Sonomechanics Blog

An ultrasonic processor is a device that uses high-frequency sound waves to create intense microscopic agitation in liquids. This process—called ultrasonication—is commonly used to mix, break apart, emulsify, extract, disperse, or process materials at a microscopic level.

Ultrasonic processors are widely used in industries such as pharmaceuticals, biotechnology, food and beverage, cosmetics, cannabis extraction, nanotechnology, and chemical manufacturing.

How Does an Ultrasonic Processor Work?

An ultrasonic processor converts electrical energy into high-frequency mechanical vibrations, usually in the range of 20–40 kHz.

The system typically includes:

• A power generator
• A transducer
• A horn or probe (also called a sonotrode) (see below the patented barbell horn from ISM)

The probe vibrates extremely rapidly inside a liquid, creating tiny vacuum bubbles through a phenomenon known as cavitation.,

When these bubbles collapse, they release localized energy that can:

• Break particles apart
• Blend immiscible liquids
• Rupture cells
• Accelerate chemical reactions
• Improve mixing and dispersion

Common Uses of Ultrasonic Processors

Emulsification

Ultrasonic processors can combine oil and water into stable emulsions used in:

• Cosmetics
• Nanoemulsions
• Pharmaceuticals
• Food products

Cell Disruption

In biotechnology and laboratory settings, ultrasonication can break open cells to release proteins, DNA, enzymes, or other intracellular materials.

Particle Size Reduction

Ultrasonic energy helps reduce particle size and evenly disperse nanoparticles, pigments, or powders.

Extraction

Processors are often used to improve extraction efficiency for:

• Botanical compounds
• Essential oils
• Hemp and cannabis extracts
• Flavors and fragrances

Degassing

Ultrasonic waves can remove dissolved gases or trapped air bubbles from liquids.

Types of Ultrasonic Processors

Probe Ultrasonic Processors

These use a metal probe inserted directly into the sample. They are powerful and commonly used in laboratories and industrial production.

Key Advantages

• Fast processing times
• Improved mixing efficiency
• Fine particle and droplet sizes
• Reduced chemical usage
• Scalable from lab to industrial production
• Can improve product consistency

Limitations and Considerations

Ultrasonic processors also have some challenges:

• Heat generation may require cooling
• High power can damage sensitive materials
• Equipment wear occurs over time
• Noise protection may be needed
• Process optimization is often necessary

Industries That Use Ultrasonic Processing

Common industries include:

• Pharmaceutical manufacturing
• Biotechnology
• Food and beverage
• Cosmetics
• Chemical processing
• Nanotechnology
• Environmental treatment
• Cannabis and hemp extraction

Ultrasonic Baths

These systems place samples inside a tank filled with water and use indirect ultrasonic energy. They are gentler and often used for cleaning or smaller laboratory tasks.

In an ultrasonic processor, amplitude refers to how far the probe tip moves back and forth during each vibration cycle. It is one of the most important performance parameters because it directly affects cavitation intensity and processing power.

What Is Amplitude?

Amplitude is usually measured in:

• Microns (µm) peak-to-peak movement
• Or as a percentage (%) of the system’s maximum output

Typical industrial ultrasonic processors operate between:

A≈10 μm to 120 μm

Higher amplitude = more aggressive cavitation.

Typical Amplitude Ranges by Application

Low Amplitude (10–30 µm)

Used for:

• Gentle mixing
• Degassing
• Sensitive biological materials
• Mild emulsification

Benefits:

• Lower heat generation
• Less sample damage

Medium Amplitude (30–60 µm)

Common for:

• Standard emulsions
• Particle dispersion
• Cell disruption
• General laboratory processing

This is often the “sweet spot” for many applications.

High Amplitude (60–120+ µm)

Used for:

• Nanoemulsions
• Tough particle deagglomeration
• Heavy-duty extraction
• Industrial-scale cavitation
• Difficult homogenization tasks

Higher amplitudes create:

• Stronger cavitation
• Faster processing
• More heat and probe wear

Why Amplitude Matters?

Cavitation intensity increases dramatically with amplitude.

Generally:

If amplitude is too low:

• Cavitation may not occur effectively
• Processing becomes inefficient

If amplitude is too high:

• Samples can overheat
• Sensitive compounds may degrade
• Excess foam or erosion may occur

Typical Industry Recommendations

Other Important Factors

Amplitude alone is not enough. Performance also depends on:

• Frequency (kHz)
• Power density
• Probe diameter
• Liquid viscosity
• Temperature
• Pressure
• Flow rate (continuous systems)

For example, a larger probe may need greater power to maintain the same amplitude.

Industrial Design Considerations

Many industrial systems are designed to maintain stable amplitude under load. Typical requirements include:

• Consistent amplitude control
• Less than ±5% variation under load
• Titanium sonotrodes for durability
• Cooling systems to manage heat
• Sound safety (see below picture of NRE-30 sound enclosure produced by Industrial Sonomechanics)
  
  

Amplitude Requirements

Amplitude requirements depend heavily on the application:

• Gentle processes use lower amplitudes
• Aggressive emulsification and extraction require higher amplitudes
• Most industrial ultrasonic processing falls in the 30–80 µm range

The correct amplitude is usually determined experimentally to balance efficiency, heat generation, product quality, and equipment longevity.

How to Choose the Right Ultrasonic Processor?

Choosing the right ultrasonic processor depends on your application, production volume, material properties, and desired results. The “best” system for a laboratory may be completely wrong for industrial manufacturing.

Here are the twelve main factors to evaluate.

1. Define Your Application

Start with what you need the processor to do.

Common applications include:

• Emulsification
• Cell disruption
• Extraction
• Particle size reduction
• Degassing
• Dispersion
• Homogenization

Different applications require different:

• Power levels
• Frequencies
• Amplitudes
• Flow configurations

For example:

• Nanoemulsions often require high amplitude
• Biological samples may require gentler processing

2. Determine Your Required Volume

Volume is one of the biggest decision factors.

Batch vs Continuous Flow

Batch Systems

Best for:

• R&D
• Small production
• Laboratory work

Continuous Flow Systems (see below Continuous Flow Configuration with ISM)

Best for:

• Manufacturing
• High throughput
• Consistent industrial production

3. Select the Proper Power Rating

Power affects cavitation intensity and throughput.

Typical ranges:

• 50–500 W → laboratory
• 500–2,000 W → pilot systems
• 2,000+ W → industrial production

More difficult materials require more power.

A common sizing consideration is power density:

Power Density=PV

Where:

• P= ultrasonic power
• V= liquid volume

Too little power can result in weak cavitation and poor processing efficiency.

4. Understand Amplitude Requirements

Amplitude strongly affects cavitation strength.

Typical ranges:

A≈10 μm to 120 μm

General guidance:

• Low amplitude → gentle processing
• Medium amplitude → general emulsification/dispersions
• High amplitude → nanoemulsions and aggressive processing

Choose a system with adjustable amplitude control.

5. Choose the Right Frequency

Most ultrasonic processors operate around:

f≈20 kHz to 40 kHz

Lower Frequency (20 kHz)

• Larger cavitation bubbles
• More aggressive processing
• Better for industrial homogenization

Higher Frequency (30–40+ kHz)

• Smaller bubbles
• More uniform treatment
• Better for delicate applications
• Frequencies above 20 kHz are not commonly applicable to industrial scale since the horns are smaller

6. Match the Probe Size to the Application

Probe diameter affects energy concentration.

Small Probes

• Higher intensity
• Small sample volumes
• Precision lab work

Large Probes

• Greater throughput
• Industrial processing
• Lower localized intensity

Titanium probes are most common because of their durability and cavitation resistance.

7. Consider Heat Management

Ultrasonication generates heat quickly.

You may need:

• Ice baths
• Jacketed vessels
• Recirculating chillers
• Heat exchangers

This is especially important for:

• Proteins
• Pharmaceuticals
• Heat-sensitive compounds
• Botanical extracts

8. Evaluate Control Features

Modern systems may include:

• Digital amplitude control
• Pulse mode
• Temperature monitoring
• Data logging
• Recipe storage
• Automated tuning

Industrial systems often benefit from PLC integration and process automation.

9. Think About Scalability

Many lab results do not scale linearly to production.

Choose a vendor that offers:

• Lab systems
• Pilot systems/Bench Scale
• Industrial systems
• Scale-up support

Consistency between development and manufacturing is critical.

10. Verify Material Compatibility

Certain materials can:

• Corrode probes
• Foam excessively
• Wear components rapidly

Check compatibility with:

• Solvents
• Acids
• Abrasive particles
• Viscous materials

11. Consider Maintenance and Durability

Important considerations:

• Probe replacement costs
• Generator reliability
• Cooling requirements
• Service availability

High-amplitude industrial systems can experience more wear.

12. Work With a Reputable Supplier

A good supplier should help with:

• Process development
• Sample testing
• Scale-up guidance
• Validation support
• Regulatory requirements

Ask for:

• Performance data
• Application notes
• Demonstration testing

The right ultrasonic processor depends on balancing:

• Power
• Amplitude
• Frequency
• Throughput
• Heat management
• Scalability

For many users, the best approach is to start with application testing and optimize parameters experimentally before purchasing a full-scale production system.

Final Thoughts

Ultrasonic processors are powerful tools that use sound energy to manipulate materials at a microscopic level. Whether used in a research lab or large-scale manufacturing facility, they can dramatically improve mixing, extraction, emulsification, and particle processing efficiency.

As ultrasonic technology continues to advance, these systems are becoming increasingly important across scientific and industrial applications.