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Ultrasonic Horn Processors

Ralsonics’ industrial ultrasonic processors are powerful tools for large scale 24X7 processing. Multiple processors can be connected in series or parallel to scale up to any volume required. Our efficient processors ensure that processing time is minimized ensuring much lower processing costs. All our industrial processors are customized to your exact requirements ensuring zero compromise on your process.

 

Ultrasonic Horn Processors are high-power ultrasonic devices designed to deliver intense acoustic energy into liquids and semi-solid materials for applications such as homogenization, dispersion, emulsification, cell disruption, degassing, and sonochemistry. Unlike conventional ultrasonic cleaners, horn processors use a probe (horn/sonotrode) to directly transmit ultrasonic energy into the sample, achieving maximum efficiency and intensity.

 

Ralsonics’ Ultrasonic Horn Processors are engineered with state-of-the-art digital generators, robust transducers, and precision-machined horns, ensuring unmatched performance for both laboratory research and industrial-scale processing.

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How It Works

  • A piezoelectric transducer converts electrical energy into mechanical vibrations.
  • These vibrations are amplified through a horn (sonotrode).
  • The horn is immersed in the liquid or sample, delivering high-frequency ultrasonic waves.
  • The resulting cavitation effect generates microscopic shockwaves that disrupt particles, break cells, and mix substances at the molecular level.

Key Features

  • Direct Energy Transmission – Ultrasonic horn delivers power directly to the sample.
  • Digital Control System – Adjustable amplitude, time, and pulse modes for precise process control.
  • Wide Power Range – From 100 W (lab scale) to 5000+ W (industrial scale).
  • Frequency Options – Typically 20 kHz (high intensity) to 40 kHz (delicate processing).
  • Temperature Monitoring – In-built safety to prevent overheating of samples.
  • Custom Horns (Sonotrodes) – Available in different sizes and materials for specific applications.
  • Automation Ready – Can be integrated with automated production systems or reactors.

Advantages

  • High Energy Efficiency – Direct delivery of power into the sample.
  • Versatility – Suitable for liquids, suspensions, and semi-solid samples.
  • Precise Control – Adjustable amplitude and programmable modes.
  • Scalable– From benchtop lab models to large-scale industrial units.
  • Effective Cell Disruption – Extracts proteins, DNA, and other biomolecules without chemicals.
  • Enhanced Reaction Rates – Accelerates chemical processes in sonochemistry and nanoparticle synthesis.
  • Compact Design – Space-efficient and easy to integrate into workflows.

Technical Specifications (Typical Range – Customizable)

Parameter Specifications
Parameter Specification
Operating Frequency 20 – 40 kHz
Power Output 100 W – 5000+ W
Amplitude Control 10% – 100% adjustable
Horn (Sonotrode) Sizes 3 mm – 40+ mm diameter
Material Titanium / Stainless Steel
Control System Digital / PLC / Touchscreen
Cooling Options Air-cooled or water-cooled
Safety Features Overload protection, auto shut-off
Modes Continuous / Pulse

Applications

  • Life Sciences & Biotechnology – Cell lysis, protein extraction, DNA/RNA shearing.
  • Nanotechnology – Nanoparticle dispersion, synthesis, and size reduction.
  • Pharmaceuticals – Preparation of emulsions, suspensions, and drug delivery systems.
  • Food & Beverages – Homogenization, emulsification, and extraction of active compounds.
  • Chemistry & Materials Science – Sonochemistry, degassing, and catalytic reactions.
  • Environmental Science – Treatment of sludge, soil samples, and pollutant breakdown.
  • Industrial Processing – Large-scale emulsification, dispersion, and mixing.

Features

Auto-tuning frequency

Microprocessor controlled frequency

Digital Timer

Set and control the process time

Optional Features

Adjustable power

Control ultrasonicator power for different applications.

Burst/pulse mode

Prevent hot zones in temperature sensitive samples

Additional tips

Complete control over all process variations required

Flow cell

Sonicate larger volumes

Water Cooled Transducer

Increase transducer life for higher power

Coloured touchscreen

Access all features easily

Temperature control

Set and control the process temperature

Programmable Control

Complete control over all process parameters

Foot switch

Prevent transducer overheating in high power applications

“FAQs”

FAQ Accordion
Q1. How is an ultrasonic horn processor different from an ultrasonic bath?

Unlike ultrasonic baths that deliver indirect energy through water, horn processors transmit ultrasonic energy directly into the sample, resulting in higher intensity and efficiency.

Q2. Can ultrasonic horn processors be used for delicate biological samples?

Yes, by adjusting amplitude and using pulsed sonication, cell disruption can be performed without damaging sensitive biomolecules.

Q3. What materials are horns (sonotrodes) made of?

Horns are typically made from titanium or stainless steel, depending on the application.

Q4. Are these systems scalable for industrial production?

Yes. Ralsonics offers lab-scale benchtop units as well as high-power industrial processors.

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