NPE Show In Orlando, Florida March 23 – 27, 2015

NPE2015

We are setting up shop at one of the biggest plastics trade shows in the world!

NPE2015: The International Plastics Showcase brings together all sectors of the supply chain to include end markets and brand owners.  Featuring industry-focused education, showcasing equipment and material suppliers, emerging technologies, and running equipment for every phase of plastics processing.  INCLUDING mold maintenance from yours truly.

If you have plans to attend, please stop by our booth.  We’d love to talk about our advantages and give you a demonstration.

Our booth is S20086 in the South Hall.  See you there!

 

Are your tank walls too dirty?

Did you know that a build up of contaminants on your tank walls and bottom can seriously affect the tanks ability ultrasonically clean your parts?  Our tank walls are polished very smooth to reflect the ultrasonic pressure waves created by the transducers and insure that every spot in the cleaning bath is cavitating.  Effective and consistent cavitation, combined with the proper temperature and detergent formulation, are the critical factors that create the most effective and efficient cleaning.  If you notice that your parts are not getting as clean (and you are still using the same detergents at the same temperature), you may consider inspecting your tank walls and bottom.  These surfaces should be absolutely smooth and contamination free.

If there is there is a build up of any kind, its time to completely clean the tank.  Here is a step by step process to ensure your tank interior is completely clean and creating the best cavitation.

1. Drain the tank.

2. Fill the tank using 2 ounces per gallon of citric acid and 1 ounce per gallon of 25-I.

3. Heat the solution to 140 Degrees.

4. Turn on your Ultrasonic tank for 30 to 60 minutes and inspect the tank walls and floor when the cycle is completed.

This process should return the stainless to a new appearance.  If your specific cleaning process leaves contaminates on your tank walls and floor, we recommend incorporating this cleaning process on a regular basis to insure your system is operating at the optimum level.

 

Cleaning in a whole new light.

In this demonstration, precision aerospace parts are ultrasonically cleaned. The contaminant is fluorescent die penetrant that glows with the assistance of a black light. This cool demonstration vividly shows the ultrasonic cleaning process in a ‘whole new light’.  Actually we thought this demonstration might be a flop because it involved a darkened room and ‘props’ (the black light) to capture the process.  However, it turned out to be pretty cool.  It shows in a very unique way how ultrasonics lifts contaminants off surfaces.

Another Massive Tank

Large-ultrasonic-tank-7Blue Wave Large-ultrasonic-tank-6recently completed Large-ultrasonic-tank-5another huge tank that we think is pretty newsworthy.    We know the last blog was also about a big tank, but this one made those tanks look small and we thought we’d show it off.  We’d like to point out that we are constantly building tanks of all shapes and sizes that are normally much smaller, but when a job of this magnitude came though the shop, everybody took notice.

“We basically had to plan the entire workflow around the tanks completed size. Maneuvering it from our welders to the electronics assembly to the testing area and eventually on the loading dock took some precision.” said Robert Schwan, Operations Manager at Blue Wave.

This tank was custom built for a client who required a method to thoroughly clean large heat exchangers.  The tank is just over 25 feet long, 5 feet wide and stands close to 6 feet tall.  It holds a approximately 3030 gallons of cleaning that is heated by a custom designed method that incorporates the client’s gas burner system.  It has a 560 gallon overflow chamber for displaced detergent, a sparge pump and sparge filtration system.  It also pumps 100 gallons per minute through a whole tank filtration system to maximize the tanks cleaning ability, cycle after cycle.

“It is cool to see a tank like that power up for the first time.” explained Sales Engineer Kalvin Frank. “There are over 448 magnetostrictive transducers silver brazed to the side walls providing the ultrasonic punch.  That’s a lot of power.”  Take a look at this video of the tank turning on.

We said this in the last blog but it is worth repeating:
The important thing to remember is that these kinds of systems are what separates Blue Wave from our competition. Anyone using piezoelectric transducer type systems would design this tank to be outfitted with drop-in, immersible transducer units which would not only be cumbersome and add cost, they simply wouldn’t last as long as the robust, magnetostrictive transducer systems Blue Wave has perfected.

“Our customers who do their homework and have experience with us, know the difference.” explains sales engineer Kalvin Frank.

A Big Job with Big Ultrasonic Tanks.

Large-ultrasonic-tank4Blue Wave makes the biggest and longest lasting industrial ultrasonic tanks in the world, but every once in awhile, we take on some big projects that are worth mentioning.

This year one of our customers in the plastic thermoforming business challenged us with creating four identical systems for four different plants. Each system needed to completely clean their large plastic molds. Blue Wave’s solution was a custom cleaning system featuring an ultrasonic tank and a rinse tank holding 450 gallons each and measuring 65″ x 57″ x 28″ apiece. The ultrasonic tank featured filtration, heat and 10,000 watts of ultrasonic power to operate.

Large-ultrasonic-tank“We’ve built plenty of tanks bigger than these, but the neat thing about this job was building four identical ultrasonic tanks and 4 rinse tanks in a row. It was like we were building Corvettes on the assembly line.” said Jeff Hancock, VP of Sales and Marketing. “The baskets that will be used to drop the molds in each tank are robust enough to hold 1,500 pounds.” he added.

The important thing to remember is that these kinds of systems are what separates Blue Wave from our competition. Anyone using piezoelectric transducer type systems would design this tank to be outfitted with drop-in, immersible transducer units which would not only be cumbersome and add cost, they simply wouldn’t last as long as the robust, magnetostrictive transducer systems Blue Wave has perfected.

“Our customers who do their homework and have experience with us, know the difference.” explains sales engineer Kalvin Frank. “These four systems will run 24/7 for decades.”

Blue Wave Tech: Changing the hysteresis can double heater life.

Changing the Hysteresis on the Omron E5GN Temperature Controller

•  This will be done with the temperature controller powered up in normal operating mode

•   Depress the LEVEL KEY  (Display changes to “L AdJ”)

•   Depress the MODE KEY  (Display changes to “i NS”)

•   Depress the MODE KEY  (Display changes to “Hys”)

•   Depress the UP KEY until the display reads 3

•   Depress the LEVEL KEY to save and exit

This will change the hysteresis from 1 degree to 3 degrees. We have found, that in some instances, this can cut the number of heater cycles in half. The hysteresis is always on the low side of the setpoint temperature.

For example, if you have a setpoint temperature of 180, and a hysteresis of 3 degrees, the heater will cycle between 180 degrees and 177 degrees.

 

Video Demonstrations: A Blue Wave Video Blog

The effects of Ultrasonic pressure waves in the cleaning tank are actually a pretty cool thing to witness. Blue Wave’s Jeff Hancock demonstrates some of these interesting properties in this video as if you were standing right in our laboratory. Understanding the basics of how ultrasonics and ultrasonic cleaning will help you realize the possibilities with your own cleaning application. Let this short video be your ‘beginners guide’ to the how ultrasonic cleaning can improve your industrial business processes.