Ultrawave ultrasonic cleaning best practice guide

Ultrasonic Cleaning

Best Practice Guide

Ultrawave Ltd Eastgate Business Park

Wentloog Avenue Cardiff CF3 2EY United Kingdom

Telephone +44 (0) 845 330 4236

Fax +44 (0) 845 330 4231

Email [email protected]

Web www.ultrawave.co.uk

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Contents

Introduction ....................................................................................................... 2

1. Setting up your new ultrasonic cleaning equipment.................................. 2

1.1 Filling the ultrasonic tank ........................................................................... 2

1.2 Detergents optimise ultrasonic activity ........................................................ 2

2. Optimising ultrasonic cleaning efficiency .................................................. 3

2.1 Positioning of the parts to be cleaned .......................................................... 3

2.2 Degas before every cycle ........................................................................... 3

2.3 Use the heating function to help shorten cleaning time .................................. 3

2.4 Always use a basket .................................................................................. 3

2.5 The lid acts as an insulator ......................................................................... 4

2.6 Cleaning times .......................................................................................... 4

2.7 Changing the fluid ..................................................................................... 4

2.8 Rinse thoroughly ....................................................................................... 4

3. Longevity depends on quality and maintenance ........................................ 5

3.1 Aqueous (water-based) detergents.............................................................. 5

3.2 Keep it clean ............................................................................................ 5

3.3 Service maintenance ................................................................................. 5

About Ultrawave ................................................................................................ 6

mailto:[email protected]



Telephone +44 (0) 845 330 4236

Fax +44 (0) 845 330 4231



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Introduction

Ultrasonic cleaning has long been recognised as one of the most effective methods of

cleaning across a diverse range of applications. No other method is as fast or efficient for

cleaning hard substrates or intricate parts.

This document outlines some key information to help you maximise the efficiency and

longevity of your ultrasonic cleaning equipment.

1. Setting up your new ultrasonic cleaning equipment

Set up your ultrasonic equipment in an area near to water supply and drainage, but

away from flood prone areas. A stand may be used to help eliminate this risk.

Ensure your ultrasonic equipment is connected to a suitable mains connection and store

any excess cable neatly.

1.1 Filling the ultrasonic tank

Before filling up the ultrasonic tank with water, ensure all drain valves (if applicable) are

in their closed position.

It is crucial that the fluid is filled at least ¾ full, not doing so can damage the ultrasonic

cleaner. Some ultrasonic cleaners are fitted with a fluid level sensor, to indicate that

enough water is filled.

1.2 Detergents optimise ultrasonic activity

Ultrasonic detergents are an essential part of the overall cleaning process. The cleaning

properties of detergents improve performance, helping to remove and loosen

contamination from the surfaces of components while also dissolving dirt.

Furthermore, ultrasonic detergents contain surfactants which reduce the surface tension

of the water. This reduction in surface tension means that higher levels of cavitation can

occur in the water, thus increasing the level of ultrasonic activity and improving the

cleaning results.

The required dosage of detergent will depend of your application and level of

contamination.




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2. Optimising ultrasonic cleaning efficiency

Ultrasonic cleaning is the rapid and complete removal of contaminants from objects by

immersing them in a tank of liquid flooded with high frequency sounds waves. These

non-audible sound waves create a scrubbing brush action within the fluid.

2.1 Positioning of the parts to be cleaned

Due to the nature of ultrasonics, all surface areas must come into contact with the fluid,

in order for ultrasonic cleaning activity to occur.

2.2 Degas before every cycle

In order to generate optimum ultrasonic activity, the gases present in ordinary tap water

need to be driven out of the cleaning solution. This is done by degassing the fluid.

The time needed to degas the liquid varies depending on the amount of gas present in

the liquid and the quantity of water in the tank. We recommend a degas period of at

least 10 minutes for smaller ultrasonic baths, increasing for larger tanks.

During the degas cycle, you will see bubbles of gas forming on the inside of the bath,

and slowly rising to the surface. Degassing is complete when you can no longer see

these bubbles.

Once the liquid is degassed, your ultrasonic cleaner is ready to use.

2.3 Use the heating function to help shorten cleaning time

For many applications, heating the liquid in the bath will help to speed up the cleaning

process. The highest levels of cavitation are achieved in fluids at temperatures of above

50°C. Ultrasonic activity itself will heat up the liquid at a rate of approximately 10-15°C

per hour if in continuous use.

When cleaning reusable medical instruments, however, the maximum temperature this

should be done at is 40°C. Setting the temperature above 40°C may cause proteins to

coagulate and “bake on” to the instruments.

2.4 Always use a basket

It is essential that items being processed in the ultrasonic cleaner do not rest on the

base of the tank. Components must be placed in a basket or if necessary, suspended

within the cleaning fluid.

When an item is in contact with the base of the tank, abrasion will occur as the item

vibrates very quickly against the tank. This will cause wear on the metal surface and in

extreme cases, the tank will develop holes and start to leak.




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2.5 The lid acts as an insulator

During operation, the lid lowers the evaporation of fumes; it also prevents contamination

from entering into the fluid. It can help reduce the level of noise produced from

ultrasonic activities.

In addition, the lid acts as an heat insulator. This means less energy would be required

to heat up the liquid for the next ultrasonic cycle.

2.6 Cleaning times

Different applications will re quire different cycle times to clean the component. The

nature and level of contamination will affect how quickly an item can be cleaned.

If the components/instruments are not clean at the end of a cycle, then a longer cycle

time may be required.

Cleaning times will become easier to judge with time, it is important to experiment with

different variables such as time, temperatures and dosage of detergent.

2.7 Changing the fluid

Your application and the nature and level of contamination will determine how often to

change the cleaning liquid.

For example, the fluid used in an ultrasonic bath for cleaning surgical instruments will

need to be changed after every session (up to twice a day), whereas the fluid in an

ultrasonic cleaner used for cleaning newly manufactured PCBs may only need to be

changed once every 3 to 4 weeks.

2.8 Rinse thoroughly

It is advised that components are rinsed thoroughly in water after they have been

cleaned. This can be done either in a separate rinse tank or under clean running water.

Rinsing ensures that any detergent or contamination residue that has adhered to the

components when the basket is taken from the tank is removed.




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3. Longevity depends on quality and maintenance

Just like most equipment, the quality of the material and manufacturing standards are

key influences on the longevity of the products. In addition, maintenance will also play a

pivotal role in maximising the lift span of your ultrasonic cleaning equipment.

3.1 Aqueous (water-based) detergents

Ultrawave recommends using only aqueous based detergent. Not only will this lower the

risk of damage to the tank, it also lowers risk exposed to the operators and impact

caused to the environment.

3.2 Keep it clean

It is important to keep your ultrasonic equipment clean. Your application and the nature

and level of contamination will determine how often to change the cleaning liquid.

The base of the bath generates ultrasonic activity by vibrating at very high speeds.

Therefore any contaminants that come into contact with the bottom of the ultrasonic

tank will act as an abrasive, causing wear on the metal which may eventually lead to

formation of pin holes.

3.3 Service maintenance

Your ultrasonic cleaning system should be professionally tested and its performance

calibrated on an annual basis. Like an MOT on a car, annual servicing ensures that the

ultrasonic cleaner continues to operate effectively, providing the cleaning and processing

results that you demand.

Servicing requirements will depend on the application and operation frequency. In more

demanding industries where a validated process is followed, such as healthcare, medical

device and pharmaceutical manufacture, more frequent performance testing and

servicing may be required.




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6

About Ultrawave

With over 25 years’ experience, we are one of the largest manufacturers of precision

ultrasonic cleaning equipment and have been supplying the highest quality systems to

companies across a wide range of industries since 1990.

Accredited to ISO13485 and ISO9001, Ultrawave is a trusted supplier to many renowned

companies from the Healthcare, Medical, Aerospace, Automotive, Manufacturing and

processing sectors and have developed a broad portfolio of products tailored to different

applications.

Our ultrasonic cleaners range in size from 0.5 litre Benchtop baths to larger industrial

ultrasonic cleaners, through to process validated healthcare products and multi-stage

automatic handling systems tailored to individual customer’s requirements.

For more information or a free no obligation initial consultation, contact Ultrawave:

Tel: +44 (0) 845 330 4236

Email: [email protected]

Web: www.ultrawave.co.uk



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Ultrawave ultrasonic cleaning best practice guide