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Selecting Your Best Industrial Ultrasonic Cleaner

Industrial ultrasonic cleaners are defined by task, not size. To start with, the best industrial ultrasonic cleaners are employed for tough and often long-term cleaning cycles. These units may be required to continuously operate for hours and must be designed to meet rigorous operating conditions.

As the user you define the task. Look for the best industrial ultrasonic cleaner you can get to meet your requirements. As examples, these might involve

removing grease, grinding media, cutting oils, chips, fines and other contaminants from newly fabricated or used parts
continuous cleaning cycles on production lines operating on a shift basis
solving cleaning challenges involving both rugged and delicate components
programmable cleaning cycles allowing you to attend to other matters
energy-saving options yielding required results at less cost

To help you improve efficiency, options are available. Examples include

pre/post rinsing to remove loose contaminants and flush cleaning solution residues
filtering to extend cleaning solution service life
integrated work tables supporting parts before and after cleaning
roller mounts facilitating large-unit mobility within your shop
dual-position basket support easing loading and draining heavy parts

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. Uniformly distributes ultrasonic cleaning power throughout the tank eliminating hot spots that can be damaging to delicate parts and dead zones where cleaning is not effective.
Pulse: Produces intermittent bursts of extra ultrasonic power to remove tenacious contaminants and degas fresh cleaning solutions.
Dynamic: Alternates between Sweep and Pulse to optimize cleaning and mixing.
Eco: Reduced power Sweep mode for quiet, gentle operation.

If you are cleaning products with particularly tenacious contaminants, get the best industrial ultrasonic cleaner equipped with either a pulse or dynamic mode. Pulse mode boosts ultrasonic power by 20%.

Before proceeding, you may find our post on ultrasonic cleaning – an in-depth look and answers to ultrasonic cleaning frequently asked questions about ultrasonic cleaners helpful.

Heaters and Timers

All industrial ultrasonic cleaners are equipped with an adjustable thermostat that lets you set cleaning solution temperatures to levels recommended by the solution manufacturer. Higher cleaning temperatures are required to efficiently remove oils, greases, wax and similar oil-based contaminants.

Timers let you set and forget the ultrasonic cleaning cycle so you can attend to other matters. As an example, timing can be set from 1 to 30 minutes or continuous. To avoid potential damage, an automatic shut-off feature activates after 6 or 12 hours or if cleaning solution temperature becomes excessive.

Industrial Ultrasonic Cleaners from Elma Ultrasonic

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 80⁰C	2
Elmasonic xtra ST mobile units	7	8 – 67	25 and 45 kHz	To 30 minutes or continuous to 12 hours	Up to 80⁰C	3

Industrial Ultrasonic Cleaners Details

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 80⁰C with auto shut-off at 90⁰C
3-year tank warranty (single shift operation)
2 Ultrasonic Modes
- Dynamic
- Eco

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 80⁰C with auto shut-off at 90⁰C
3 year tank warranty (single shift operation)
Swapped out control and generator assembly reduces downtime
Pre-rinsing and filtering options extend cleaning solution life

Tips on Selecting and Using your Industrial Ultrasonic Cleaner

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 on

Calculating Industrial Ultrasonic Cleaner Size

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 (definitely not placed on the tank bottom) you’ll need to pay attention to the dimensions of the basket.

For example, the 42.8 gallon Elma 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 industrial ultrasonic cleaner tank and is important because parts must be fully immersed in the ultrasonic cleaning solution.

Elma ST Industrial Ultrasonic Cleaner — Elmasonic xtra ST

Selecting Ultrasonic Cleaning Solution Chemistry

The correct cleaning solution chemistry is as important as ultrasonic frequency, operating features and other points covered in this post on selecting your best industrial ultrasonic cleaner.

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 pulse or dynamic mode on the units featured here.

Our page on industrial ultrasonic cleaning solution formulations provides a useful guide to help you select those that meet your cleaning requirements.

When it’s Time for Cleaning 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. Large floor-mounted units can be equipped with filters available as options with the Elmasonic xtra ST series.

But eventually efficiency will decrease and cleaning solutions must be drained then disposed of following local regulations. When the tank is empty take the time to clean it following directions in the instruction manual. Replace and degas a fresh batch and you are ready to resume operations.

Contact Tovatech for Answers to Your Questions

Selecting your best industrial ultrasonic cleaner is defined by what it does, not its size. These units are specified for tough cleaning tasks, are able to operate over an 8-hour shift, and offer features and benefits promoting thorough and efficient cleaning results.

You will find examples on how these cleaners are employed by browsing our blog.

Please contact our cleaning experts for more information on selecting the right equipment and cleaning solution formulations to meet your requirements.

Match Ultrasonic Cleaner Frequency to Cleaning Task

Ultrasonic frequency is defined as sound waves above the range of hearing, nominally 20,000 cycles per second, or 20 kilohertz (KHz). The kHz designation – thousand cycles per second – derives from Heinrich Hertz (1857-1894), who discovered radio waves or radio frequency.

Ultrasonic frequency (or frequencies) is a key criterion when purchasing an ultrasonic cleaner for parts cleaning or for related sonicator bath applications.

Popular ultrasonic cleaner frequencies range from 35 kHz to 45 kHz with exceptions at both ends.

Ultrasonic Cleaning and Ultrasonic Frequency

The correct ultrasonic frequency yields superior results in terms of efficiency, thoroughness, and in certain cases avoiding damage to parts being cleaned.

Moreover, there are projects where more than one ultrasonic frequency is recommended, or when you are cleaning a variety of products calling for different ultrasonic frequencies.

Which leads into an explanation of how ultrasonic cleaners work. If you are familiar with this, feel free to skip to What Ultrasonic Frequency Should I Use?

A Brief on How Ultrasonic Cleaners Work

Understanding how ultrasonic cleaning works calls for an understanding of equipment components. At the basic, however, these units consist of:

Tanks to hold the cleaning solution. Tanks should be of stainless steel; their volume depends on the size of objects being cleaned.
Ultrasonic transducers that create the cavitation (as explained below) are bonded to the bottom and/or sides of the tank. Immersible transducers are also used.
A generator to power the transducers
Controls that range from a simple on-off switch to sophisticated microprocessors that govern cleaning time, sweep, pulse, degassing, temperature, ultrasonic frequency, ultrasonic power, auto safety shutoffs and other refinements.

Ultrasonic cleaning equipment ranges from small tabletop units to huge, multi-gallon industrial cleaners. The capacity of the cleaners has little or no bearing on the features they can offer. Desired feature decisions are up to you, the purchaser, with help from experts at Tovatech: Elma’s exclusive master distributor in North America.

A good place to start is reviewing our post on parts cleaner specification tips and taking the time to view our learning center video on how ultrasonic cleaners work.

Another good source of info are the answers to ultrasonic cleaner frequently asked questions.

At the end of this post we offer points to consider beyond ultrasonic frequency when purchasing your ultrasonic cleaner.

The Role of Transducers in Ultrasonic Frequency

As noted above, ultrasonic transducers create the ultrasonic energy that creates cavitation that does the cleaning or sonicator bath activity.

There are two basic types of transducers: piezoelectric (a.k.a. electrostrictive) or magnetostrictive, but their function is the same.

The ultrasonic cleaner generator provides electric current to the transducers, causing them to vibrate at ultrasonic frequencies that in turn cause the bottom (and sides as the case can also be) of the tank to vibrate, sending sound waves through the ultrasonic cleaning solution.

This vibration forms the microscopic vacuum bubbles that implode, (not explode) on contact with items in the ultrasonic cleaner tank. This releases powerful jets of the cleaning solution that quickly and safely strip contaminants from all immersed surfaces.

The process is called ultrasonic cavitation. Ultrasonic frequency governs the cavitation bubble size, which directly affects the cleaning process.

What Ultrasonic Frequency Should I Use?

In a sentence, the lower the ultrasonic frequency the larger the bubbles and the more vigorous the cleaning action – although the relative size of bubbles is not observable by the naked eye.

Photomicrograph of an imploding cavitation bubble

A low frequency such as 25 kHz produces (relatively) large cavitation bubbles that implode vigorously and therefore are favored for cleaning heavily soiled parts such as fabricated and cast metals or parts with coarse contaminants such as polishing pastes.

The vast majority of cleaning operations can be performed with equipment operating at 37 to 45 kHz range.

Complex and delicate surfaces should be cleaned at higher frequencies such as 80 kHz. The relatively smaller high-frequency bubbles release less energy upon implosion and are more numerous than those created at lower frequencies. This means they clean more gently and are able to penetrate difficult-to-reach surfaces such as cracks, crevices and blind holes.

Higher frequencies are also recommended to avoid damaging highly polished surfaces of soft metals such as aluminum and silver.

Dual-frequency ultrasonic cleaners are a good choice if you clean a variety of products with differing characteristics.

Matching Ultrasonic Cleaner Equipment to Ultrasonic Frequency

Here’s a representative guide to help you select Elmasonic ultrasonic cleaners delivering the right ultrasonic frequency for your cleaning tasks. Please check the links for added details including multi-frequency options.

Cleaning Task	Suggested Equipment
Remove coarse and tenacious contaminants; pre-cleaning robust surfaces such as stainless steel and cast iron	Floor-mounted xtra ST at 25 kHz or Shiraclean units at 40 kHz
Industrial-scale cleaning jobs	Benchtop Xtra at 37 kHz or Floor-mounted xtra ST at 25 or 45 kHz
Common benchtop cleaning jobs	Elmasonic E Plus, Select and P Series units at 37 kHz
Heavy-duty benchtop cleaners for long cleaning cycles	Elmasonic xtra TT or Xtra at 37 kHz
Heavy-duty industrial large part cleaning	Floor-mounted Shiraclean units at 40 kHz and xtra ST at 45 kHz
Medical and dental instrument cleaning	Elmasonic E Plus or Select at 37 kHz
Laboratory and medical cleaning jobs	Elmasonic P at 37 or 80 kHz
Fine cleaning sensitive surfaces	Elmasonic P at 80 kHz; floor-mounted xtra ST at 45 kHz
Highly sensitive surfaces such as micro-electronics and optics	Elmasonic P at 80 kHz

Points to Consider Beyond Ultrasonic Frequency

Ultrasonic “Noise”

While “ultrasonic” is defined as sound above the hearing range, ultrasonic cleaners, especially those operating a low frequencies, are not silent.

The noise emanates from vibrations in tank walls and products being cleaned, and relates to the ultrasonic frequency being used. For example, there is a significant difference in noise generation between a cleaner operating at 25 kHz and one operating at 80 kHz.

You can reduce the impact of noise with hearing protectors and by options including sound deadening lids and noise protection boxes.

Ultrasonic Cleaning Chemicals

Cleaning solution chemistry is as important as ultrasonic frequency when it comes to getting the best results from your ultrasonic cleaner.

A good tutorial is our post on cleaning solutions for ultrasonic cleaning tasks. It notes that most commonly used ultrasonic cleaning solutions fall into three categories: alkaline, acidic and neutral. These are listed in ultrasonic cleaning chemistries.

These cleaning formulas are usually supplied as concentrates. This means a little goes a long way. When formulated with non-toxic biodegradable ingredients disposal concerns are eased. Manufacturers provide dilution and cleaning temperature recommendations.

Because most ultrasonic cleaning solutions are water based there may be a concern about rusting when cleaning ferrous parts. Rust inhibitors such as elma KS can be added to address this.

Ultrasonic Cleaner Capacity

When purchasing an ultrasonic cleaner consider the size of the parts you are cleaning.

Most parts are placed in cleaning baskets, the dimensions of which are less than tank dimensions.

You’ll want to specify an ultrasonic cleaner tank size based on the corresponding basket size that will accommodate the parts to be cleaned.

Added to that, parts to be cleaned must be totally immersed in the cleaning solution.

Because of this you must consider what is called the working depth of the cleaning solution.

This is defined as the distance from the inside bottom surface of the basket to the surface of the liquid in a filled tank.

If the working depth of the equipment you are considering is not provided or unclear from the specs, ask the manufacturer.

Rather than go into more detail here, please check our post on selecting ultrasonic cleaner size.

In Conclusion

We hope this post is helpful when it comes to choosing the correct ultrasonic frequency for your cleaning challenges. You’ll find additional important information by viewing our informational video in our ultrasonic cleaning learning center.

When it comes to selecting the right unit and ultrasonic frequency and other important specification details for your tasks please contact the experts at Tovatech: Elma’s exclusive master distributor in North America.

Sample Preparation in an Ultrasonic Bath

Sonication Baths for Sample Preparation

Sonication baths are used to prepare samples in research and development, transforming analytes into measurable form. This can involve complex procedures that in many cases must avoid chemical degradation from heat or mechanically induced damage.

For example, a sonicator may be used to extract an active pharmaceutical ingredient (API) from its carrier, or excipient, prior to conducting content uniformity and potency assay tests. Many USP monographs recommend using an ultrasonic bath to dissolve samples prior to analysis.

This post describes sonication bath equipment options for sample prep, examples of where the process is used, and provides suggested operating procedures.

How to Clean Hot Melt Adhesive Guns and Spray Paint Nozzles

How to Effectively Clean Spray Guns

Spray guns are indispensable tools across numerous industries, from automotive refinishing and manufacturing to artistic applications. However, the very materials they apply – paints, coatings, adhesives – can become their biggest enemy when residues dry and clog critical components. A poorly maintained spray gun leads to uneven spray patterns, reduced efficiency, and ultimately, compromised results. While traditional cleaning methods often involve manual scrubbing and harsh solvents, a more advanced and effective solution exists: using an ultrasonic cleaner. This guide will delve into how ultrasonic technology can revolutionize your process to clean spray guns, ensuring optimal performance and extending the lifespan of your valuable equipment.

How Ultrasonic Cleaning Speeds Aircraft Engine Maintenance

The Power of Ultrasonic Cleaning Aircraft Engine Maintenance

Maintaining the safety and operational efficiency of aircraft engines is paramount in the aviation industry. For Aviation Maintenance Technicians (AMTs), Aircraft Maintenance, Repair, and Overhaul (MRO) organizations, and airline maintenance facilities, adhering to rigorous procedures outlined in aircraft engine maintenance manuals is non-negotiable. Ultrasonic technology has emerged as a critical tool in this sector, providing significant advantages in both the cleaning of aircraft engine components and Non-Destructive Testing (NDT) operations. This guide explores the diverse applications of ultrasonic energy in aircraft engine maintenance, highlighting its effectiveness and benefits.

Ultrasonic Cleaner Accessories Broaden Business Opportunities

Investments in multifunctional ultrasonic cleaner accessories quickly pay for themselves by extending the versatility of your ultrasonic cleaner. Examples include

For Ultrasonic Cleaning
- confidently complete challenging cleaning tasks
- use diverse cleaning chemicals in a single cleaning cycle

In the Research Lab
- increase sample prep cycle throughput
- accommodate multiple sample prep projects in a single run

An Intro to Multifunctional Ultrasonic Cleaner Accessories

Ultrasonic Cleaner Accessories in the Shop

A cleaning basket is a cleaning basket, right? And as a professional, you know that it is not good practice to overload a cleaning basket or allow contact between parts being cleaned.

Imagine the basket of your benchtop ultrasonic cleaner as a condo or an apartment house with diverse occupants.

Consider a Modular Basket System allowing you to subdivide a simple ultrasonic cleaning basket into several compartments or levels…

Ultrasonic Parts Cleaners Promote Peak Performance

Instead of “Knowledge is Good,” the Faber College motto in “Animal House,” we propose “Clean is Good.” This is not a joke, when it comes to “clean” in keeping costly equipment up to peak performance. Here’s how ultrasonic parts cleaners promote peak performance across a broad range of products.

An Ultrasonic Parts Cleaner? Why Is It Important?

Cleaning parts, whether new or being refurbished, can represent a significant amount of time and, without the proper equipment, can be unpleasant or uneconomical.

For example:

Solvent spray tanks, aerosol sprays, manually scrubbing with flammable solvents, abrasives and other alternatives – beside yielding unsatisfactory results – can raise environmental, health and safety concerns.
Complex parts – the methods above often can’t reach parts with cracks, crevices and blind holes.
Labor – time clocks run during parts disassembly, manual cleaning and reassembly. The power of ultrasonic energy can substantially reduce labor costs, insure superior cleaning results and free personnel to attend to other tasks.

Lab Test Sieve Cleaning with an Ultrasonic Cleaner

Cross-contamination is a constant concern in all laboratory practices and can be addressed by strict operating procedures to assure equipment is thoroughly clean before use. Thorough fine mesh lab sieve cleaning used in analytical, science and testing laboratories can be crucial in meeting GLP standards.

Lab sieves, because of their design, present special cleaning challenges to assure residues from prior screenings are completely removed from fine mesh screens.

Manually scrubbing the sieves is not a sure-fire means to clean them. A time-consuming operation in itself, the chief area of concern is potential contamination of subsequent products being processed because 100% of the particles may not be removed. Moreover, manually scrubbing fine mesh lab sieves can damage them.

Tovatech offers two options for ultrasonic sieve cleaning

One is the SRH 4/200 designed to be used in conjunction with a standard Elma ultrasonic cleaner with a size 300 tank, and the other is one of the uniquely designed Easy 50R or Easy 350R ultrasonic cleaners from Elma. These two cleaners can also be used for cleaning small instruments and for sample prep.

The Elma SRH 4/200 Cleans Up to 4 Fine Mesh Lab Sieves

Safely cleaning fine mesh sieves is achieved with Elma’s cleverly designed stainless steel SRH 4/200 sieve rotation holder. It is electrically powered and easily fits onto a 300 size Elmasonic ultrasonic cleaner, such as the heater-equipped EP300H or Select 300 ultrasonic cleaners.

Up to four 200 mm (8 inch) diameter lab equipment sieves from various manufacturers are placed into the unit much as plates are loaded into a dishwasher, and held in place by rollers. Once the sieves are clamped into the holder ultrasonic energy is applied while the sieves rotate into and out of the ultrasonic cleaning bath.

Ultrasonic cavitation produced by the EP300H or Select 300 generator-powered transducers creates billions of minute bubbles that implode vigorously against the screen mesh to quickly but safely dislodge trapped particles.

Specifying a Large Ultrasonic Cleaner

In many cases ultrasonic energy is the “go to” solution when it comes to meeting challenges associated with cleaning large parts. Cleaning large parts calls for a large ultrasonic cleaner – one that accommodates parts size and has added features facilitating the entire cleaning cycle. This means more than considering a unit with the capacity to hold parts being cleaned.

Calculating Large Ultrasonic Cleaner Capacity

Remember the old saw about the guy who builds a boat then can’t get it out the door? When specifying an ultrasonic cleaner, the point to remember is parts must fit in the tank.

Top Ultrasonic Cleaner Markets

A report by Polaris Market Research citing ultrasonic cleaner market size through 2032 notes that ultrasonic cleaning “has become a preferred choice because it provides thorough and consistent cleaning, effectively eliminating contaminants, including from intricate and hard-to-reach areas.”

The Polaris report cites markets where ultrasonic cleaner machines find application. This post offers equipment and cleaning solution suggestions related to certain of these markets.

For information on the ultrasonic cleaning process please check how ultrasonic cleaners work.