Generating new technologies

Case study: ultrasonic cleaning

Background

In an industrial environment it is important to keep as many processes as possible running in a similar mode. For a continuous (e.g. printing) process, introducing a batch procedure can act as a significant bottle-neck. Some batch processes, such as an inspection or Quality Control procedure, can work on a sample basis. When the batch process is a critical production step it affects the entire system. Despite this fact, many off-the-shelf solutions for inspection or cleaning are not inline processes, or require development to integrate them into a production line. Sentec's expertise in sensing technologies, metrology and process development are all brought to bear on this type of problem.

The opportunity

In this development programme Sentec's client, a leading multinational manufacturer of photographic materials and printing systems, had a quality control problem that was blocking development of a new product. To be commercially viable the solution would need to fit within a continuous process.

The client's requirements:

High performance removal of adhered residues
Reduced reliance on chemical agents
Suitable for delicate substrate
In-line process

Our approach

Identification of suitable processes
Preliminary testing of processes to investigate effects on substrate
Selection of preferred process in collaboration with client
Laboratory development of prototype in-line process
Laboratory proof of process efficacy
Design of production system
Installation of system in collaboration with client

Results

After some consideration, it was decided ultrasonic cleaning offered the best fit to client's requirements. An inline system developed around this principle produced a highly successful solution, which halved the quantity of aggressive chemicals required and delivered environmental and cost benefits.