Why Use Ultrasonic Cleaning Equipment?

One of the first factors generally considered when buying big-ticket cleaning equipment is price. However, far too many business owners get stuck on the sticker price of a piece of equipment rather than the long-term costs associated with a product. Some of the most important factors on this front are cleaning costs as well as wear and tear on the equipment that leads to replacement. What if we told you industrial ultrasonic cleaners could get even the dirtiest equipment cleaned (in most cases) with a single pass rather than having to run them through a machine over and over again? Would that pique your interest?

Well, these are but a few of the benefits of using ultrasonic cleaning equipment. Here are just a few examples and how ultrasonic cleaners are a far better option.

Filter Cleaning Businesses

Whether you own a filter cleaning business or need to clean filters regularly as part of your business, you probably already know this can be a rather expensive process. Filters themselves can be a bit costly, so you want to have them cleaned effectively, but you also need to ensure they are not being damaged in the process.

Some companies/businesses will use power washers to get their heavy-duty filters clean, but this can sometimes damage the filters and still may not get them entirely clean. Soaking, powerful chemical solvents, scrubbing… these are all things that can either leave the filters dirty or actually damage the material, thereby making the filters less effective or outright unusable.

Some of the most common contaminants caught in these types of filters are:

• Carbons
• Carcinogens
• Grease
• Lubricants
• Metal shavings
• Oil
• Rust
• Paint
• Petrochemicals
• Varnish

Ultrasonic cleaners are able to get deep inside these filters to clean every crevice because of cavitation. In its simplest terms, this is the process where vapor bubbles form (in ultrasonic equipment, these bubbles are created by the ultrasonic waves), then implode, removing surface contaminants from the parts being cleaned. Think Scrubbing Bubbles on steroids. Your filters (or your client’s filters) are immaculately cleaned with no damage or wear and tear.

Pharmaceutical Benefits

The pharmaceutical industry is yet another industry with every expensive equipment that needs to be cleaned immaculately on a daily basis. Traditional cleaning in this industry can be quite costly, with many hours of downtime if the equipment is not properly cleaned. Ultrasonic cleaners work quicker and far more efficiently than an individual is capable of doing.

And, just as we mentioned above, because this cleaning equipment uses water-based cleaning solutions, it means less exposure to harsh chemicals that can break down equipment over time, not to mention the cost of PPE equipment and the dangers associated with using such harsh cleaners.

Also, consider that because the equipment will be better maintained, you will be prolonging the equipment’s overall lifespan, all of which means more money to your bottom line.

Need More Information?

If you are considering an ultrasonic cleaning solution, a member of our team at Omegasonics would love to discuss your options. Be it one of our standard models or a custom build, we have a cleaning solution to fit your needs. To see our full line of Ultrasonic cleaners, click here. To speak to one of our experts today, give us a call at 888-989-5560.

These 7 factors will help you  answer the questions “how do I choose an industrial ultrasonic cleaner and what is the right ultra sonic cleaner for your cleaning application”.

1. Ultrasonic cleaner frequency

What frequency is best for ultrasonic cleaning or as some refer to as ultrasound cleaning?

Ultrasonic cleaning is a process that uses an appropriate cleaning agent and ultrasound (usually from 20–400 kHz). The ultrasonic cleaning frequency must match the cleaning application. Different frequencies produce different results. The most common cleaning frequencies range from 25kHz to 80kHz. Lower frequencies such as 28 kHz produce fewer and larger bubbles that are aggressive for heavy duty industrial applications. 40-80 kHz and up produces very tiny bubbles packed tightly together which create a gentle scrubbing action for semi-conductors and high-end electronic components. 40kHz produces a large number of smaller bubbles that produce powerful cavitation. Omegasonics factory sets at 40 kHz which is the best frequency for industrial and commercial cleaning applications.

2. Ultrasonic generator power

How much power do you need for an ultrasonic cleaner?

The power of an ultrasonic cleaner is measured by watts per gallon. The correct wattage for our tank capacity is important (Watts/Gallon) for efficient ultrasonic cleaning. When cleaning with ultrasonics, always use a higher power level for heavy contamination. The ability to control power output is important because it allows you to tailor the output to cleaning needs. The ultrasonic generator is what produces the power which sends the signal to the ultrasonic transducer that produces ultrasonic cleaning waves in the tank.

3. Ultrasonic cleaning solution soaps, chemicals and detergents

How do you know what is the best ultrasonic cleaning solution for cleaning your item?

Ultrasonic cleaning detergents dissolve and dislodge surface residues. Not all cleaning solutions work effectively in ultrasonic equipment; some general-purpose cleaners break down at temperatures as low as 140F and cavitation action can cause some general chemicals to break down into their components. Omegasonics’ chemicals are formulated for specific cleaning applications and designed not to breakdown during cavitation. Different soaps work for different applications and materials. For example, alkaline chemicals remove dirt and smoke while acidic solutions remove corrosion and heat scale. If you are cleaning a delicate item then you will want to use a ultrasonic cleaning solution with a lower pH such as 10.0, if you are cleaning a general item such as glass or plastic then you will want to use a solution that has a pH around 11.3-11.8 and with metal items you will use a solution that has a pH at around 2.0 to remove rust. Can you use tap water in an ultrasonic cleaner? The answer is yes, but if you are cleaning any type of electronics in the ultrasonic cleaner than de-ionized water is recommended.

4. Ultrasonic cleaning temperature

What temperature do I use when cleaning my item in an ultra sonic cleaner?

Most ultrasonic cleaning is done at temperatures ranging from 100°F to 150°F. The correct temperature will expedite the cleaning process. Start with lower temperatures & work up to higher temperatures. All of our machines come with digital temperature controllers.

5. Ultrasonic tank part loads and tank sizes

What size ultrasonic cleaning tank do I need?

Part loads relates to the mass of the items being cleaned within the ultrasonic tank, increased part loads require more energy to process; small loads will clean faster than larger loads due to available energy for the load. If you overload your tank with parts, it will decrease the amount of cavitation that is hitting the surface of the parts being cleaned and will not only affect the cleaning process but will also affect the cleaning consistency. If you are cleaning a lot of parts at once then you will want a larger tank to accommodate your cleaning needs. Omegasonics also offers custom tanks.

6. Material makeup

What can ultrasonic cleaners clean?

You probably have heard of ultrasonic cleaners mostly for cleaning jewelry but did you know that you can clean any hard durable item in an ultrasonic tank? The number of items that can benefit from ultrasonic cleaning is vast. The reason? There are just two basic “eligibility requirements” before something can be cleaned in this manner.

The cavitation that powers ultrasonic cleaning and scrubs contaminants off parts will only occur in a liquid environment. Ergo, the item must be one that won’t be damaged by immersion. Some of the things on that list might surprise you. For instance, most of us would react with horror at the idea of combining electronics and water, but as long as proper drying techniques are used, an ultrasonic cleaner will not only clean electronic devices, but clean them more quickly and completely than any other method. The second requirement is that the part can be dried relatively easily. This eliminates items that are absorbent, but most others can simply be air dried with a blower.

For this reason, ultrasonic cleaning is used to remove unwanted materials from everything from jewelry to long rifles, from super-delicate lenses to massive engine parts, from surgical instruments to motherboards.

You may be wondering if ultrasonic waves will damage relatively brittle materials, such as glass or ceramics. Ultrasonic cleaning is perfectly safe for these materials.

What should you not put in an ultra sonic cleaner? Do not put anything textile such as clothing, shoes, rugs and stuffed animals. They absorb the ultrasonic cavitation.

7. Ultrasonic cleaning time

How long does an ultrasonic cleaner take to clean?

There are many factors that determine how long an item will have to remain in the ultrasonic tank for the cleaning process, including: “frequency, power, soap, temperature, load, and material”, also what type of dirt or oil is on the item. Cleaning normally lasts between three and six minutes, but can also exceed 20 minutes, depending on the object to be cleaned. All of our machines come with digital timers that allow you to be able to set your desired cleaning time.

What are the advantages of cleaning with ultrasonics and ultrasound cavitation?

• Efficient – Ultrasonic cleaning provides the ability to clean baskets of parts rather than individual items.
• Thorough – Ultrasound is the most thorough cleaning method known to science. Contents cleaned manually by hand will never be as clean as contents processed ultrasonically. Ultrasonic bubbles can reach areas impossible to access by brushes or sponges
• Gentle – The ability to control the cleaning variables allows the same equipment to clean everything from industrial parts to delicate crystal and China.
• Consistency – Cleaning with ultrasonics is always consistent.

For more information on choosing the best ultrasonic cleaner in 2021 watch our video below.

Just like when Goldilocks broke into the home of the Three Bears, she tasted the first porridge and it was too hot. Then she tasted the next porridge-too cold. Once she moved over to the third porridge, you guessed it, just right. But this was according to Goldilocks taste preference. Some other intruder with different taste sensations may have had an entirely different experience with temperature.

Same thing goes with industrial cleaning applications. There is no one magical temperature for all. What determines the bath temperature involves several factors.

• What contaminant are you removing?
• What chemistry are you using?
• What type of material are you cleaning: plastic, soft metal, hard metal, graphite etc?
• What is the desired outcome – how clean does it need to be?
• Is there another step following the cleaning process?

We all know that cleaning in hot water is better than cold based on years of dish washing experience. Then why not go with the hottest water possible, almost boiling, and cut to the chase?

Because cleaning soaps break down and fail at different temperatures. Having the correct detergent to decouple contaminants from surfaces is even more important than the bath temperature in most cases. If you destroy the detergent formulation, you won’t achieve your cleaning results, regardless of how hot you operate the bath.

Because plastics will warp and generally deform in fluids that are above their melting point.

Because soft metal surfaces can get scarred or develop star bursts on the surfaces during ultrasonic cleaning. Surface scarring will show through even in secondary plating processes. Extremely hot water is very detrimental in this situation.

Because cleaning personnel could encounter serious safety issues such as burns, when the bath fluid is extremely hot.

If your application deals with removing heavy greases, mold release or carbons from cast iron surfaces, then the hotter the better. But in most cleaning applications, you need to operate in an operating range of 120 – 150°F which is fairly hot as it is.

So just like Goldilocks, getting your bath cleaning temperature “just right” is key to cleaning success

Having an integrated ultrasonic cleaning system in a facility allows for a smaller footprint for the machine, opening up the factory floor for other equipment and working space, provides a single point of electrical connection for all stages of the process, and makes the unit mobile so it can be moved around the facility as needed.

Complete ultrasonic cleaning stations are typically arranged as three- or four-stage systems. In a three-stage unit, the ultrasonic cleaner, rinsing station, and drying station modules are built into a single housing so parts can be quickly moved from cleaning process to cleaning process. The four-stage unit also adds a pre-wash module ahead of the ultrasonic cleaner in facilities where removing any loose scale, grease, oil, or dirt is helpful before parts are placed in the ultrasonic cleaner.

Multistage ultrasonic cleaning systems are compact, portable, and convenient. Omegasonics makes the DX3 and DX4 three- and four-stage ultrasonic cleaners.

Here’s a general overview of how each of the stages function

Pre-wash – This cycle is used to remove gross contamination from the surface of parts. This keeps the majority of sludge out of the ultrasonic cleaner, so it doesn’t need to be cleaned as often and allows the unit to do its job more efficiently. Designs vary, but the pre-washer may include a heater or spray nozzles to facilitate contaminant removal.

Wash – This stage is the heart of the ultrasonic cleaning unit. This provides the actual final cleaning to remove any residual contaminants from the surface, hidden passageways, blind holes, and cracks and crevices in the parts. These units are heated to optimize cleaning and have a programmable timing cycle to minimize the power and time used for cleaning.

Rinse – This cycle removes remaining detergents from the parts after they’ve been washed. Rinse stations are heated, and typically use de-ionized water or other specialized cleaning agents to ensure no residue is left behind.

Dry – A recirculating hot air dryer is the final stage, used to dry the parts quickly so they can be moved on to the next process. The drying step is also critical for parts that may oxide or rust quickly if moisture is not removed.

Automation – Some ultrasonic cleaning systems also come with automated pick-and-place systems. While this is useful for highly automated production systems, it is very expensive—often doubling the price of an integrated unit.

Omegasonics builds three- and four-stage ultrasonic cleaning systems—the DX3 and DX4, respectively. Our units are designed for maximum portability with built-in casters and a single point of connection for utilities, and fabricated from corrosion-resistant materials. They do not include automation, so they are reasonably priced and economical for even small and midsize businesses.

The high-efficiency hot air dryer is contained within the system to maximize space and improve convenience. We highly recommend them to any facility that uses ultrasonic cleaning regularly as a portion of its processes.

Contact us if you or your facility is looking for a convenient, compact, and economical solution for your ultrasonic cleaning system needs. You can also find us on LinkedIn and Twitter.

It’s because of these benefits we see them being used in a wide range of industries throughout the world, including medical, food processing, electronics, aerospace, and disaster recovery, among other more conventional places.

As parts get smaller and more intricate, and companies push to drive down the cost of doing business, ultrasonic cleaners become the “parts cleaner of choice.” In this first of a two-part series, we will begin to investigate the benefits of ultrasonic cleaners by looking at five of their advantages.

1. Time Savings – Ultrasonic cleaners emit up to 40 thousand sound pulses per second, and each pulse provides cleaning action as it impacts the part surface. Because of this high-frequency wave action, ultrasonic cleaners can remove contaminants faster and better than other types of cleaners.

2. Gentle Cleaning – Ultrasonic cleaners remove contaminants without abrasion, harsh scrubbing, or high-pressure sprays, making them ideal to clean even the most delicate parts. This is why they are used to clean microchips, computer parts, plated parts, and irreplaceable family heirlooms.

3. Versatile Contaminant Removal – Ultrasonic cleaners can remove an almost endless variety of contaminants from a part’s surface, including oil, grease, wax, shavings, dirt, dust, clay, sand, parting compound, soot, carbon, and oxidation, down to a microscopic particle size. No other parts cleaning system offers that level of flexibility in the same unit.

4. No Part Too Complex – Ultrasonic cleaners really “shine” when it comes to cleaning complex parts. Because the cleaning detergent and high-frequency waves penetrate all surfaces, even hidden passageways, narrow openings, crevices, cracks, and blind-drilled holes get just as clean as the visible surfaces without the intense hand-cleaning costs.

5. Low Power Consumption – Compared to other types of parts-cleaning systems that use a variety of motors to pump, spray, circulate, agitate, and capture the cleaning chemical and its vapors, ultrasonic cleaners need only one small motor to filter the solution. The rest of the cleaning is done with efficient electrical energy and transducers, keeping power consumption to a minimum.

We have only scratched the surface as far as benefits are concerned. In the second article of this two-part series, we will look at even more advantages that ultrasonic cleaners provide. Their versatility, gentle cleaning action, ability to clean complex parts, time savings afforded, and low power consumption requirements have drawn many industries to their use, and in the next article, we’ll see that there are plenty of other compelling reasons as well.

For more information on ultrasonic cleaners visit the Omegasonics website. You can also find us on LinkedIn and Twitter.

Go to part 2 in the series.

1.  SIZE MATTERS – Pick the right tank size. Don’t buy a unit that is too small for you largest critical parts, or a unit that can’t handle the amount of parts (per load) you are putting into it.

If you think the unit you are buying is too small before you buy it, then it will definitely be too small once you start using it.

As a result, you won’t be able to see the great benefits of ultrasonic cleaning because you will put even more parts through then you ever imagined.

2.  FREQUENCY – Make sure you have the best frequency for your application. For most applications, and by most I mean 95%+ in the world, 40 kHz is the frequency for you. Unless you have a rare specification calling out 25 kHz or are doing sub-micron cleaning of sensitive electronics requiring 68 kHz and above, then look no further than 40.

3.  POWER – You need the right cleaning power for your application. Here is where it is best to discuss your application with a qualified ultrasonics company so you know what is required. Most equipment is outfitted with the correct ultrasonic power for the bulk of applications.

4. CHEMISTRY – Though most ultrasonic applications are cleaned in a water based solution, those solutions generally require some type of soap additive. Here again it is recommended to contact a qualified ultrasonics manufacturer to discuss your specific application and get the right chemistry. There are soaps designed to remove oils and then separate out in the bath. Some applications do better with a surfactant, but chemistry is a blog post of its own.

5. PROCESS – The process involves the dwell time of the ultrasonics, the bath temperature, the chemistry concentration. Best to get a “How to Do Process Sheet” from your favorite ultrasonic systems manufacturer.

Hopefully these tips have helped you, and as always if you’re in need of professional consultation, you can always contact us.

Fans across the country spent hours studying up on their favorite players to draft the ultimate fantasy team.

If you didn’t pick up Adrian Peterson, Percy Harvin, or Donovan McNabb, then you may not have any Vikings on your team this year. However, here’s one Viking that should help your team: an ultrasonic Viking Multi-Stage unit.

As you know, if you play fantasy football, the key to a good team is the ability to be diverse. You want a team that is not one-dimensional. You need two strong running backs, a QB who can throw for a lot of yards and TDs, and at least two consistently targeted receivers and/or tight ends. Likewise, a good ultrasonic unit should be efficient, effective, and able to handle audibles such as specialized and hard to clean parts!

We, at Omegasonics, suggest that you analyze the “opponent” before you make your first round ultrasonic pick. Ask the questions, “What kind of items will I be cleaning?” and “How do I want to dry those items?”

How to Make your First Round Ultrasonic Pick (System):

• Viking X2: (choose 2): ultrasonic wash, heated rinse, and ultrasonic rinse
• Viking X3: (choose 3): ultrasonic wash, heated rinse, ultrasonic rinse, and hot air dryer
• Viking X4: ultrasonic wash, heated rinse, ultrasonic rinse, cascade rinse and hot air dryer

How to Make your Second Round Ultrasonic Pick (Tank Size):

• Pro: 18″ length x 18″ width x 14″ depth
• Pro Plus: 18″ length x 24″ width x 14″ depth
• Super Pro: 18″ length x 34″ width x 14″ depth
• Power Pro 6000: 24″ length x 36″ width x 20″ depth

No matter which ultrasonic machine you end up selecting, your unit comes with all of the parts necessary to take your team to the championship.

Each System Includes:

• Stainless steel tanks – all fully insulated
• Exterior Hammerton powder coat finish
• Digital temperature controls – each tank
• Digital timer controlled ultrasound-wash
• Dual stage filtration-wash stage
• Single stage filtration-rinse stage
• Low-level float sensors – each stage

Omegasonics hopes your team has much success against the competition this season, both in your fantasy league and with your business. If you have further questions, feel free to contact one of our ultrasonic cleaning and restoration experts toll free at (800) 669-8227…. before you incur a play clock violation.

Have an ultrasonic day!

Frank covers what kind of recovery rate could be expected for various items of content, and which pieces of equipment should be purchased first in order to provide the fastest return on investment.

As government regulations on toxic chemicals used in the workforce were tightened, industrial companies were frantically searching for newer and safer ways to clean their dirty, oily, and contaminated parts.

Today, it is more important than ever to maintain and achieve the highest quality levels of precision cleaning in many different industries due to constantly changing requirements.

There are hundreds of industries that use ultrasound as their first choice for safe and effective cleaning. Currently, ultrasound is the premier cleaning technology for the automotive, marine, pharmaceutical, aerospace, musical instrument, firearm, disaster restoration and other industries requiring absolute precision cleaning.

Other methods of aqueous-based industrial cleaning can use a lot of water, which goes directly down the drain or has to be collected and disposed of properly depending on the toxic levels. Water waste can come from the manufacturing process, scrubbers, mops, tanks and more. There are several technologies that recycle water but these systems can be costly especially for smaller operations. Despite the effort and resources, none of them have been nearly as effective as ultrasound.

Are you in a specialized industry that could benefit from ultrasonic cleaning? Take a look at some of these industrial ultrasonic cleaning case studies to see how companies of every size are cleaning more efficiently and increasing their bottom line!

But the most commonly recognized application for ultrasonic cleaning known to the general public is jewelry.

Everyone has been to a jeweler in the mall and heard those little tiny tanks buzzing away to the delight of many female customers who see their diamond rings and bracelets sparkle like new again.

It’s fun to even watch business executives with Rolex watches awe in amazement. Ultrasound became a highly popular method for cleaning sensitive minerals, diamonds and other types of jewelry.

These small ultrasonic jewelry machines would eventually evolve into larger sizes with most manufacturers carrying a line of six to eight models. Tabletops are generally “commercial duty” – meaning that they are designed to operate two to three hours per day as opposed to true “industrial grade” units that can run a full ten-hour production shift. In industrial settings, tabletops are primarily used for smaller-sized parts and low volume work. Typical tabletop units range from one-half to eight-gallon tanks, but they can still provide the same benefits as larger systems at a much-reduced price, as long as the ultrasonic power requirements are low and the usage time is low.

Motorcycle, ATV and Jet Ski carburetors are commonly cleaned using ultrasonic tabletop machines. Previous methods used toxic chemicals such as carburetor spray and brushes, not to mention a lot of time and labor! However, even with all of that labor, the cleaning process is not fully effective. With ultrasound, cleaning success is highly probable each time without the use of toxic solvents.

One of the most unique factors about having a tabletop machine in your facility is the convenience of the size. Tabletops are no bigger than a microwave oven and can be placed on any workstation. This allows an employee to save time by working at their location as opposed to making many unnecessary steps going back and forth to a central cleaning station somewhere else inside the plant. This saves considerable effort and enhances employee productivity.

A tabletop ultrasonic washer may be a great fit for you and your company.

To see typical tabletop sizes and specifications go here.