Industrial ultrasonic processors are vital tools for applications like nano-emulsification, cell lysis, nanoparticle dispersion, and nano-crystallization—processes that are widely utilized across numerous industries. Choosing the right system is crucial for achieving superior results and ensuring uninterrupted production, at large volumes on the plant floor.
In this blog post, we will explore the key features that drive performance, helping you make an informed decision and ensuring your ultrasonic processor meets the specific demands of your application.
Table of Content:
1. High Amplitude Capability: The Required Key Feature
2. Efficient Processing of Large Volumes of Liquid Material
3. Liquid Material Temperature Control
4. Industrial Ultrasonic Processors for Continuous, 24/7 Processing
5. Beware of Imitations When Selecting an Industrial Ultrasonic Processor
6. Applications Expertise, Multi-Application Use, and Beyond
7. Conclusion and Request ISM Ultrasonic Processor Pricing Link
High Amplitude Capability: The Required Key Feature
When selecting an industrial ultrasonic processor, achieving the necessary ultrasonic amplitude is crucial for optimal performance. Ultrasonic amplitudes of at least 70-80 microns are typically required to harness the full power of ultrasonic cavitation for processes such as nanoparticle dispersion, extraction, degassing, nano-emulsification, and sonochemistry. For instance, in a recent peer-reviewed publication, it was demonstrated that achieving high ultrasonic amplitudes significantly improved the efficiency of cell disruption [1].
The following short video also demonstrates a recent amplitude comparison experiment for nano-emulsification, revealing why amplitude is the most critical parameter in many ultrasonic processes.
Efficient Processing of Large Volumes of Liquid Material
When it comes to efficiently processing large volumes of liquid material, scalability is a critical factor in selecting an ultrasonic processor. A truly effective system must be able to handle increased batch sizes without compromising performance. This requires the ultrasonic processor to maintain consistent, high-amplitude output even as the ultrasonic horn tip diameter increases. Barbell Horns®, designed and patented by Industrial Sonomechanics, are the only ultrasonic devices capable of achieving this feature.
ISM’s unique ultrasonic horns ensure that when working with a large horn tip diameter to accommodate industrial volumes, the amplitude remains constant, delivering the powerful cavitation necessary for high-quality results.
The following video compares two nanoemulsion samples prepared with NanoStabilizer®-LT formulation and processed using two different high-amplitude ultrasonic horn tip sizes. Although the small probe tip on the right can operate at high amplitudes, it is unable to effectively handle the larger sample size, demonstrating that high amplitudes and large diameter horns are essential for scaling up to large-volume processing.
Liquid Material Temperature Control
Maintaining precise temperature control is another essential feature for achieving consistent results in ultrasonic processing. Whether you are working with sensitive biological materials, such as mushroom extracts, or conducting high-energy chemical reactions, controlling the temperature of your liquid material ensures optimal performance and prevents thermal degradation.
ISM’s advanced ultrasonic systems offer the capability to maintain your liquid at any desired temperature within a wide range. ISM’s flow-through components are equipped with cooling jackets and can be automated for exact temperature regulation, making our processors reliable and ideal for working with heat-sensitive substances. Additionally, they are specifically designed to work with high-viscosity liquids and to prevent clogging and equipment downtime, ensuring uninterrupted operation even when sonicating challenging materials such as slurries that tend to settle.
Industrial Ultrasonic Processors for Continuous, 24/7 Processing
The ability to operate continuously, 24/7, is a critical feature for industrial ultrasonic processors, particularly in high-demand production environments. Consistent, around-the-clock operation ensures that large-scale processing tasks are completed efficiently, without interruptions that could affect productivity.
ISM addresses this need with advanced water-cooled transducers, an essential part of our IP portfolio and ultrasonic processors. Integrated into the BSP-1200 and ISP-3600 systems, these transducers are fully sealed from the outside environment, making them ideal for working in high-humidity conditions and with flammable materials like organic solvents. The water-cooled transducer design not only supports continuous operation but also enhances safety and reliability, making ISM systems a dependable choice for industrial-scale applications.
Beware of Imitations When Selecting an Industrial Ultrasonic Processor
When selecting an industrial ultrasonic processor, it is crucial to choose a system built on innovative, non-infringing technology. The market is flooded with devices that attempt to mimic patented designs, but these imitations often fall short in performance, reliability, and safety.
Industrial Sonomechanics' technology, Barbell Horns® and water-cooled transducers, are protected by multiple patents, ensuring that you are investing in a system backed by genuine innovation and proven results. Choosing a processor with protected, non-infringing technology not only safeguards your operations but also ensures that you are benefiting from the highest standards of ultrasonic processing, free from legal complications and performance issues.
Applications Expertise, Multi-Application Use, and Beyond
Along with evaluating the industrial ultrasonic equipment, it is important to consider the equipment vendor. Original equipment manufacturers, such as ISM, can provide superior technical support and application expertise. A vendor with deep knowledge of diverse processing applications can guide you in optimizing ultrasonic technology for your specific needs, whether you are working with nanoemulsions, liposomes, or other complex materials.
As an original equipment manufacturer, Industrial Sonomechanics provides comprehensive client support—from technical assistance with setting up and operating an ISM ultrasonic processor, to training and retraining, maintenance, process optimization, and scale up. Additionally, we offer all-in-one NanoStabilizer® ingredients, formulation developmental services, and are frequently involved in long-term developmental projects with our clients. We also partner with organizations to conduct clinical trials.
Conclusion
In summary, when selecting an industrial ultrasonic processor, prioritize key features such as high amplitude output, continuous operation, scalability, and precise temperature control. These attributes are essential for ensuring your system meets the rigorous demands of applications in research, manufacturing, or product development. By focusing on these critical capabilities and partnering with a provider dedicated to innovation, you can consistently achieve high-quality results that enhance efficiency and drive innovation throughout your operations.
References:
1. Bystryak, S., Santockyte, R., & Peshkovsky, A. (2015). Cell disruption of S. cerevisiae by scalable high-intensity ultrasound. Biochemical Engineering Journal, 99, 10-17. https://doi.org/10.1016/j.bej.2015.03.014.