The Benefits of Automated Cleaning with Ultrasonics

An ultrasonic parts washer is a device that uses ultrasound to clean items. Ultrasonic cleaners work by agitating a liquid, usually water-based detergent solutions, at high frequencies. The high-frequency vibrations create cavitation bubbles in the liquid. These bubbles collapse and release energy to form liquid jets that are powerful enough to remove dirt and grime from the surface of the items being cleaned.

Ultrasonic cleaners are effective at cleaning a wide range of parts, and are particularly useful in industrial settings where thorough cleaning of semi-finished goods or final products is required. The ultrasonic cleaning process involves a custom combination of multiple stages, including washing, rinsing, and drying, often requiring multiple tanks.

Parts may be manually transferred from tank to tank by an operator. Or the system can be automated, in which case an overhead carrier system, essentially a robot, passes the baskets through the cleaning stages.

The Benefits of Using an Automated Ultrasonic Parts Washer

Ultrasonic parts cleaning often plays a pivotal role in the production process. In some industries, companies require high throughput systems or even those that can handle continuous processing. Automated ultrasonic cleaners, also called conveyor washers, require minimal manual input and can offer a number of benefits over manual cleaning methods.

Increased Productivity

Automated parts cleaners don’t need to take breaks and won’t get distracted. They are faster and more efficient and can even run 24/7 if needed, minimizing the need for equipment downtime. Many automatic parts washers operate on a timer, so you can set the machine and walk away. As such, opting for an automated system over a manual model can greatly increase productivity, speed up cleaning, and massively reduce the number of manhours needed. This can reduce labor costs or free up staff to perform other critical tasks. Automated cleaners can often be used in conjunction with other automated machines to create a more efficient and effective workflow.

Full Control Over The Ultrasonic Cleaning Process

Some automated parts cleaning systems can be easily controlled from a digital panel. For example, UPCorp’s Sonic Touch® II enables you to control and view a range of functions including temperature, time, 7-day heat time, ultrasonic intensity, pump and filter, low liquid level, and diagnostic systems. It even integrates text messaging and email to enable constant monitoring and send alerts to the manufacturer or supervisor for troubleshooting or scheduled maintenance.

Avoid Human Error

When using a manual ultrasonic cleaning system, there are a number of things that could go wrong, including the operator missing a stage or mishandling and damaging delicate parts. With an automated cleaning machine, you have consistent movement of parts along the various stages and systems are designed to handle parts with care.

Limit Risk of Injury

As with the operation of any production equipment, there is risk of injury, for example, due to misuse or malfunction. Limiting manual input means minimizing this risk and the associated liability. Automation also limits exposure of operators to potentially hazardous detergents such as a highly acidic solvent or caustic cleaning fluid.

How to Choose the Best Automated Ultrasonic Cleaner

When choosing an automated industrial parts washer, there are several factors to consider, such as the size and shape of the unit and the ultrasonic frequency required.

Automated ultrasonic cleaners are available in a wide range of sizes and configurations to accommodate different commercial cleaning needs, so it is important to select a unit that is appropriate for the task at hand. For example, you'll need to ensure that the basket size will allow for your largest part to be fully submerged.

You'll also need to determine how many stages and consequently tanks your automatic parts washer should have. While three-stage systems are common (wash, rinse, dry), some processes require additional stages, for example, for passivation or an extra rinse step. Another key consideration is which features are important to you, such as wash and rinse agitation (for ensuring all contaminants are flushed) and digital control.

Finally, but perhaps most importantly, you need to bear in mind that an ultrasonic cleaner can represent a large capital investment. As such, it's vital to opt for an automated parts washer that's well-constructed and highly durable (stainless steel units made in the US are a top choice). In addition, a competitive warranty can provide cost savings in the long term.

Automated Ultrasonic Cleaners save time and increase productivity

Ultrasonic cleaning provides the ideal option for parts cleaning in many industries. But manual units require operators to move parts from one stage to the next which costs money, time, and productivity.

Automated ultrasonic cleaners are available in a variety of sizes and configurations to meet your specific needs. They also offer a range of features, including adjustable settings, programmable timers, and automatic shut-offs. Plus they can be easy to operate and maintain.

Overall, automated parts washing can save you time and money while improving the quality of your finished product, making them an ideal choice for many businesses.