Zenith Mfg. & Chemical Corporation began as a custom ultrasonic cleaning
equipment designer and manufacturer, and has been manufacturing cleaning
machines and associated components since 1935, and has unequalled experience in
the design and manufacturing of these systems.
Most manufacturer's of ultrasonic cleaning equipment shy away from
custom-manufactured equipment, or significantly increase their prices on the
equipment. These manufacturers make the same machines every day. It
is much easier to manufacture standard machines than custom machines for any
manufacturer. There are several reasons for this approach. Custom systems
must be initially designed, and engineered to support the required application. CAD
diagrams and parts lists must be created from scratch. Custom-parts must
be ordered and checked for applicability.
Having several decades of experience manufacturing custom ultrasonic
cleaners, Zenith has established a highly-efficient system for addressing the
complications which exist when manufacturing these machines. As a result,
customers may actually SAVE money when purchasing a custom system over a
standard equipment design. For example, most standard tank sizes of
ultrasonic cleaning equipment are rectangular in shape. However, if your
part is long and narrow, a long and narrow tank design with lower ultrasonic
power may suit your needs. This change in equipment design can result in
reduced ultrasonic component costs and manufacturing costs.
Custom equipment design can also address applications which are impossible to
address using standard ultrasonic cleaning systems. For example, a recent
Zenith customer needed to clean metal rings manufactured of aluminum.
Rings were to be cleaned in a vertical orientation, one in front of another hung
on an overhead post, with no space in-between neighboring parts. To make
things even worse, the rings were manufactured of a 1/2" deep u-channel, causing
neighboring parts to "nest" into one-another. When the rings were stacked
one in front of another and submerged in a liquid, enormous amounts of liquid
was being trapped in the bottom of each ring. And, since the rings were
stacked directly in front of one-another, drying using traditional hot air
drying ovens was highly inefficient, and did not meet the 5 minute-per-batch
cycle time required by the customer. The ultrasonic cleaning system also
needed to address different ring sizes, from 6" in diameter to 22" in diameter,
and the customer needed to ability to add a basket of any ring size at any time
on-the-fly. Finally, the system required an Automated Return Conveyor and
Basket Handling System to eliminate the need for operators to return baskets
from the Unload Conveyor to the Load Conveyor.
Zenith's primary concern was to address the liquid being captured at the
bottom of each ring. Not only did this liquid make fast drying impossible,
it also would cause a large transfer of cleaning fluid into the rinsing tank
when baskets were transferred. This would continuously reduce the liquid
level in the ultrasonic cleaning tank, would contaminate the rinse water which
prevented zero-residue cleaning results, and significantly increase water
consumption as a result.
To address this difficult cleaning application, Zenith started by selecting
MBT Automation System for
its ability to oscillate parts independently in each tank. Next, fixed
compressed air-powered Air Blow-off Nozzles were mounted to the front of each
tank which would serve to remove excess liquids trapped at the bottom of the
rings. A motorized Return Conveyor System and Pneumatic Parts Handling
System was also installed for seamless and reliable basket handling without any
Baskets would enter the processing tanks for liquid processing. Upon
completion of liquid processing, each basket was raised until the bottom of the
rings in a particular tank were only a few inches below the Blow-off Nozzles.
When precisely in position, the Blow-off Nozzle would travel down the center of
the rings in each tank, evacuating the water which was trapped on the bottom of
each ring, for a recipe-determined adjustable time period. This system
completely solved this customer's cleaning requirements. Per-batch
processing times were performed in 5 minutes when operating continuously.
This is just one example out of thousands of custom applications that Zenith
has addressed in its history. If you have any cleaning application which
cannot be solved with standard cleaning machines, contact Zenith. Solving
challenging ultrasonic cleaning applications is our specialty.
For additional information,
85 Oak St.
Norwood, NJ 07648-0412