Discover why our Industrial Cleaning Equipment are European references in terms of quality and performance.
Learn more about the potential Commercial Applications of High Power Ultrasound, and its operation.
Ultrasounds cleaning systems are based on high-frequency sound waves transmitted through a cleaning liquid. The component to be cleaned is submerged into the cleaning liquid. The treatment lasts between 10 and 45 minutes and does not require the presence of any laborer.
The ultrasound waves generate a process known as Cavitation, in which millions of air bubbles present in the liquid are compressed until they implode, releasing high levels of energy. This energy impacts against the dirt, grease or coal dust adhered to the surface of the object, removing them without damaging the object.
The result is a micro-brushing effect on the objects. Since the air bubbles are smaller than 1µm, they get into any openings, regardless of their size. Therefore, ultrasound cleaning is the most suitable cleaning system for highly complex components of any material (alloys, steel, alluminium, copper, bronze, titanium, certain plastic types etc.)
Parameters of the Process
The ultrasounds cleaning process is designed specifically for each application to optimize performance and total cleanness. To this end, different temperature, frequency and chemical combinations are used. Our lab determines the best process parameters for each problem:
Temperature: Temperature increases (80-90ºC) in liquids augment steam pressure and facilitate the presence of bubbles (Cavitation). This results in increased cleaning power.
Frequency: It determines the size of the bubbles generated during Cavitation. High dirt levels require lower frequency levels, with higher power. High frequency levels are used for finishing operations or to clean delicate components (Optics, jewels).
Chemicals: Each application requires a certain chemical and concentration level based on factors such a working temperature, type of dirt, cleaning time and material. Ultrasound waves optimize the effects of the cleaning agents, thus reducing the level of chemicals needed.
A suitable combination of the above named parameters significantly reduces cleaning time, which is the fourth parameter of the Ultrasounds Cleaning Process.
Ultasounds cleaning presents several advantages in terms of quality and cost efficiency:
Microscopic cleaning quality: The best surface cleaning quality.
Homogeneous results, even for components with complex geometries.
Efficiency: 80% more efficient than conventional systems.
Labour costs: Once the components are in the machine, labourers are not required.
Chemicals: 6 times less chemicals.
Save water: Inmersion clening significantly reduces water consumption.
Health and Safety: A safe system for the staff and the working environment. It avoids direct contact with dangerous chemicals.
High-Power Ulrasound (HPU) is a new sciencitif field. Only recently have large-scale commercial applications been developed, mainly in the food sector, where a new generation of solutions will change the engineering of many production processes, increasing their efficiency.
UltraTecno is world leader in the manufacturing of HPU equipment in many sectors, cooperating closely with the Austrialian enterprise Cavitus Pty Ltd, a worldwide point of reference in the development of HPU applications with numerous patents in this field.
We have worked closely in the re-engineering of processes with major transnational companies in the food sector in Australia, USA, Europe and Asia.
A Cutting-Edge Technology
High Power Ultrasound (HPU) is a state-of-the-art technology with a significant innovation component. It has numerous operational advantages, combined with straight-forward installation and use:
- Full integration in existing facilities. It complements your current processes increasing their efficiency, without costly re-engineering or productivity decreases.
- Modular Design, It adapts to the output of your production lines by adding as many equipments as necessary.
- Low maintenance and high reliability: No components in motion.
- Straight-forward installation: It does not require any costly changes to your production processes.
- Simplicity of use: No adjustments or continuous monitoring of processes required.
- Low consumption: Significant energy saving as compared to other systems.
- It meets requirements for use in the food industry.
- It does not heat the products processes and therefore it does not alter their original properties.
- Demostration and validation of our systems to plant scale.
- Process engineering, manufacturing and start-up.
- Operation and maintenance support.
- Sunflower oil and palm.
- Milk products, soja and proteins.
- Processing of farm products.
- Industrial chemicals.
Ultrasound is cyclic sound pressure with frequency greater than the upper limit of human hearing (20 – 100 kHz). Ultrasound applications are based on a physical phenomenon called “Cavitation” that can be induced in any liquid.
The resulting sound waves cause the tiny bubbles –naturally present in any liquid- to expand (during stages A and B, characterized by low pressure) and contract until they implode (during stages C and D, characterized by high pressure). The formation and implosion of these bubbles (a process known as “Cavitation”) occurs at rates of thousand of times per second.
The implosion of these bubbles generates high local pressures (2000 bar) and temperatures (5000K), which do not result in global temperature increases.
|Gas bubble short before implosion||Results of Cavitation on an aluminum foil|
Energy released by Cavitation
Schockwaves -They transfer kinetic energy. Applications:
They clean organic / inorganic surfaces and porous internal structures, joints and fissures (by disintegrating polluting substances);
Sound waves –They transfer heat and mass. Applications:
They improve the extraction rates of color / aroma / nutrients / by-products;
Vibration – They reduce friction on surfaces. Applications:
They prevent undesired substances from adhering to machines and membrane filters
New Applications of High Power
High Power Ultrasounds have become a feasible alternative to many conventional processes in the food industry (homogenization, grinding, mixing, pasteurization, separation solid/liquid)
High Power Ultrasounds have also shown their ability to increase the efficiency of certain traditional processes, such as filtering, extracting, fermentation or crystallization when applied as an added technology to conventional processes.
Usually, the introduction of HPU is based on the fast Return on Investment they guarantee. Nevertheless, the use of HPU is sometimes motivated by unique functionalities that can only be achieved through them.
Each commercial application requires a development process during which the different factors affecting the process (power, intensity, flow, pressure, temperature, viscosity and solid concentration) are adjusted until optimum operation of the HPU equipment for a certain function is guaranteed.
The list below shows some of the commercial applications of High Power Ultrasounds on which UltraTecno and Cavitus are working to develop commercial applications in the near future: