Ultrasonic System Purpose Built to Clean Injection Molds

Emerson has introduced the new Branson MCX Series ultrasonic mold cleaning systems, featuring side-mounted immersible transducers and powerful immersion heaters that reportedly provide more effective cleaning than other systems. The company said compared to manual cleaning of plastics injection molds, which can take hours, the Branson MCX Series can clean a mold in 15 to 20 minutes, depending on the tool’s design and level of residue.

Emerson notes that its units are purpose-built for cleaning injection molds, including the use of side-mounted transducers versus systems with transducers on the bottom of the tank. Given that most plastic injection molds are rectangular, with a lot of the cavity design details on the surface facing the side of the tank, side-mounted transducers accomplish a more intense and focused cleaning compared to bottom-mounted transducers.

Compared to traditional manual cleaning, which can require high concentrations of sometimes toxic cleaning solutions, brushes and other tools, Branson ultrasonic cleaning systems use ultrasonic technology to produce fluid cavitation, a non-contact cleaning process. Mold halves are placed between the transducers mounted on opposite sides of the tank, which is filled with cleaning solution.

The system emits ultrasonic waves into the solution, creating minute bubbles—or cavities—that eventually implode, releasing tremendous amounts of energy. The resulting turbulence dislodges contaminants from the mold surfaces and even blind holes and tiny crevices, where brushes cannot reach. The cavitation turbulence enhances the effectiveness of the cleaning chemicals and results in better release, improved productivity, less maintenance, longer mold life and reduced chemical waste.

The MCX Series cleaners are pre-configured in three stock tank sizes to accommodate small molds (up to 24 by 24 by 10 in.); medium-sized molds (up to 38 by 38 by 14 in.), and molds as large as 52 by 48 by 17 in. The side-mounted immersible transducers can deliver cavitation in 25 and 40 kilohertz frequencies. In addition, the MCX Series can be configured to include one or more rinse stations to remove latent chemistries and add rust-inhibiting chemistries to improve mold life and performance.