Production line ultrasonic cleaning involving continuous operation over work shifts is best accomplished with an industrial ultrasonic cleaning machine. Here you'll learn the differences between "standard" and "industrial" ultrasonic cleaners, and tips on picking the best unit to meet challenging cleaning tasks.
Pro Tip: Industrial ultrasonic cleaners are defined by task, not size. As the user you define the task, looking for the best industrial ultrasonic cleaner you can get to meet your requirements.
Standard or Industrial: What's the Difference?
We'll start by comparing key differences between "industrial" and "standard" units then define terms, features and benefits that contribute to efficient cleaning cycles.
- Construction: Standard ultrasonic cleaners such as the Elmasonic E Plus line feature corrosion-resistant pressed stainless steel tanks. Heavier-gauge welded stainless steel tanks are used for industrial units which may be required to operate up to 8 hours per day.
- Mobility: Large industrial ultrasonic cleaners are wheel-mounted allowing operators to move them about the site as needed.
- Equipment Maintenance: To avoid lost production time due to control malfunction, Elmasonic xtra ST and Shiraclean units have modular designs for easy in-house component replacement.
- Cleaning Solution Maintenance: Large capacity industrial ultrasonic cleaners require several gallons of cleaning solution. To extend cleaning solution life pre-cleaning rinsing, weir, spray bar, and solution filtration systems are available as standard or options on certain product lines.
- Standard ultrasonic cleaners have lift-off lids. Industrial units often offer a choice of either lift-off or hinged lids. Hinged lids reduce noise, evaporation and return solution drip-off back into the tank.
- Drains: Standard units above a certain volume have stopcock-operated drains. Industrial models have heavy-duty ball valve drains to facilitate solution replacement.
Industrial Ultrasonic Cleaner Terminology
Picking the best industrial ultrasonic cleaner for your operations requires an understanding of ultrasonic cleaner terminology. This enables you to decide if the various features and benefits offered by the unit apply to solving your requirements.
Ultrasonic Cleaner Frequency
Ultrasonic frequency is given in kilohertz (kHz) or thousands of cycles per second. Frequency relates to how vigorous or how gentle the ultrasonic cleaning process works on products in the cleaning bath. Lower frequencies such as 25 kHz are used on rugged, heavily soiled parts; higher frequencies such as 37 and 45 kHz are selected for parts with complex shapes or delicate finishes.
Some industrial ultrasonic cleaners offer dual-frequency options. For a more detailed explanation, check our post on ultrasonic frequency selection.
Ultrasonic Cleaner Operating Modes
Operating modes are parameters you set on your industrial ultrasonic cleaner to tailor its operation to your particular task. Here is a brief explanation of these modes:
- Sweep: Continuous slight variation of frequency to uniformly distribute ultrasonic cleaning power throughout the tank.
- Pulse: Produces intermittent bursts of extra ultrasonic power to remove tenacious contaminants.
- Dynamic: Alternates between Sweep and Pulse to optimize cleaning and mixing.
- Eco: Reduced power Sweep mode for quiet, gentle operation.
Before you proceed, you may find our post describing how ultrasonic cleaners work, and answers to ultrasonic cleaning frequently asked questions helpful.
Heaters and Timers
Manufacturers of ultrasonic cleaning solutions (discussed below) provide recommended cleaning temperatures for their products.
Industrial ultrasonic cleaners have heaters to quickly bring the solution to the recommended temperature. This lets you start operations sooner, especially when employing large-capacity cleaning tanks. Some models automatically shut off if the cleaning solution temperature becomes excessive or if the liquid level is too low.
Timers let you set and forget the ultrasonic cleaning cycle so you can attend to other matters. Additionally, some models offer continuous operation with automatic shut-off after 6 or 12 hours to avoid potential damage to tank or parts.
A Snapshot of Industrial Ultrasonic Cleaners
The following table and subsequent equipment details will help you select the best industrial ultrasonic cleaner for your operations.
| Industrial Ultrasonic Cleaner Model | # Tank Sizes | Tank Size Range (gal.) | Ultrasonic Frequency | Timer | Adjustable Temperature | # Ultrasonic Modes |
|---|---|---|---|---|---|---|
| Elmasonic Xtra tabletop units | 5 | 1 – 7 | 37 kHz | To 30 minutes or continuous to 6 hours | Up to 80°C | 2 |
| Elmasonic xtra TT tabletop units | 2 | 0.75 – 4.8 | 37 kHz | To 30 minutes or continuous to 8 hours | Up to 80°C | 2 |
| Elmasonic xtra ST mobile units | 7 | 8 – 67 | 25 and 45 kHz | To 30 minutes or continuous to 8 hours | Up to 80°C | 3 |
| Shiraclean mobile units | 7 | 25 – 204 | 40 kHz | To 99 minutes | Preset to 150°F, control 120-160°F | 1 |
A Deeper Look at Industrial Ultrasonic Cleaner Options
The Elmasonic Xtra series of industrial benchtop ultrasonic cleaners is perfect for production lines, workshops and service bays where extra cleaning power and longer-term cleaning cycles are important to maintaining productivity and customer satisfaction. The tanks are designed to be operated continuously up to 6 hours.
- 5 tank sizes from 1 to 7 gallons
- 37 kHz ultrasonic frequency
- 1 to 30-minute timer or continuous to 6 hours with auto shut-off
- Adjustable temperature up to 80°C with auto shut-off at 90°C
- 3-year tank warranty (single shift operation)
- 2 Ultrasonic Modes
- Dynamic
- Eco
While supplies last the Elmasonic xtra TT industrial benchtop cleaners provide extra ultrasonic power to handle tough cleaning challenges in cycles to 8 hours with auto-shutoff. The heavy-duty welded stainless steel tanks carry a 3-year warranty.
The 7-member, wheel-mounted Elmasonic xtra ST family comprises the workhorse units of Elmasonic industrial ultrasonic cleaners. They're found in shops handling a wide range of cleaning tasks – from grungy engine components to newly fabricated assemblies ready for painting, plating or further processing.
Splash-proof LED-equipped control panels tell at a glance what frequency is being used – 25 or 45 kHz – which functions are operating, and the status of cleaning cycles in terms of time and cleaning solution temperature.
- 7 tank sizes from 8 to 67 gallons
- 25 kHz and 45 kHz ultrasonic frequency
- Maximum ultrasonic power
- 3 Ultrasonic Modes
- Sweep
- Pulse
- Dynamic
- Programmable cycles for routine tasks
- Two basket positions for cleaning and draining
- 1 to 30-minute timer or continuous to 12 hours with auto shut-off
- Adjustable temperature up to 80°C with auto shut-off at 90°C
- 3-year tank warranty (single shift operation)
- Swapped out control and generator assembly reduces downtime
- Pre-rinsing and filtering options extend cleaning solution life
Offered in 7 tank sizes from 25 to 204 gallons, Shiraclean ultrasonic cleaners are engineered for demanding industrial and laboratory applications, including removal of chips and coolant from machined parts, solder flux removal, injection-mold cleaning, and 3-D mold support removal. These large industrial ultrasonic cleaners feature
- High-capacity cleaning for large and complex industrial parts
- Uniform 40 kHz sweep-frequency cavitation for repeatable results
- Integrated filtration and skimming to extend bath life
- Digital controls with safety monitoring for daily operation
- Rugged stainless construction with mobile heavy-duty base
- A two-year parts warranty
Pro Tip: Calculating your Ultrasonic Cleaner Size
A critical consideration is making sure your unit is large enough to accommodate the cleaning tasks it has been purchased to perform, and using the ultrasonic cleaning solution - or chemistry - best suited to the cleaning task. Here are some tips:
Determine how large the parts are that you will be cleaning. Here are suggestions:
- Measure the dimensions of largest parts you will be cleaning
- Select equipment having a tank that will accommodate them
- Will you be cleaning batches or individual parts
- If you clean more than one part per cycle, keep them separated - not stacked
Because parts are cleaned in baskets (exception noted below) you'll need to pay attention to the dimensions of the basket.
For example, the 42.8-gallon Elmasonic xtra ST1600H has tank dimensions 23.6 x 23.6 x 17.7 inches WDH. Its basket dimensions are 18.9 x 20.7 x 11.8 inches.
You'll also need to know what is called the working depth of the cleaning fluid as it relates to the size of parts you're cleaning. It is the distance from the inside bottom surface of the basket to the surface of the liquid in a filled cleaner tank. It is important because parts must be fully immersed in the ultrasonic cleaning solution.
Exception to Baskets: High-capacity industrial cleaners such as the Shiraclean units can be provided with bottom racks for product support.
Pro Tip: Take into consideration cleaning solution displacement caused by immersed parts. You may find it necessary to drain off and set aside solution if parts displacement raises levels above the recommended cleaning tank level. If the tank has a weir, make sure the weir can accommodate the displaced solution.
Selecting Ultrasonic Cleaning Solution Chemistry
The correct cleaning solution chemistry is as important as ultrasonic frequency, operating features and other points covered here.
The vast majority of today's ultrasonic cleaning solutions are biodegradable, meaning that they reduce or eliminate disposal concerns of the past. They are shipped as concentrates that are diluted with water then mixed in the cleaning tank by running the ultrasonic power.
Our page on industrial ultrasonic cleaning solution formulas provides a useful guide to help you select those that meet your cleaning requirements.
When it's Time for Solution Replacement
Depending on cleaning solution chemistry, oily contaminants float to the top (demulsifying formulations) or remain in the solution (emulsifying formulations). Hard contaminants fall to the bottom of the tank and must be removed manually or by a filtering system.
To extend cleaning solution life, operators of benchtop units should skim off and set aside oily floating contaminants for later disposal. Large floor-mounted units, depending on models, can be equipped with pre- and post-rinsing platforms, weirs, spray bars, skimmers and filters to extend solution life.
Eventually efficiency will decrease and cleaning solutions should be drained and discarded following local regulations. When the tank is empty take the time to clean it following directions in the instruction manual. Refill and degas a fresh batch and you are ready to resume operations.
Pro Tip: A Note on Cleaning with Flammable Solvents
In cases where water-based concentrates do not do the job, cleaning with flammable solvents such as acetone, IPA or toluene may be required. This creates what the NFPA defines as a hazardous area requiring compliance to strict safety standards. A portion of compliance involves the use of explosion-proof ultrasonic cleaners such as the SoL XP units available in 6 tank capacities from 2 to 33 gallons.
For more on this check our case study on cleaning with flammable solvents.
Applications for Industrial Ultrasonic Cleaning Machines
- Removing grease, grinding media, cutting oils, chips, fines and other contaminants from newly fabricated or reconditioned parts
- Continuous cleaning cycles such as production lines operating on a shift basis
- Cleaning and reconditioning industrial filters
- Removing grease, varnish and other tough contaminants from disassembled gasoline, diesel and aircraft engine components
- Removing mold support from 3-D printed products
- Passivating stainless steel tubing
- Reconditioning diesel particulate and exhaust gas recirculation cooler filters
Contact Tovatech for More Information
A good source of information is found in posts describing how ultrasonic cleaners work and providing answers to ultrasonic cleaning frequently asked questions.
Then it's time to contact the scientists at Tovatech for unbiased recommendations on selecting the correct unit, cleaning solution chemistries and accessories that best meet your industrial ultrasonic cleaning challenges.