Hunter Ultrasonic cleaning
How does ultrasonic cleaning work?
Ultrasonic cleaning is the use of ultrasound (high-frequency sound waves) in a water-based detergent to remove contaminants from immersed items.
The sound waves being transmitted through the water-based detergent cause the rapid formation and collapse of millions of tiny bubbles. The collapse of the bubbles is called cavitation. The cleaning action happens due to this cavitation, which releases energy when the bubble collapses.
Heating the water usually enhances and speeds up the cleaning process, and most detergent solutions are designed to work best at a slightly elevated temperature.
Cleaning time will vary, depending on such things as how much contamination there is on the item to be cleaned, the age of the water-based detergent and the degree of cleanliness desired.
We provide an illustrated description of the process here.
What can be cleaned with Hunter Ultrasonics?
It is important to pick the right system for the job. Not all ultrasonic cleaning systems will effectively clean the same items. Variables in the design of the system impact its ability to effectively clean certain things. These variables are:
Size the tank
Specialized equipment supplementing cleaning by tank (drying, testing or rinsing systems)
Operating temperature of water-based detergent
Detergent ingredients
Ultrasonic frequency and types of transducer rods being used
Hunter Ultrasonics can clean most metallic, glass, ceramic and plastic items. This includes:
Metallic filters
Ceramic filters
Exhaust Gas Coolers
Filter housing
Fuel injectors
Turbochargers
Bearings
Heads
Pistons
Gears
Water pumps
Electric motor windings
If you do not see it on this list, please call us – chances are we can clean it for you.
What contaminants will Hunter Ultrasonics remove?
Hunter Ultrasonics system are optimized to remove contaminants such as:
Diesel particulates
Soot and ash
Carbonized parts
Water contaminants
Oil and lubricants
Oxide coatings
Shop dirt
Carbonized parts
Flux
Polishing compounds
Waxes
If you do not see it on this list, please call us – chances are we can clean it for you.
Do I have to dissemble my equipment to clean it ultrasonically clean it?
No, you usually do not. Hunter Ultrasonics will not harm items such as o-rings, gaskets or rubber spacers and will clean around these items. Ultrasonic cleaning can penetrate the smallest openings (anywhere water can penetrate); areas hand cleaning can not access and will provide the most effective overall cleaning available.
Should I wear proper PPE (personal protective equipment) when working with ultrasonic cleaning equipment?
Yes. We strongly recommend that all operators strictly follow their company’s PPE guidelines.
Specifically, hearing and hand protection should be worn when working with our equipment.
Hearing protection
Although the ultrasound emitted from most ultrasonic cleaning tanks is above the human hearing range, it will cause hearing damage with prolonged exposure at closer range. At 4.57 meters (15 feet) Hunter Ultrasonic tanks are below the 85 dBA threshold required by both the CCOHS and the OSHA for 8 hour exposure or time weighted average. It is recommended that personnel working within 4.57 meters (15 feet) of an operational Hunter Ultrasonic cleaning tank wear hearing protection.
Operating our Xtractor unit does not require hearing protection.
Injury protection
When in operations, the water-based detergent in Hunter Ultrasonics tanks is kept quite hot (usually above 50 degrees Celsius.) We recommend wearing water-proof heat resistant gloves, such as 14” gauntlet style PVC coated gloves, to place or remove items from within our tanks.
We also recommend the heat resistant gloves when placing or removing DPF filters from the Xtractor.
Drying Diesel Particulate Filters
Why do I have to dry the diesel particulate filter before putting it back in service?
The ultrasonic bath is only one part of the process in ensuring you have the cleanest DPF possible, as well as one which will not quickly re-clog with particulates.
The ultrasonic bath cleans and loosens particulate matter in the filter substrate. It removes a lot of the contaminants; but not all. Some of the particulate matter will remain in the filter and will need to be removed with rinsing and drying.
Hunter Ultrasonics’ patented Xtractor is the easiest and fastest way to remove all final loose particulates.
Putting a DPF back in service right after coming out of the tank may also cause the exhaust to discharge all of the loose particulates out of the filter and into the local environment. If this is inside your facility, it could lead to expensive cleaning costs.
Click here to see our patented process.
What is the fastest way to dry a diesel particulate filter?
Hunter Ultrasonics’ patented Xtractor is the fastest and safest way to dry a diesel particulate filter. It is up to 3x faster than kiln baking methods according to the PIT Groups 2019 report “Comparative Testing of Diesel Particulate Filter Cleaning Methods” and will not cause thermal cracking.
Should I test my filter to set a baseline diesel particulate filters prior to cleaning?
Yes. It is important to measure and record the status of the filter you are about to clean so that you can determine, after cleaning and drying, that your filter is ready to go back into service. You can not tell by looking at a filter how clogged it is with diesel particulates. Only a backpressure test can establish a baseline. Hunter Ultrasonic’s Xtractor measures backpressure prior to cleaning and again during the drying process, making it easy to determine the state of the filter.
Diesel Particulate Filters
What is a diesel particulate filter? What does it do?
A diesel particulate filter (DPF) is a filter designed to remove diesel particulate matter (soot and ash) from the exhaust gas of a diesel engine.
The particulates are primarily back carbon but can also contain oil, ash, hydrocarbons and sulfur oxides. They are the result of the incomplete combustion of the diesel fuel in the engine. This soot worsens air pollution and is harmful to our health.
The number of particulates emitted by an engine varies widely dependent upon engine type, age, and the emissions specification that the engine was designed to meet.
In 2007 and subsequent years the use of diesel particulate filters (DPFs) on the emissions of diesel engines, including those used in transportation, mining, farming, and construction was mandated in Canada and the United States.
What is a DPF made of?
There are many types and models of diesel particulate filters. Most commonly, DPFs are constructed with stainless steel and coated with platinum or palladium. The filter element is usually made from Cordierite; but can made from silicon carbide or metal fiber.
Can I clean my DPF instead of replacing it?
Yes. Most types of diesel particulate filters can be safely cleaned and put back in service. Proper regular cleaning can extend the life of the filter, avoiding the most expensive cost of replacing the filter. Proper cleaning, such as Hunter Ultrasonics’ process will not harm the wash coat or the substrate and will not void your warranty.
When should a DPF be cleaned?
We recommend cleaning your DPF with Hunter Ultrasonics as part of your regularly scheduled maintenance. Regularly cleaning your filter will extend its service life. Hunter Ultrasonic’s patented drying process will not add to your service time.
Is cleaning of a diesel particulate filter effective?
Yes. Up to 96% of the fouling deposits were removed from the filter by Hunter Ultrasonics according to the PIT Groups 2019 report “Comparative Testing of Diesel Particulate Filter Cleaning Methods”.
Steam filters
What is a steam filter?
A steam filter is an in-line high-efficiency filter used to remove contaminate particles from steam. Steam is used in many industrial applications. The filters come in many sizes and rating. Filtering the steam helps avoid product contamination as well as equipment downtime. Industrial steam is usually distributed in piping systems which often have small nozzles that can be easily fouled by contaminants in unfiltered steam.
What is steam used for?
Steam has many industrial applications including sterilizing, cooking, cleaning, drying, curing and temperature control. For example:
Culinary steam is injected directly into large vats of processed foods as a method of cooking.
Process steam is used to clean or sterilize surfaces, tools and containers used in processing and packaging. It is used by commercial linen services to clean clothing, bedding and other items made from textiles.
What contaminants can be found in steam?
Particulate contaminants found in steam can include rust, scale, dirt and sediments. These most often originate from the water used to create the steam.
What type of steam filters be cleaned using ultrasonics?
Any stainless steel or sintered stainless steel steam filter can be cleaned using ultrasonics.
What is the most effective way to clean (regenerate) steam filters?
According to Donaldson Filtration Solutions, the most thorough regeneration of their steam filters – both the P-GS and P-GSL N elements - can be achieved using ultrasonic cleaning. Ultrasonic regeneration leaves elements near new. In general, the more frequently an element is cleaned, the better the regeneration.
When should I clean (regenerate) my steam filter?
Different manufactures have difference recommendations. It is suggested by Microdyne that the filter element by regenerated when the differential pressure reaches 15 psi or 1.0 bar and replaced when it can only maintain a pressure drop that meets or exceeds 10 psi or 0.7 bar. Donaldson suggests on average every 3 to 12 months, and replacing the filter after 6 ultrasonic cleanings.
Does ultrasonic cleaning contaminate the filters?
No. Ultrasonic cleaning does not contaminate the filters.