Sonicator – Hielscher Ultrasonics | Lab to Industrial Scale
Our digital probe sonicators cover lab bench, pilot, and full scale production so you can transfer amplitude, energy per volume, and process time with confidence. Real time monitoring and automatic data logging document every run for GLP, GMP, and investor diligence. Modular accessories allow you to move from open beakers to closed flow cells, temperature controlled reactors, and inline production skids as throughput grows. With responsive application engineers and global service, Hielscher makes it straightforward to validate, optimize, and scale ultrasonication. Ready to choose the right sonicator for your process? We are here to help.
Hielscher Sonicators: Power for All Volumes and Processes
Our probe type sonicators cover the full range from hands on lab work to high volume industrial processing. Power classes span compact benchtop tools through multi kilowatt inline reactors, so you can begin with small development batches and scale to continuous production on validated parameters.
Sonicator UP400St (400 Watts)
Hielscher Sonicator UP400St
Lab Sonication and Process Development
The compact and robust sonicator UP400St delivers when you need reliable ultrasonic power in beakers, small batches and pilot scale flow trials. Batch volumes reaches up to about 8 liters (2 gallons), and with flow cells you can process larger volumes per hour, making it a practical bridge between process development and small production runs. Typical applications include: Botanical extraction, product formulation and particle size reduction. Digital touch screen control, integrated SD card data logging, Browser remote control, temperature monitoring, and interchangeable sonotrodes support method development, documentation, and smooth transfer from research and development to small production runs.
Sonicator UIP1000hdT (1000 Watts)
Hielscher Sonicator UIP1000hdT
Process Optimization and Production
The UIP1000hdT is the perfect sonicator for process development, optimization, and medium batch or continuous flow processing. It delivers high ultrasonic power into pressurizable flow cells or open vessels for emulsification, dispersion, extraction, and sonochemical reactions, covering the gap between small lab systems and multi kilowatt production lines. Parallel clustering extends throughput when needed. Fully digital with touch screen control, SD card data logging, remote control via Ethernet, temperature and pressure monitoring, and a broad sonotrode range enable systematic parameter studies, and smooth transfer from first sonication runs to validated manufacturing.
Sonicator UIP16000hdT (16000 Watts)
Hielscher Sonicator UIP16000hdT
High Performance Sonication
The high power UIP16000hdT is the industrial sonicator for large scale inline homogenization, deagglomeration, extraction, and high shear mixing in demanding production environments. It couples massive ultrasonic power into pressurizable flow cells and skid mounted process lines, making it perfect sonicator for full scale throughput. The 16 kilowatts of continuous ultrasonic power support substantial flow rates. Multiple UIP16000hdT units can be clustered in parallel or series to match very high capacity targets. Rugged, heavy duty construction suits 24/7 operation with abrasive slurries, viscous feeds, or reactive chemistries. Easy to control, advanced data logging, various remote control interfaces, and real-time temperature and pressure monitoring give operations teams the traceability and control needed for regulated manufacturing.
| Feature | Probe-Type Sonicators | Bath Sonicators | Conventional Homogenizing Techniques |
|---|---|---|---|
| Energy Transfer | Direct and highly efficient, as the probe directly contacts the sample. | Indirect and less efficient, as energy is unevenly dispersed throughout the bath. | Mechanically driven, often resulting in lower energy transfer efficiency. |
| Precision | Highly precise and individually controllable, allowing for targeted application of energy. | Less precise, with energy distributed across the entire bath. | Moderate precision, depending on the mechanical setup. |
| Sample Size Flexibility | Effective for small to medium volumes; can be adjusted for various sample sizes. | Best suited for larger volumes or multiple small samples simultaneously. | Varies; often limited by the size and type of homogenizer. |
| Processing Time | Shorter processing times due to efficient energy transfer. | Longer processing times due to dispersed energy application. | Varies; can be longer due to less efficient energy application. |
| Temperature Control | Localized heating can occur; often requires external cooling. | Better for temperature-sensitive applications as the bath can absorb heat. | Moderate control, often requires external temperature management. |
| Scalability | Completely linearly scalable, which facilitates the step from feasibility to industrial production tremendously. | Hard to scale up du to uneven sonication and limitations to bath sizes. | Not easily scalable due to difficulties in maintaining the same process parameters (e.g., pressure, shear force) across different scales, leading to variability in the final product. |
| Cost | Higher initial cost, but more efficient for specialized tasks. | Generally lower initial cost but less efficient. | Varies depending on the equipment and application. |
Flow-Cell Reactors for Sonicators
For industries and laboratories that require continuous ultrasonic processing, Hielscher Ultrasonics offers advanced flow-cell reactors compatible with their powerful probe-type sonicators, including the UP400St (400 watts), UIP1000hdT (1000 watts), and UIP16000hdT (16kW).
Designed for Inline Sonication
Flow-cell reactors are designed to enable efficient inline sonication, where liquids are treated as they pass through the reactor chamber. This setup is ideal for processes that benefit from consistent, reproducible results over long durations, such as emulsification, particle size reduction, or cell disruption. The flow-cells provide an excellent solution for users who need to scale up from batch processing to continuous, high-throughput production.
Key Advantages
One of the key advantages of Hielscher’s flow-cell reactors is their ability to be pressurized, which significantly enhances the cavitation effects generated during sonication. When a liquid is subjected to ultrasonic waves, cavitation occurs – this involves the formation, growth, and collapse of bubbles, releasing intense energy that disrupts particles or breaks down cells. Pressurizing the flow-cell amplifies these cavitation forces, resulting in even more effective sonication. For the UP400St, UIP1000hdT, and UIP16000hdT, this pressurization capability is crucial for maximizing energy transfer and achieving superior process efficiency, particularly in challenging applications such as the production of nanoemulsions, dispersions, and the extraction of valuable compounds.
Process Optimization
Inline sonication using flow-cell reactors is a process-optimizing technique that offers multiple benefits for high-performance applications and industrial manufacturing. Compared to traditional batch processing, inline sonication ensures a continuous flow of material, allowing for precise control over sonication parameters and better scalability. By avoiding batch-to-batch variability, inline sonication improves product consistency, making it the ideal solution for industries that prioritize high-quality, reproducible results. Moreover, Hielscher sonicators, when used with flow-cell reactors, provide significant time, labour, and energy savings, enhancing overall process efficiency and reducing operational costs. For companies involved in large-scale production or research, inline sonication offers a path to improved productivity, reduced downtime, and superior product outcomes.
Whether you are in a research laboratory or a large-scale industrial facility, probe-type sonicators offer a versatile and effective solution for a wide range of applications.
- high efficiency
- state-of-the-art technology
- reliability and robustness
- adjustable, precise process control
- batch and inline
- for any volume
- intelligent software
- smart features (e.g., programmable, data protocolling, remote control)
- easy and safe to operate
- low maintenance
- CIP (clean-in-place)
Design, Manufacturing and Consulting – Quality Made in Germany
Hielscher ultrasonicators are well-known for their highest quality and design standards. Robustness and easy operation allow the smooth integration of our ultrasonicators into industrial facilities. Rough conditions and demanding environments are easily handled by Hielscher ultrasonicators.
Hielscher Ultrasonics is an ISO certified company and put special emphasis on high-performance ultrasonicators featuring state-of-the-art technology and user-friendliness. Of course, Hielscher ultrasonicators are CE compliant and meet the requirements of UL, CSA and RoHs.
The table below gives you an indication of the approximate processing capacity of our ultrasonicators:
| Batch Volume | Flow Rate | Recommended Devices |
|---|---|---|
| 0.5 to 1.5mL | n.a. | VialTweeter |
| 1 to 500mL | 10 to 200mL/min | UP100H |
| 10 to 2000mL | 20 to 400mL/min | UP200Ht, UP400St |
| 0.1 to 20L | 0.2 to 4L/min | UIP2000hdT |
| 10 to 100L | 2 to 10L/min | UIP4000hdT |
| 15 to 150L | 3 to 15L/min | UIP6000hdT |
| n.a. | 10 to 100L/min | UIP16000 |
| n.a. | larger | cluster of UIP16000 |
Frequently Asked Questions
What is a Sonicator?
A sonicator is a device that uses power ultrasound to agitate particles in a sample, typically in a liquid. This high-intensity ultrasound energy creates rapid pressure changes, leading to the formation and collapse of small bubbles, a process called cavitation. The resulting mechanical forces can break apart cells, disperse materials, or homogenize mixtures, making sonicators useful in fields like biology, chemistry, and materials science for tasks like cell disruption, mixing, extraction and emulsification. Therefore, probe-type sonicators are a well-established technique of homogenization, extraction and wet-milling on lab and industrial scale.
Why Should I Use a Sonicator?
Use a sonicator when you need fast, uniform energy delivery for cell disruption, sample homogenization, and liquid solid mixing. Controlled ultrasonic waves accelerate processes from cell lysis to nanoparticle dispersion and emulsification. With proper cooling, sonication remains a low heat method that helps preserve temperature sensitive materials, making it valuable in labs and manufacturing.
Hielscher Sonicators in Research and Science
Below you can find a selection of scientific articles featuring Hielscher probe-type sonicators in batch and inline operation. The articles span from ultrasonic extraction over dispersion to electrochemistry. If you are looking for a specific application and related scientific references, please contact us.
- FactSheet UP400St – 400 Watts Powerful Probe-Type Sonicator
- FactSheet UIP1000hdT – 1000 Watts Powerful Sonicator for Bench-top and Industry
- Han N.S., Basri M., Abd Rahman M.B. Abd Rahman R.N., Salleh A.B., Ismail Z. (2012): Preparation of emulsions by rotor-stator homogenizer and ultrasonic cavitation for the cosmeceutical industry. Journal of Cosmetic Science Sep-Oct; 63(5), 2012. 333-44.
- Petigny L., Périno-Issartier S., Wajsman J., Chemat F. (2013): Batch and Continuous Ultrasound Assisted Extraction of Boldo Leaves (Peumus boldus Mol.). International Journal of Molecular Science 14, 2013. 5750-5764.
- I. Fasaki, K. Siamos, M. Arin, P. Lommens, I. Van Driessche, S.C. Hopkins, B.A. Glowacki, I. Arabatzis (2012): Ultrasound assisted preparation of stable water-based nanocrystalline TiO2 suspensions for photocatalytic applications of inkjet-printed films. Applied Catalysis A: General, Volumes 411–412, 2012. 60-69.
- Pameli Pal, Jugal K. Das, Nandini Das, Sibdas Bandyopadhyay (2013): Synthesis of NaP zeolite at room temperature and short crystallization time by sonochemical method. Ultrasonics Sonochemistry, Volume 20, Issue 1, 2013. 314-321.
- Almir Draganović, Antranik Karamanoukian, Peter Ulriksen, Stefan Larsson (2020): Dispersion of microfine cement grout with ultrasound and conventional laboratory dissolvers. Construction and Building Materials, Volume 251, 2020.
- Manganiello R., Pagano M., Nucciarelli D., Ciccoritti R., Tomasone R., Di Serio M.G., Giansante L., Del Re P., Servili M., Veneziani G. (2021): Effects of Ultrasound Technology on the Qualitative Properties of Italian Extra Virgin Olive Oil. Foods. 2021 Nov 22;10(11):2884.