The increasing efficiency in a manufacturing environment can sometimes seem like an inch-by-inch process. A slim improvement here, some overhead shaved off there. But what if you could invest in a single proven technology and attain shorter throughput time and reduced costs?
You may have to clean parts turned in for refurbishment, prepare aerospace components for a coating, or remove contaminants from equipment used to assemble medical devices. But whatever the application, ultrasonic cleaning can make the process more accurate and make your facility more efficient. Here's how:
LESS TIME SPENT ON DISASSEMBLING AND REASSEMBLING
Contaminants in many parts and tools hide away in areas that can’t physically be reached with a cleaning tool or the stream of a sprayer, so the part must be disassembled for cleaning and reassembled at some point later in the process. The “cleaning tool” in ultrasonic cleaning is microscopic and can reach everywhere liquid can reach.
Ultrasonic waves produce microscopic bubbles through cavitation. Millions of these bubbles will grasp the object being cleaned, and create a high-energy impact when they collapse. This continual cycle of forming and collapsing bubbles creates a scrubbing action that reaches every point on every surface of the item. Except for the part of the item that is or there are air pockets present within the part, there will be no need for the reassemble/disassemble cycle, and eliminating it will save you labor cost and production time.
LESS LABOR SPENT ON CLEANING ITSELF
Depending on the ramification of the part, cleaning can be labor-intensive and take a huge amount of time as well as precise attention to detail. Whether a worker uses manual cleaning with a brush or sprayers or places them in a machine, the parts must be handled, scrubbed, and carefully supervised.
For example, a part that has a convoluted geometry, such as a roller with deep, narrow grooves or a transmission component. The worker has to manually remove contaminants from the nooks and crannies of the piece, even after soaking or spraying. But, the microscopic bubbles produced in an ultrasonic cleaner will form in all those impassable spots, cleaning them more adequately and in far less time.
FEWER “DO-OVERS” FROM INCOMPLETE CLEANING
If a product, tools, or parts remains partially contaminated, you’ve lost time and money. If the product needs to be cleaned between fabrication and the application of a coating, partially cleaned parts will bring your manufacturing process to a stop and sock you in the bottom line as you pay to have them cleaned for a second time.
Since ultrasonic cleaning is precision cleaning, you can be assured that all contaminants are removed on the first pass and the components will always be ready for the next step.
LESS RISK, COST, AND TIME ON THE SAFETY FRONT
Mild detergents are the only chemicals used in ultrasonic cleaning; the rest of the cleaning medium is water. That’s because ultrasonic cavitation does the hard work of removing impurities hence there’s no need for harsh chemicals. This not only reduces the risk to your employees from handling toxic brews, but it also reduces your need for safety equipment, expensive waste removal, training, and compliance
You may be using a machine to wash your components, and while it’s far more adequate than hand washing, such machines can be a maintenance nightmare. Each will contain dozens or even hundreds of moving parts in its pumps, conveyors, and sprayers. Although, an ultrasonic cleaning system will contain a single filtration pump and no other moving parts. It takes one more task or more likely, dozens of your maintenance team’s list
If you have machinery or tools that require regular cleaning, every moment you save on the cleaning process is a moment of downtime you’ve eliminated. With ultrasonic cleaning, you’ll clean those items more swiftly, with no chance that you’ll have to send them back through for a second cleaning. That means more uptime and that means a better bottom line.