Mold and
die cleaning systems
Swiss Quality
Foreword | 3
Purity is in the life-blood of Switzerland. Since 1982 an
epicentre for ultrasound-based cleaning has been
established here in the form of KKS. It is motivation and
the power to innovate that move us. Along with
technical knowledge and control of our actions. Above
all it is our ability to perceive vibrations. This means:
we listen to our customers. We address their needs and
explore their applications. We consider it our mission
to create technologically leading solutions for ultrasound-based cleaning and surface finishing processes
Purity as a
vision
Purity as a vision
Purity through utrasound
Gentle and cost-effective care for your valuable molds and dies
5
Ultrasonic cleaning
5
Proven technology is indispensable for mold cleaning as well
6
SINGLE, DUAL or MIX frequency technology
7
for our customers. In this way we provide greater
performance, cost-effectiveness and flexibility. And we
create significant added value for our customers.
Together with you we want to be successful as an internationally renowned specialist in these niche markets
and to make an effective contribution to further
development.
KKS markets a complete range of systems built for
mold and die cleaning. Leading businesses from these
sectors of industries have chosen us as their technology partner due to the quality of our systems, as well as
KKS Mold and die cleaning systems
Possible process steps
Key factors for mold and die cleaning
their durability and excellent performance. The KKS
9
10
KKS – Solutions without Limitations
13
Typical solutions for mold and die cleaning
14
Manual systems type "Poly" – for smaller molds and dies
14
Manual cleaning systems type "NW" with separate
hot air dryer – for medium-sized molds and dies
14
vertical movement of goods
15
Automatic linear systems type "Lift-Shift"
15
Further information at:
www.kks-ultraschall.ch
with our cleaning solutions, make ultrasonic cleaning
an efficient and at the same time environmentally sound
method, capable of cleaning products of all types.
We provide a small insight in the world of purity on
the following pages. If you should have any questions
about our products and the possibilities to clean
Cleaning system with automatic lifting unit and
SINGLE, DUAL and MIX frequency technology combined
your molds and dies, we will be pleased to be of assistance at any time.
Ultrasonic technology in general | 5
Purity through
ultrasound
Gentle and cost-effective care for
your valuable molds and dies
sion) tear apart the liquid’s intermolecular bonds,
A thorough cleaning is essential in the maintenance of
of the liquid at the boundary of the cavity. During
rubber, plastic and aluminum molds and dies. If the
the compression phase, this vapor condensates again.
cleaning process is insufficient, the molds have to be
This creates millions of microscopic cavitation bubbles
replaced more frequently, which ultimately results
with oscillating sizes. If a sufficient level of ultrasonic
in financial losses. Rubber- and plastic molds, as well as
energy is applied, the cavitation bubble can no longer
core boxes often are still cleaned by hand, which is
oscillate in a stable fashion and collapses during
a tedious process and removes debris insufficiently.
the following compression phase (“transient cavita-
In addition, the time-consuming and high-effort manual
tion”), creating millions of smaller bubbles or disappea-
removal procedure of persistent residue may perma-
ring into the liquid. This creates immense localized
nently damage the molds.
pressures (shock waves) as well as turbulences and
KKS‘s leading ultrasonic and process technology offers
currents. These phenomena are what actually causes
an economical, gentle and reproducible solution for
the removal of dirt particles from the surface of the
cleaning your valuable molds and dies, customized to
component.
creating transient and bubble-like cavities (bubbles),
which are instantly filled with vapor due to vaporization
your individual needs and requirements.
Collapsing bubble near to a
boundary with microjet
Ultrasonic cleaning
Microjet
The ultrasonic generator creates an alternating
The advantages of ultrasonic cleaning
• Pore-deep clean surfaces without scratching, brushing
or scraping – also on porous or open-pored structures,
complex geometry, small gaps or blind holes in the item
electrical field whose energy is transformed into mechanical energy by piezoelectric transducers and
transmitted into the cleaning solution. This creates
Oscillating bubble
Collapsing bubble
pressure changes in the liquid.
to be cleaned
• Short cleaning times from a few seconds to minutes
• Straightforward and quick to apply
Liquid
Compression / expansion
High sonic pressure, compression
Item to be cleaned
• Can be used for practically all types of contamination
and materials
• Prevention of tedious and expensive manual work –
the cleaning becomes a successful experience
Suction phase, rarefaction
Cavitation bubbles
(increasing radius
with low pressure)
Cavitation bubble
implosion (breakdown
of the bubble)
• Significantly fewer chemicals additives are required
than for many conventional cleaning processes
• The cleaning process can be automated and provides
reproducible results
Liquids are held together by bonding forces, so called
During this process cavitation bubble implosions
cohesive forces. These act among the individual atoms
occur mainly at the boundary areas between the liquid
and molecules of a substance and thus determine
and the component. The microjets created by the
the tensile strength of a liquid. The pressure changes
sudden influx of liquid are directed to the surface – pre-
caused by ultrasonic waves (Expansion and Compres-
cisely where they are required for effective cleaning.
6 | Ultrasonic technology in general
Ultrasonic technology in general | 7
Proven technology is indispensable for mold cleaning as well
SINGLE, DUAL or MIX frequency technology
The technology of aqueous ultrasonic cleaning has
All systems can be equipped with SINGLE, DUAL or
been implemented for quite a while and is successfully
MIX frequency technology. This enables a most
Purest technology
used in numerous industries. Ultrasonic mold and die
effective and flexible cleaning process for diverse
KKS provides technologically leading solutions for
cleaning systems, whether operating manually or
materials at various contamination levels.
every application area.
automatically, usually consist of at least one cleaning
tank, one rinsing tank and one blowing off station.
High frequency
Depending on the required ultrasonic performance, the
SINGLE frequency The generator operates at
one frequency.
DUAL frequency
The generator can be operated
at two frequencies, either of which
can be selected for cleaning.
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ning
results. The cleaning effect can therefore be
MIX frequency
If two transducers with two
compared to the use of countless micro-brushes that
generators are installed in an ultra-
are also able to reach places difficult to access.
sonic tank, it is possible to clean
Since ultrasound is transferred by putting the metal
items in the relevant bath using both
frequencies simultaneously.
tanks feature multiple ultrasonic transducers on the
bottom and / or its side.
TechnologyMeaning
The cleaning process is also supported by a
cleaning medium adaptable to the contamination level,
which together with the cavitation bubbles generated in the bath by ultrasound, achieves excellent clea-
into vibration, even the smallest drillings, such as cool-
Low frequency
ing channels and runners are cleaned thoroughly.
The ultrasonic frequency plays an important role: at
low frequencies large cavitation bubbles are produced
that produce shock waves with high power as they
implode. At high frequencies on the other hand the
radius of the bubbles is smaller and the implosion
forces are therefore lower. For this reason tenaciously
Abblase-Station
After the ultrasonic cleaning process is completed, the
molds and dies are rinsed in water dosed with a
corrosion protection medium. This prevents the residual
transfer of e.g. cleaning media or loose particles in
subsequent processes.
adhering contamination most effectively removed at
low ultrasonic frequencies.
Time and again the DUAL or MIX frequency technology
proves itself to be one of the most efficient and
effective ultrasonic cleaning processes. Comparisons
and experiments have confirmed that the combination
of coarse and fine cleaning in the same process increases flexibility and it is possible to achieve excellent
cleaning results not obtained previously.
The process is finalized by blowing off or drying
the molds.
KKS Technology for mold and die cleaning | 9
US-Reinigung
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Possible process steps
The following process steps can be individually combined to fulfill
KKS Mold and die
cleaning systems
specific requirements.
Ultrasonic Cleaning
Ultrasonic Rinsing
Rinsing
• Powerful ultrasonic
• Ultrasonic rinsing module
• Flow-Rinsing
Konservieren
cleaning module
Abblase-Station
Trocknen
• SINGLE, DUAL or MIX frequencytechnology
• Application-specific arrangement
of the transducers
Thanks to our extensive knowledge in developing
cleaning processes and surface refinement
equipment, we have an eye for appropriate solutions
for every requirement. Led by advanced project
Conserving
Blowing-off
Drying
management methods (we are ISO 9001 and
• Prevention of corrosion of the
• High-performance suction and
• Hot air or vacuum dryer
ISO 13485 certified), using carefully selected components, and driven by the passion for our craft,
cleaned molds
• Short or long-term corrosion
we transform your specifications into durable high-
protection of the complete
quality systems. With the utmost precision.
surface
blow gun or compressed air gun
Drying options:
• Hot air drying: the well prooved
and cost-efficient method
• Vacuum-drying: the molds –
Solutions without Limitations
Conservation options:
even the capillaries – are
Our services include manufacturing standard
• High-performance suction and
completely dry and ready for use
components as well as individual, customer-specific
systems.
blow gun or compressed air gun
• Transferring the cleaning
solution from the ultrasonic bath
to the rinsing tank
• Corrosion protector
• Dewatering-fluid
• Lubrication
immediately. The ideal drying
solution for blind holes.
10 | KKS Technology for mold and die cleaning
KKS Technology for mold and die cleaning | 11
Key factors for mold and die cleaning
Ultrasonics: the arrangement of the ultrasonic
Pump-filter circuit: an accurately arranged
transducers, their performance and operation frequen-
pump – filter circulation process retains debris from
cy are key factors for the cleaning results. We equip
the tank. It must be adapted to the size of the system
all systems based on customer-specific requirements.
and the items to be cleaned.
Your advantages
Our factors of success
• Efficiency – KKS ultrasonic cleaning systems reduce
• Consulting – KKS relies on years of established
time consuming and expensive manual cleaning
experience, which will contribute to your success. We
processes. Your molds and dies are clean within a
also conduct trials to meet your specific require-
few minutes.
ments.
• Increase in production – the fast cleaning
processes guarantee a high availability of your molds
technology and provides adequate specific chemicals
and dies.
for cleaning-, conserving- or dewatering processes.
• Increased lifetime – gentle cleaning processes
prevent damages to surfaces and salient edges.
• Improved cleanliness – complicated and delicate
geometries, recesses, grooves, cooling channels etc.
are relieved from all residual contamination.
Ultrasonic tank with immersible transducers on two sides,
grid floor
Filter circuit to increase
the operating life of the
cleaning medium
Level of the tank: at different work piece volumes,
Oil skimmer / band skimmer: oil and grease separates
excess water drains into an overflow pocket.
from the molds and dies during the cleaning process.
Therefore the tank maintains a consistent liquid level.
The residuals float on the surface and drain into an
In addition, the accurately measured overflow pocket
overflow tank / reservoir by passing a weir where they
ensures that the work pieces are rinsed adequately.
are continuously removed. The interaction of the
overflow tank / reservoir and the oil separator ensures
that oil which could adhere to the work pieces during
removing the items from the tank floats on the surface.
Overflow pocket, coarse filter and integrated exhausting
Oil skimmer / band skimmer for effective removal of oil and grease
• Process media – KKS is familiar with the process
• Improved quality – transfer of residuals and
contamination is prevented.
• Ultrasonic technology – our core competency.
KKS has developed ultrasonic generators and transducers for decades. They are known for their high
energy- and power density.
• The system concept – KKS systems are reliable and
durable; they are built of corrosion-resistant stainless steel. The size and equipment is adapted to your
specific requirements.
• Training and assistance – KKS trains and assists
the operators of the systems. This is how we ensure
reproducible cleaning results.
US-Reinigung
Abblase-Station
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12 | KKS Technology for mold and die cleaning
KKS Technology for mold and die cleaning | 13
Injection molds – before and after cleaning
KKS – Solutions without Limitations
Contamination: plastic- and rubber residuals
Our services include manufacturing standard components
as well as individual, customer-specific systems. As a dynamic,
innovative and solution-oriented company, we offer to our
customers environmentally sound, economically valuable and
technologically advanced solutions. This, our application
know-how and more than 30 years of experience make us the
ideal partner for your development and production projects.
• Comprehensive solutions for cleaning molds and
Ultrasonic cleaning
Rinsing
Blowing off
• Highly alkaline cleaning solution
• Tap water
• Compressed air gun
• Ultrasonic equipment on the
• Vertical movement of the molds
bottom and on one side
dies of all sizes and shapes
Whether complicated geometries or a wide range of
dimensions – KKS cleaning processes guarantee highest
cleaning efficiency!
• Standard units as well as customer-specific solutions
• Vertical movement of the molds
Individual combination of process steps such as ultrasonic
cleaning, ultrasonic rinsing, DI-rinsing, conserving, and
drying. Implemented according your cleaning requirements!
• Manual, semi-automatic and fully automatic systems
Integrated vertical and/or horizontal movement of goods,
fully automated processes, integration of the unit into
existing production processes and control centers. The wide
range of different tank sizes, ultrasonic frequencies and
optional integrated functions ensure maximum flexibility and
efficiency!
• Leading edge ultrasonic technology
We consider it our mission to create technologically leading
solutions for ultrasonic cleaning processes for our customers.
In this way we provide greater performance, cost-effectiveDetailed view
before cleaning
Detailed view after
cleaning
ness and flexibility. And we create significant added value for!
Thanks to our extensive knowledge in developing cleaning processes we have an eye for appropriate solutions
for every requirement. Led by advanced project management methods, using carefully selected components and
driven by the passion for our craft, we transform your
specifications into durable high-quality systems. With the
utmost precision.
14 | Typical solutions for mold and die cleaning
Typical solutions for mold and die cleaning | 15
Manual systems type "Poly" – for smaller
Cleaning system with automatic lifting device
molds and dies
including vertical movement of goods
The system type "Poly" is built of polished stainless
The semi-automatic mold cleaning process enables
steel or chemical-resistant “polymer”. It is designed for
automatic immersing and lifting, as well as the movement
cleaning smaller dies and molds. Equipped with an
of molds and dies during the cleaning process. The
oil separator and oil skimmer, it adequately removes
transfer from one tank to another is performed on rollers
residuals, grease, oil or general contaminants. The
manually. Depending on the cleaning requirements, a
baskets for / dies / molds / mold inserts are exchanged
function for vertical movement can be integrated. The
manually.
system can be equipped with an overflow chamber
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Konservieren
featuring integrated pump- and filter circulation, oil sepaUS-Reinigung
Abblase-Station
Konservieren
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15-02-11-KKS-FORM-E01
Typical solutions for mold and die cleaning
Trocknen
rator and oil skimmer, as well as an integrated hot air dryer.
Process layout:
Ultrasonic cleaning
Process layout:
Rinsing
Conserving
Blowing off
Ultrasonic cleaning
Manual cleaning systems type "NW"
Rinsing
Conserving
Automatic linear systems type "Lift-Shift"
with separate hot air dryer – for medium-sized
The molds / dies are cleaned in a fully automated
molds and dies
process, which is operated by using an SPS control unit.
The manual system type "NW" is designed to clean
This enables consistent process parameters and the
medium-sized to larger dies and molds. Based on
highest level of reproduction potential and productivity
customer request it is available with a separate hot air
of your mold and die cleaning process.
dryer up to 200°C – or with an integrated unit as a
This system is equipped with an overflow chamber
component system. An operation panel placed on an
ergonimical position simplifies system operation
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Konservieren
featuring integrated pump- and filter circulation, oil
Abblase-Station
Trocknen
and monitoring of process data.
separator and oil skimmer. The blowing off station
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Konservieren
Abblase-Station
(image on the right) is operated manually.
Process layout:
Ultrasonic cleaning
Hot air drying
Process layout:
Rinsing
Conserving
Blowing off
Hot air drying
Ultrasonic cleaning
Rinsing
Conserving
Blowing off
KKS Ultraschall AG
Swiss Quality
Frauholzring 29
P.O. Box 168
CH-6422 Steinen
Phone +41 41 833 87 87
Fax +41 41 832 25 50
info@kks-ultraschall.ch
www.kks-ultraschall.ch
www.kks-ultraschall.ch
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