab tasks such as degassing and sample prep can be accomplished with the Elmasonic Easy 50R and Easy 350R ultrasonic cleaners.
Ultrasonic Cleaning Small Parts
Problem: A customer told us that “handling and cleaning challenges arise when my jobs call for cleaning very small parts and assemblies – and baskets prove impractical.”
Solution: Fine mesh immersion baskets are available in several sizes. These can be suspended in the cleaning solution, or rest on the bottom of conventional cleaning baskets in the ultrasonic cleaner tank.
Another Solution: Insert the fine mesh baskets into beakers containing the desired cleaning formulation or solvent. Ultrasonic cleaner beaker kits are available for small-parts cleaning using conventional or flammable solvents, in which case the cleaning formula or solvent is in the beaker and the tank contains water and a surfactant. Observe safety precautions if you clean with flammable solvents.
Enhanced Protection for Delicate and Highly Finished Parts
Higher ultrasonic frequencies such as 80 kHz, and using a feature such as the Eco Mode help avoid part damage due to vibrations. Some jobs may require further protective measures.
Problem: A customer phones in, “I’m cleaning ophthalmic instruments with very fine points. How can I avoid damage that can occur when the tips are in contact with metal cleaning baskets?”
Solution: You can protect delicate and highly polished sensitive products from potential vibration damage by placing a silicone basket mat on the bottom of the basket. These can be cut to size and should cover the entire bottom of the basket.
Controlling Cleaning Solution Temperature
Ultrasonic cleaning solutions are formulated for specific cleaning tasks and to operate at a recommended temperature. Units equipped with heaters speed temperature increases to the specified level. But the process itself also heats solutions.
Problem: “My long-term cleaning cycles cause solution temperature to rise above recommended levels. What to do?”
Solution: To avoid cleaning solution temperatures from getting too high, a useful accessory is a cooling coil. This can be inserted in the ultrasonic cleaner tank and connected to a source of cold water or a recirculating chiller.
Avoid Tank Damage from Acidic Cleaning Solutions
Ultrasonic cleaner tanks are fabricated of pressed or welded corrosion-resistant stainless steel. While safe for mildly acidic cleaning solutions such as elma tec clean S1, concentrated inorganic acid solutions such as nitric acid or sulfuric acid can cause damage.
Problem: “I’ve had to turn down jobs requiring concentrated nitric acid. Is there a way I can accept these jobs without damaging my unit?”
Solution: To safely use higher acidic (or any stainless-unsafe) ultrasonic cleaning solutions, we suggest an acid-resistant tub or insert tray.
Use water along with a little surfactant in your tank (or your regular formula). Ultrasonic energy passes through the tray walls to act on parts being cleaned in the acidic solution. Note that the insert must be immersed into the tank – the rim of the tray rests on the rim of the tank. If your tank is filled with cleaning solution you will have to drain and set aside most of the contents to avoid an overfilled tank.
Removing Cleaning Solution Residues
Cleaning solution residues remain on products after cleaning cycles. These should be removed before parts enter further processing such as plating and coating.
Problem: A customer reports “Space is limited in my shop, and there is no convenient spot such as a sink to wash parts after they’ve been cleaned. Any ideas?”
Solution: Cleaning solution residues are removed in an Elma Sink immersion unit. Simply transfer your parts in the cleaning basket from the cleaning tank to the water-filled immersion unit and agitate if needed. Place the rinsed parts on the ultrasonic cleaner tank lid for draining.
Pro Tip: Avoid rust damage to ferrous parts by adding 0.05-0.5% elma KS rust inhibitor to the water.
When Parts Drying Takes Too Long
Water-based ultrasonic cleaning solutions are environmentally friendly, but prolonged drying can raise issues.
Problem: “My cleaning cycles consist of multiple products in the same cycle, but my throughput is slowed because it takes too long to dry the parts.”
Solution: If air-drying takes too long, and employing alternates such as blow dryers is impractical, consider an Elma Dry accessory to speed the process. It dries parts with either warm air at 70⁰C (158⁰F) or room temperature air. Replaceable filters remove dust from the air blown on the parts.
Solving Ultrasonic Noise Issues
While “ultrasonic” is defined as sound above the human range of hearing, ultrasonic cleaners are not silent due to equipment and parts vibration. It is especially noticeable at lower ultrasonic frequencies.
Problem: “We’re located in a building occupied by other businesses. A new neighbor has approached me stating that the noise is disturbing his employees. There’s no way I can add to wall thickness to cut down noise transfer.”
Solution: Significant sound reduction to 85% is achieved when your ultrasonic cleaner is housed in a glass-doored, internally illuminated, ventilated ultrasonic cleaner mute box accessory. Available in sizes to accommodate Elmasonic benchtop units, they allow your operators to fully monitor the progress of cleaning cycles as displayed on the ultrasonic cleaner’s control panel.
Get the Full Picture on Ultrasonic Cleaning Accessories
The old proverb “the right tool for the job” applies to selecting ultrasonic cleaning accessories that help make your operations more efficient or solve other operational issues.
We’ve touched on only a few of the accessories that provide solutions to common ultrasonic cleaning tasks. Check the complete range by downloading our 94-page Elmasonic Accessories Catalog.
Contact the Professionals at Tovatech
Then Contact the Professionals at Tovatech to discuss your challenges and for unbiased advice on selecting the right accessory “tools” you need to amp up your ultrasonic cleaner performance.