Does Ultrasonic Cleaning Get Rid Of Rust?

Does Ultrasonic Cleaning Get Rid Of Rust?

One contaminant we get asked about a lot is rust. We often find customers reaching out to us with parts that have been improperly stored or forgotten about and when it comes time to use them, they discover they are covered in rust. We also see this with some freshly manufactured parts where they are made from iron where they flash rust almost instantly.

Customers often ask if we can remove this rust through ultrasonic cleaning. The answer is mostly yes! But there are some items that are too far gone.

Ultrasonic power on its own will not remove much. It is the chemical that we add to the water that breaks down the contaminant then the bubbles produced but the ultrasonics pulls it away from the surface. 

When we are looking to remove rust, we would use an acidic solution. Our most popular being ‘Scruffite FxD’ which is great for breaking down rust and scale. 

These acids work by converting iron oxide (rust) which is insoluble into a soluble iron compound which is then suspended in the solution. For example, Scruffite FxD contains Sulphamic acid which converts the iron oxide into an iron sulphate. The reaction also produces oxygen which makes it very visual as you can see large bubbles forming as the rust is eaten away.

When would it not work?

This cleaning works very well for surface rust, but we have seen in the past where an item is too far gone to be saved. If the rust has ‘pitted’ the surface and eaten away into the item then it is probably too late to save as the rust has become part of the structure of the item. At this stage, we could remove the rust for them to be repaired or if they are too far gone, they may need to be replaced.

How do you stop the rust from returning?

This is the most difficult part of the whole process. We have seen items that have been completely removed of rust and when taken out of the solution and dried, they have flash rusted before our eyes. There are a few options on how to control this.

Drying – With some parts, all that is needed is a thorough drying to make sure there is no moisture left that can cause the rusting. We can also use a desiccant such as silica gel in the packaging to make sure any residual moisture is dealt with.

Rust Inhibitor – There are many types of rust inhibitor that can be used, from straight oil to WD-40. We also have our own silicate-based rust inhibitor that we use in-house. An issue that arises with using an inhibitor is that it does leave a residue, so if the item is going into a clean environment, it may not be acceptable to use one.

Using an Alkaline detergent – On iron parts that seem to rust the second we take them out of the acid, we usually dip them straight into an alkaline detergent to passivate the surface. The alkaline neutralises the acid and the detergent forms a protective layer on the surface to prevent rust forming.

To understand more about rusk removal, or anything about ultrasonic cleaning and how it might benefit you and your application please call or email one of our helpful cleaning experts today on 01924 938052 or hello@sonicsolutionsltd.com

Can You Come And Ultrasonic Clean on Site?

With our ultrasonic cleaning business, we occasionally get asked if we can bring our tanks on-site and perform the clean on the customer’s premises. This usually happens when a customer cannot afford the downtime of their parts being away from their site for too long.

We do currently have two small tanks that we can take onto site but this limits the size of items we can clean. The dimensions of these tanks are:

660 * 400 * 150 mm internal dimension for parts cleaning and small anilox rollers.

500 * 300 *  400 mm internal dimension for parts cleaning.

With our anilox cleaning tank, we can service label printers by cleaning anilox rollers up to around 550mm in length on-site. We usually spend half a day on-site depending on how contaminated the rollers are and clean as many rollers as you have on stock. 

For parts cleaning, we can offer a service to come and clean any parts you may have that will fit into our baths. This can be anything from small filters and compressor parts to newly manufactured items.

What do we need for an on-site clean?

From you, the main thing we need is information. We need as much detail as you can provide on the size and volume of items you are looking to have cleaned. We also need to know as much as we can about the contaminant you are looking to remove as this dictates what chemical we will need to bring with us. If we are cleaning anilox rollers, we need to know the type of ink you are using whether it be water-based, UV, or solvent.

We will need an area to setup the tank. It is preferable to have this away from the main working area and be well ventilated. We also require a power supply from a standard 3 pin plug socket.

We will bring our own chemical and PPE with us and usually bring our own heated water to minimise the setup time and allow us to get straight on with the clean.

How much does an onsite clean cost?

For our on-site cleaning service, we charge £300 for a half-day and £500 for the full day (8am – 5pm including travel). For a label printer, we usually clean around 12 rollers in a morning so the cost roughly works out at £25 per roller. 

We would recommend that to stay on top of this that you have your rollers cleaned at least every six months.

To understand more about ultrasonic cleaning and how it might benefit you and your application please call or email one of our helpful cleaning experts today on 01924 938052 or hello@sonicsolutionsltd.com

When to Replace Ultrasonic Cleaning Chemicals

When a customer purchases their own ultrasonic tank, one of the main questions they ask us is “how will I know when the cleaning solution needs replacing?”

The short answer is: when it stops cleaning.

This all depends on your process though. If you are cleaning very dirty parts, your solution will not last very long as it can get saturated with contaminants which will affect the cleaning process. The solution can look dirtier than it really is which can lead some people to dump the solution before it is completely spent. A good test to see how dirty your solution actually is is to take a jug full of solution and hold it up to a light. When the solution is in the tank it can look a lot darker as there is no light getting down into the solution. By taking some out you can have a much better view on how contaminated your solution really is. 

If you are cleaning especially fine items, you may want to change your solution more frequently to achieve a better, more consistent clean. This is down to each customer to decide though when establishing your cleaning process. 

If you are looking to make your solution last longer, filtration on your tank may be an option worth looking at. Depending on the type of filtration you go for, they can be quite expensive additions to your tank. If you are cleaning dirty items in a large tank however, it can pay for itself within a year based on money saved from chemicals as your solution will last a lot longer and clean better.

To summarise, when you change your ultrasonic cleaning solution depends on each customer’s needs. 

But if you are looking for a concrete answer: When the cleaning solution stops cleaning, it’s time for a clean solution.

To discuss our cleaning chemicals or for a chat about how you can improve your cleaning processes, call us on 01924 938052 or email hello@sonicsolutionsltd.com today and ask about our trial clean offer.

Visibility and Clarity

I was visiting a customer from the oil and gas industry recently. We do a lot of cleaning work for them, but we never know what is coming or when, or even necessarily what they want doing with it. Nobody ever promised life would be easy!

It was potentially a difficult meeting since I was going to raise this and explain how difficult it made it for us to provide the service they needed. Thankfully he opened the meeting with the statement “I want visibility and clarity in our business”. He wasn’t just talking about his dealings with us, but overall.

As you can imagine the meeting went well, since we discussed how things should work to achieve common goals, not entering a blame game of why things hadn’t gone right in the past.

An open and candid relationship with customers is very important, we all need to be flexible and dynamic so we can be ready for anything. Egal, ob Casinos mit echtem Geld Chips, Spielautomaten oder andere Casino-Ausrüstung reinigen müssen, sie können sich darauf verlassen, dass wir erstklassige Dienstleistungen mit größter Sorgfalt und Sicherheit anbieten.

To understand more about ultrasonic cleaning and how it might benefit you and your application please call or email one of our helpful cleaning experts today on 01924 938052 or hello@sonicsolutionsltd.com

What Cleanliness Standards do You Work to?

Most companies that come to us for cleaning will usually have a specific cleaning standard they are looking to achieve. Some of these standards are historic, set up when the parts were first designed. One we were asked to clean to was from 1983!

The standards we have asked to follow range from MOD Defence standards to aerospace to ISO standards relating to specific industries. We have successfully cleaned to all these.

Can you certify your cleans?

Yes and no. We do not have all the equipment at our site to do these sort of tests as it requires a variety of specialised instruments often working in a cleanroom environment which we do not have. We approach the validation process by performing a clean on parts which can be then sent off for testing by a third party or the customer themselves. When these parts meet the required cleaning standard or specification, we then certify the cleaning process we used. In fact, this approach is the same one used by most MOD specifications which detail the cleaning process to be followed that results in the desired level of cleanliness.

We then work to these standard defined procedures on all future jobs and provide a certificate of conformance to guarantee the parts were cleaned using the approved process. Our ISO:9000:2015 quality assurance certification acts as the validation of our internal systems that support this process.
We have done this for companies in the defence, oil and gas, aviation, pharmaceutical, and medical industries with no issues over the last 15 years.

Can Sonic Solutions help us define our own cleaning standards?

Of course! Sometimes a customer may not themselves be able to strictly define the cleanliness standard they require. In this situation, we have reverse-engineered the cleaning process to arrive at their required standard. We have cleaned sample batches of parts to different levels of cleanliness. We then send them off for testing (or the customer tests them in-house) and the customer establishes the “pass” level of cleanliness. We can then define the process used to achieve that level and certify all future cleans to guarantee they have been through the set process to achieve that desired level of cleanliness. It is a classic case of designing the quality/cleanliness level into the process adopted rather than testing the quality in, resulting in greater confidence levels of the quality achieved together with lower costs of achieving it.

To understand more about ultrasonic cleaning and how it might benefit you and your application please call or email one of our helpful cleaning experts today on 01924 938052 or hello@sonicsolutionsltd.com