Ultrasonic Wire Cleaning Systems
Wire cleaning is a difficult task when compared to most
traditional ultrasonic cleaning applications. The contaminant, typically a
sodium-based dry lubricant, is pressed deeply into the surface of the material
as it passes through the wire drawing process. In some cases, liquid
lubricants may also be used which are less difficult to remove. Not only
are the contaminants highly bonded to the surface, wire manufacturing processes
are performed at elevated speeds, which reduces the contact time between the
wire and the cleaning operation.
To overcome the difficulties associated with wire cleaning
operations, Zenith modified its SSS-960 Ultrasonic Strip Cleaning System to
address wire cleaning, in a system called the SSW-960 and SSW-132. These
systems include an extended ultrasonic cleaning chamber, an ultrasonic rinsing
chamber, and high-speed compressed air
drying systems to clean wire with the
most stubborn contaminants at high rates of speed. Additional features,
such as an additional blow-off operation between cleaning and rinsing areas,
conserve the use of water, and ensure perfect results with little equipment
In the past, manufacturers of wire relied on spray washing
systems to address the removal of oils and particles from the product.
However, there are limitations to these designs. The primary complaint of
customers owning spray washing systems for wire is the consumption of water,
leaking seals and spray which contaminates the environment, and continuous spray
nozzle maintenance. All of these issues are non-existent on a Zenith SSW
wire cleaning system.
A Zenith Ultrasonic Wire Cleaning System overcomes the
limitations of a spray washing system by utilizing the precision,
low-maintenance cleaning capabilities of ultrasonic cleaning technology.
By incorporating this technology, and extending the length of the ultrasonic
cleaning chamber, dry and liquid wire lubricants are quickly and effectively
Wire is passed horizontally through a series of ports
and chambers in the system, and connected to wire take-up equipment on the exit
end of the system. Loading is an easy task, thanks to the stainless steel hinged access cover which
includes polycarbonate viewports. The system can be loaded in under 1
Wire entering the ultrasonic cleaning system is first subjected to the
ultrasonic cleaning chamber, which bombards the material with
CROSSFIRE Multiple Frequency
Ultrasonics to rapidly remove all contaminants from the surface of the wire.
The included Spray Under Submersion Nozzles add to the effectiveness of the
cleaning chamber by removing the largest volumes of oils, and can be used to
directly address detailed part areas. The ultrasonic system has the
ability to penetrate the microscopic "hills & valleys" on the surface of the
material, leaving no residues behind, even in the most detailed areas of the
Lubricants which are removed from the product are siphoned to the
heated Cleaning Fluid Holding Tank, which stores the fluid, heating it to
operating temperature, and filtering it with optional
Filtration Systems, if required,
to maximize the life of the cleaning fluid. Wire cleaning system designs
also include exclusive Cleaning Chamber Filtration Ports which divert the
contaminants which collect on the bottom of the ultrasonic cleaning chamber to
the fluid holding tank, where the existing filtration system can remove it from
As the strip material exits the cleaning chamber, excess
cleaning fluid is removed by the included Cleaning Fluid Removal Chamber.
By removing the detergent from the wire before it enters the rinsing chamber,
rinse water integrity is preserved which minimizes rinse water consumption,
while simultaneously preventing detergent spotting on the material being
Next, the wire enters the included ultrasonic rinsing
chamber which includes high frequency ultrasonics to penetrate every area of the
material, ensuring that all detergent residues have been removed. The
use of ultrasonic components in the rinse tank provides mechanical scrubbing of
the wire surface with the even energy distribution of high-frequency ultrasonics. Additional information regarding frequencies and their
effects can be found under the "Technical Info" drop down list under
The wire is then dried using a custom air wipe assembly in the
Drying Chamber. All water removed from the wire is siphoned back to the
Rinse Fluid Holding Tank. The material then exits the system and is
recoiled immediately using existing take-up equipment.
Maintaining a Zenith ultrasonic wire washing system is
simplicity itself. The system requires only periodic cleaning and
replacement of cleaning and rinsing fluids when required. Optional
filtration systems will further reduce required holding tank cleaning
operations, which are easily performed using the included ball valve-equipped
drain and fill ports.
With a Zenith Wire Cleaning System, evaporative losses are
reduced drastically since water is never vaporized by spray nozzles. As a
result, operational costs are reduced since heating systems can be smaller in
size. Heating systems represent the largest electrical consumption devices
on any cleaning system.
Zenith wire cleaning systems are manufactured
largely of type 304 stainless steel for superior long-term corrosion resistance.
All wetted surfaces are either stainless steel, or compatible plastic materials.
Smooth-transition Wire Guides are included throughout the machine to support
the wire and prevent damage. Internally-mounted components are
conveniently positioned near the front of the machine. Filtration housings
are externally mounted for convenient access. Level switches prevent
operation of the heating or ultrasonic systems in the event of low liquid
Optional equipment includes Automatic Water Level Maintenance,
Signal Towers to indicate when holding tanks require additional liquid, Closed
Loop Deionization Systems if medical-quality results are required and no
deionized water supply exists, and Rinse Water Quality Meters to indicate when
rinse water requires replacement.
Contact Zenith Manufacturing for more information on our line of
Ultrasonic Wire Cleaning Systems.
For a downloadable PDF Brochure,
85 Oak St.
Norwood, NJ 07648-0412