1. Abnormal equipment vibration parameters (most common)
(1) Insufficient amplitude: Low amplitude (<15μm) results in inadequate vibration energy. This fails to generate effective interfacial micro-rebound or overcome the material's adhesion; this issue is most common with buttercream, soft cheese, and nougat.
(2) Frequency mismatch/drift: Aging of the transducer or booster, or incorrect assembly torque, causes a deviation from the resonant point. Although the blade appears to be vibrating, the actual effective vibration is minimal; friction increases and localized heating occurs, causing fats or sugars to melt and stick to the blade surface.
(3) Incorrect power matching: Insufficient power prevents clean cutting, while excessive power generates too much frictional heat, causing sugars and milk fats to melt into a sticky liquid that adheres to the blade edge.

2. Issues with the blade itself
(1) Blade wear, dulling, or edge rolling: The contact surface area increases, reducing the self-cleaning effect of the vibration.
(2) Rough blade surface or scratches: Wear or peeling of PTFE/ceramic non-stick coatings leads to direct metal contact with high-sugar, high-fat ingredients, enhancing molecular adhesion.
(3) Incorrect blade selection: The blade profile or thickness is mismatched with the product, resulting in excessive contact area.

3. Material characteristics
(1) High sugar, fat, or moisture content: Examples include buttercream, mousse, soft cheese, toffee, and brownies. Frictional heat from vibration causes slight melting of sugars and fats, forming a sticky film on the blade surface.
(2) High material temperature: Higher temperatures increase the fluidity of fats and syrups, significantly raising adhesion; unchilled soft desserts are much more likely to stick to the blade than refrigerated ones.
(3) High water activity: Moisture can form hydrogen bonds with the titanium alloy blade surface, leading to adhesion.

4. Incorrect process parameters
(1) Excessive downward pressure: Over-compressing the material keeps the blade pressed tightly against it, disrupting the vibration interface. This prevents the vibration from effectively repelling the material and can squeeze out fillings or fats. (2) Mismatched cutting speed: If the feed rate is too slow, the blade remains in the food product for an extended period, causing continuous heat accumulation; if the speed is too fast, ultrasonic energy cannot be transmitted effectively, leading to material stretching and adhesion.
(3) Blade residue: Residue (such as icing or cream) from previous cuts hardens on the blade surface; upon restarting, the heat causes it to melt again, creating a base that promotes further adhesion.

5. Assembly and maintenance issues
(1) Insufficient tightening torque at the connection between the booster and the blade, or contamination on the contact surfaces, leads to vibration transmission loss and a reduction in the blade's actual amplitude.
(1) Poor heat dissipation causes a significant rise in the blade's overall temperature during continuous operation.

Rapid improvement strategies
1. Equipment: Re-calibrate resonance and increase amplitude to the 20–30 μm range to match the specific food product's frequency; inspect the transducer, torque settings, and heat dissipation system.
2. Blade: Grind and repair the cutting edge; replace the blade (using a food-grade PTFE coating) if the coating is worn; clean the blade after every shift.
3. Material: Pre-cool high-sugar and high-fat products to reduce the fluidity of fats and syrups.

4. Process: Reduce downward pressure, optimize cutting speed, and avoid prolonged contact during the cutting process.