Ultrasonic Homogenizers, Processors and Dispersals
Ultrasonic Homogenizers are sometimes referred to as processors or dispersers.
SpecShield has been manufacturing ultrasonic homogenizers for more than a decade. Our in-house research laboratory has improved on the existing systems, while implementing and creating never before used tech for our state of the art homogenizers. We currently produce 5 variations.
- Standard Ultrasonic homogenizer
- Dustproof Ultrasonic homogenizer
- Flow-through Ultrasonic homogenizer
- Table-top Ultrasonic homogenizer
- Ultrasonic homogenizer with elongated waveguide
The waveguide (sonotrode), the operating element of an ultrasonic homogenizer, vibrates mechanically at a frequency of several tens of thousands of times per second, with an amplitude of several microns, and can perform various useful tasks depending on the goals and materials used for processing.
An ultrasonic processor is most often used to convert solid and liquid media to dispersed state (superfine dispersing and atomizing). For this reason, it is called an ULTRASONIC DISPERSER and used to grind solids in liquids for suspensions, liquids in liquids for emulsions or liquids in gases for atomizing.
Ultrasonic vibrations create high-dispersion and homogeneous mixtures, with particles no more than several fractions of a micron in size, e.g.: suspensions where solid microparticles are suspended in liquids, emulsions with immiscible microparticles of one liquid in a second liquid, and solids with liquid micro-drops in gas.
Suspensions are dispersed when solid particle aggregates bonded by adhesion, agglutination or cleavage forces are exposed to ultrasound.
During ultrasonic dispersion of suspensions, the degree of product fineness is several orders of magnitude higher than in conventional mechanical grinding. Without ultrasonic processing, high-quality emulsions for many liquids cannot be obtained at all.
During operation, the waveguide generates high cavitation and acoustic flows in liquids to mix liquids that cannot be mixed by any other method (e.g. oil and water).
It is a fast and effective way to make high-quality emulsions and suspensions; extract dry matter to liquid; accelerate coagulation by several times; clean and sterilize any item in a cleaning solution and remove contaminants from the surface quickly and efficiently.
Ultrasonic processing is indispensable in many sectors, including chemical and pharmaceutical industries, perfume manufacturing, biotechnology, and nanotechnology.
The food industry is yet to take full advantage of all the benefits offered by ultrasound technology.
For example, if milk is treated for only one minute, its structure will become more homogeneous because of milk fat dispersion; more importantly, the shelf life of such milk without heat treatment will be much longer.
Vegetable oil/water emulsions produced by the disperser considerably reduce vegetable oil consumption when making bread.
Ultrasonic processing is very efficient in winemaking: it improves wine quality and shortens wine maturation time because it accelerates tartaric stabilization by several times.
Ultrasonic dispersers are based on advanced microprocessor-controlled piezoceramic radiators and ultrasonic generators.
Specially designed and optimized replaceable operating tools (waveguides) are made of titanium alloys.
The generator automatically adjusts to loads: the higher the density of processed liquid is, the more energy the radiator gives away.
Ultrasound speeds up production processes by several times improving their efficiency. Production processes enhanced by the ultrasound technology, such as wood impregnation, intensification of galvanic processes, wine and cognac ageing, etc., save time and money and deliver superb performance.
Ultrasonic Welding of Polymer Materials
Before a new welding machine is put into production, we model future welding processes and study the properties of new materials to achieve optimal performance and to provide equipment that will last our users well into the foreseeable future. SpecShield is committed to continuous and vigorous research of ultrasonic welding processes: we constantly add new materials to our list of weldable elements. If you are looking for the best ultrasonic welding equipment, do not hesitate to contact us; send us your test specimens and see for yourself the welding quality and speed we are able to offer. Weld materials do not have to have the same composition to be welded. For example, these materials can be welded together using ultrasonic technology: cardboard paper and plastic (Tetra Pak), metals and non-metals, different polymer materials such as ABS plastics, polyamide, polystyrene, spunbond, etc.
Ultrasonic welding is increasingly being used for challenging applications such as connecting elements and components to manufacture items out of different plastics and nonwoven fabrics, because it ensures a durable connection in a quick and easy manner. Unlike conventional welding, ultrasonic welding of polymers provides a stronger bond between welded materials without cumbersome pre-weld surface preparation and post-weld dressing. Moreover, there are no internal stresses in the weld zone and in many cases the weld is not visible at all.
Ultrasonic welding may either be seam welding (continuous or stitch welding) or contour welding (closed/unclosed). SpecShielddevelops and produces powerful (up to 3 kW), high efficiency piezoceramic radiators and generators designed specifically for ultrasonic welding machines to minimize ultrasonic pulse length and guarantee high welding quality. For example, when spunbond is welded, the ultrasonic pulse length for a weld 300 mm long and 3 mm wide is only 0.01 s (10 ms).
Based on these radiators, SpecShielddevelops and produces customized ultrasonic welding machines for polymers such as spunbond, polystyrene, polyamide, polyethylene, polyvinyl chloride (PVC) and more, tailored to the customer's process in order to offer the best efficiency and value.
Welding is a process that creates a permanent connection between the atoms of welded elements. Metals are welded by heating and fusing, i.e. mixing metal molecules in contact areas. Ultrasonic welding is used to weld polymer materials without high temperature exposure. During ultrasonic welding materials are exposed to microdeformations, friction, heating, dispersion, and diffusion induced by high-frequency mechanical microvibrations (18 to 100 kHz).
A durable connection is made in the ultrasonic environment and under a certain pressure in the welding area. When ultrasonic settings of a welding machine, e.g. vibration frequency, power consumption, and pressure, are correct and match those required for the specified material, welding speed may be as high as fractions of a second, including weld cooling/hardening time. Ultrasonic welding is classified by the type of welding machines: spot welding, contour press welding, seam welding, spot-and-seam welding machines and portable instruments such as low-power stick guns. Power consumption is 100 to 2,000 kW.
Ultrasonic Drilling Machines
UZS-2 – Ultrasonic Drilling Machine
The UZS-2 tabletop machine makes perforations of any shape in glass, stone, ceramics, etc., without creating internal stresses in the perforated material. This means that perforations in glass can be made very close to the edge of a workpiece; also, many perforations can be made close to each other, without the risk of breaking the glass due to internal stresses. The shape of perforations depends on the profile of the processing titanium tool. A flat instrument, the so-called ultrasonic knife, may also be used.
- Maximum mains power, W: max. 500
- Power voltage, V: 120
- Maximum dimensions of the ultrasonic generator (LxWxH), mm: 300х200х130
- Maximum dimensions of the perforation unit (LxWxH), mm: 550х450х850
- Maximum weight of the ultrasonic generator, 4.5kg
- Maximum weight of the ultrasonic perforation unit, 80kg
UZSK-6 Ultrasonic Drilling Machine
The UZSK-6 machine uses the ultrasonic technology to make perforations ranging from 0.7 to 10 mm in diameter in solid and fragile materials.
These machines are in great demand in the jewelry industry, souvenir-making, and the electronics industry (perforating printed circuit boards). They are also used for creating through and blind pin holes (max. 2 mm in diameter) in semi-precious and precious stones, ceramics, and other solid and fragile materials, including with an ordinary sewing needle. With the help of a custom instrument, the operating tool (needle) is replaced in a matter of seconds, without the need for a soldering iron.
The operating tool is stand-mounted.
The work area is LED illuminated.
- Hole diameter: min. 0.7 mm
- Drill depth: up to 10 mm
- Hardness of processed material: up to 7 units
- Maximum mains power, W: max. 100
- Needle changeover time, s: 90
- Soldering: by induction
- Power voltage, V: 220
- Maximum dimensions of the ultrasonic generator (LxWxH), mm: 300х200х130
- Maximum dimensions of the drill unit (LxWxH), mm: 360х320х600
- Maximum weight of the ultrasonic generator, kg: 4.5
- Maximum weight of the ultrasonic drill unit, kg: 10
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