Evergreen Solutions: Achieving Chemical Purity
with Advanced Industrial Ultrasonic Cleaners
Case Study-33
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Introduction
Achieving chemical purity in aluminium silicate manufacturing is a challenging yet critical task. Used as a raw material in the production of Pharma, Cosmetic, chemicals, oil, and greases., aluminium silicate is a much-needed and abundant commodity. However, the competitive market for this critical raw material has resulted in extreme cost-saving measures ranging from recycling, reuse, and extraction. Our client is a 120 Cr turnover aluminium silicate manufacturing and recycling company., where achieving and maintaining the highest standards of purity in their extracts was paramount. Despite employing various cleaning methods, the company struggled to determine the most effective process. In their pursuit of a solution, they came across our advertisement and contacted us for assistance. Unlike other suppliers, we conducted a detailed analysis and tailored our approach to meet their specific needs.
The Challenge
The client had explored multiple cleaning methods but couldn’t pinpoint the optimal process for ensuring chemical purity in aluminium silicate extracts. They required a solution that could effectively clean the extracts without compromising their integrity. The client’s previous experiences with other suppliers left them dissatisfied, as none had offered a comprehensive solution backed by empirical data and trials. They needed an innovative approach that combined precision and reliability.
Our Approach
Understanding the complexities involved, we decided to conduct thorough tests on the aluminium silicate samples provided by the client. We received three to four different types of aluminium silicate and ran them through a series of tests using different cleaning media, frequencies, power settings, temperature variations, and time settings. Our goal was to identify the most effective combination that would ensure optimal chemical purity.
Testing Process
Selection of Cleaning Media
We experimented with various cleaning solutions to identify the best option for each type of aluminium silicate. By testing different media, we ensured that the chosen solution would efficiently remove impurities. We conducted various trials at different concentrations and included post-wash rinse and drying, to optimize the solution and offer them a simulated experience of what they would receive as a cleaned product. The different readings were packed and returned to the client for detailed chemical analysis. The analysis was conducted and samples were also checked through a microscopic instrument.
Frequency and Power Adjustments
Utilizing advanced sonication and acoustic cavitation technologies, we adjusted the frequencies and power settings to achieve the optimal balance for cleaning without damaging the material. These adjustments were crucial in enhancing the effectiveness of the ultrasonic bath. A similar process of obtaining different cleaned samples was then packed, labeled, and sent to the client.
Temperature Control
We tested different temperature settings to evaluate their impact on the cleaning efficiency and chemical integrity of the aluminium silicate. Temperature played a significant role in maximizing the cleaning potential of the ultrasonic bath. The sampling and packaging were done through microscopic analysis at the client’s end.
Time Optimization
By varying the cleaning durations, we identified the ideal time required for each sample to achieve chemical purity without overexposure. This step ensured that the process was both efficient and effective. Details and samples were shared with the client.
Results
Of the cleaned samples that were sent back to the client for verification, the client confirmed that our tests had successfully identified the optimal cleaning process. They were impressed by our detailed approach and the thoroughness of our testing. They noted that our willingness to conduct trials and provide a data-driven proposal distinguished us from at least 10 other suppliers they had consulted.
Designing the Custom Industrial Ultrasonic Cleaner
With the client’s feedback and the successful testing results, we designed a custom industrial ultrasonic cleaner tailored to their specific needs. The machine was engineered to:
Accommodate various types of aluminium silicate: Compartments were provided with the cylindrical basket. The basket was designed to be a rotation system, which ensured the parts were evenly exposed to the sonication.
Utilize the identified optimal cleaning media and settings: A chiller was integrated to ensure that the solvent media could be in a used safer way.
Ensure consistent chemical purity with every cleaning cycle: A system of filtration and recycling was also integrated to reuse the cleaning media and to ensure economy of use over a while.
Leverage sonication and acoustic cavitation to enhance cleaning efficiency: With a variable power setting, the sonication system has an option of increasing or decreasing the power., thus giving the customer the ultimate control over his cleaning process.
Implementation and Impact:
The custom ultrasonic cleaner was delivered and implemented, transforming the client’s cleaning processes. From having no idea how to achieve cleaning and increase the value of their recycled aluminium silicate ., the client now had the opportunity to maximize his quality, compliance, and utility options. The cleaned products also opened up doors for the implementation of different products for different industries., thus expanding their market reach and business potential. Having worked with different chemistries, the client is also now confident of their process and is considering volumizing their output.
They experienced significant improvements in chemical purity, operational efficiency, and overall product quality. The use of an advanced sonication process has allowed for the use of acoustic cavitation for aluminium silicate cleaning., an unheard-of technological innovation. This equipment exceeded their expectations, providing a solution that was both innovative and effective.
Client Feedback
The client praised our unique approach and highlighted several key benefits:
Customized Solutions: Our willingness to conduct trials and design a machine based on empirical data demonstrated our commitment to their unique needs.
Enhanced Purity: The precision and effectiveness of our cleaning process resulted in unparalleled chemical purity.
Operational Efficiency: The custom machine integrated seamlessly into their existing operations, improving efficiency and reducing downtime.
Technological Innovation: The use of sonication and different frequencies of acoustic cavitation has set a new standard in industrial cleaning.
Conclusion
This case study exemplifies our dedication to providing tailored, data-driven solutions in industrial cleaning. By prioritizing the client’s specific requirements and employing a meticulous testing process, we delivered a custom ultrasonic cleaner that revolutionized their operations. Our approach not only set us apart in a competitive market but also underscored our commitment to innovation, quality, and sustainability.
If you have a customized solution requirement for cleaning, do connect and we could discuss it over the phone email, or through a Zoom meeting. This consultation is free and is a service we provide.
