Industrial (Plastics Recycling)

Business need

A major recycling company in the midlands had a major issue when processing plastic scrap for recycling. They use a type of filter to recirculate air in the reprocessing machine. Over time as the process reduces the plastic into smaller and smaller pieces the particles get trapped and block the filter, rendering them useless. Unable to clean them effectively they were discarded after 2 uses at great cost to the company.

Our role

The recycling company found Sonic Solutions online and contacted us hoping we could help. We followed our normal process of enquiring about the contaminant, the material type of the item to be cleaned, and the level of cleanliness required for the next process, followed by a free trial clean.The results from the trial were outstanding and the client was so impressed he quickly sent an entire batch up for us to clean.

The outcome

A HUGE direct cost saving of over £75,300 per annum on replacement filters. On top of these direct cost savings their engineering support manager reported increased productivity totalling over 20% from the recycling lines using the cleaned filter discs compared to the blocked old discs. His only comment on the value of this increased productivity was a smile!

Other reported benefits included;

• Improved quality and consistency of finished product;
• Increased reliability of production output;
• Higher capacity allowing quicker delivery;
• Improved ability to increase output in response to demand;
• Higher customer satisfaction from a more consistent product.

As concluded by the Engineering Manager “All in all a massive win for us, reducing costs and increasing revenue simultaneously in a very competitive market.”

Business need

Light aircraft like Cessna and Hawker Beechcraft have a specialised heat exchanger that periodically blocks up internally with carbonised oils and greases. and externally in the fine aluminium heat dissipating fins from airborne particulates. Aircraft are grounded if the heat exchange system is not passed as airworthy, potentially costing a few thousand pounds a day.

Our role

The cleaning of grease and particulate from hard to reach places is almost custom-made for ultrasonics, but there were 3 considerations with this job. Number 1 was that the fins were very easily damaged being made of thin aluminium and damage is irreversible. Number 2 was we can’t use the usual, heavy alkaline degreasing chemicals we would normally use since these react with aluminium. Number 3 was we had a rigorous cleaning standard from Honeywell, the heat exchanger’s manufacturer, to adhere to. We therefore opted for a slightly longer and more careful clean with an aluminium friendly solution containing water miscible, non-aromatic solvents. We monitored the progress throughout the process taking extra care when handling not cause any damage. Finally an extensive flush through to remove any remaining loose particulate, check flow rates through the internal pipework, and remove residual smells of the cleaning chemical as the unit heats up.On occasion we have also cleaned associated ducting, pipework, gauges and valves using the same basic process, and with the same successful outcome.

The outcome

The final results were impressive. A combination of ultrasonics, light water jetting, and flushing restored the heat exchanger to airworthiness within the 3 day period allocated for ground maintenance. Asides from the cost of a new heat exchanger, multiple thousands, the additional cost of waiting for a replacement were avoided. Whilst not a frequent customer it is telling that Sonic Solutions have been cleaning these heat exchangers for over 10 years through 3 reincarnations of the aircraft maintenance Company, with the same personnel returning to us each time ! We also learnt how best to handle heat exchangers with a similar configuration and over the last 10 years have repeated this process with the same successful outcome.

Business need

A large UK printing company coating auto fabrics were having a problem with the coating curing onto their chtome anilox roller and blocking the cells. It was proving impossible to clean by hand so they were having to throw their 2 metre chrome rollers at a rate of 2 per month. The cost was becoming prohibitive but the tough coating was unable to be removed by any of their existing suppliers so they were seeking an alternative to both reduce replacement costs and production downtime.

Our role

We offered to do some free trials for the printing company. We have anilox rollers in house and have done hundreds of trials with inks, dyes and coatings over the years so we’ve developed an extensive catalogue of what does and doesn’t work. After receiving a sample of the coating that they use we set up our test roller and applied the coating. On this occasion we were unable to remove it with any of our normal range of cleaning solutions, but noticed a combination of 2 chemicals did have some success. Working with our chemists, we developed a new mix of these solutions, which we then successfully trialled on an “uncleanable” roller from the customer.

The outcome

Once a successful cleaning process has been developed it is then a matter of economics and process requirements whether it is better to subcontract the cleaning or for the customer to acquire the equipment and chemical together with the know-how and do it themselves. Due to how frequently the chrome rollers needed cleaning they opted for their own tank and the cleaning chemical we had developed, together with a commissioning at which we trained them in the cleaning process. Since our partnership began, they have never had to replace a roller due to that coating not being able to be removed saving them over £4000 per month and preventing lengthy downtime as rollers are recoated. As a recurring theme of using what we learn in new areas, we have since used and recommended the new cleaning chemical to other customers with similar issues.

Business need

A leading Scottish oilfield technology company make electrical sensors for the artificial lift systems sector of the oil industry. These sensors are housed in metal casings and subjected to extreme heat and pressures so any particulate or hydrocarbon contamination remaining on the metalwork from its manufacture would be potentially disastrous for the functioning of the electrical boards and circuits. The cost of testing failures was running at unacceptably high levels when they contacted us for a solution. The alternative of in-house cleaning to an acceptable standard had been found to disrupt the production schedule, unpopular with the workforce and not very effective.

Our role

They approached us to clean the cutting oils and swarf from the highly specialised precision engineered parts to a high cleanliness specification. The also required us to package the cleaned parts to prevent contamination during transport and storage, so the parts were ready to go straight into assembly when needed. After the initial successful trials they now ship thousands of these parts to us requiring large scale cleaning without sacrificing the standard of cleanliness. Rigorous systems, processes and training of personnel has ensured we have fully supported our customer as they have dramatically expanded their operations over the last 2 years.

The outcome

The feedback we got from our customer was fantastic. All parts have reached the required levels of cleanliness to the point that the company now use our process as a benchmark for determining the level of cleanliness needed for other parts they manufacture going into similar harsh environments. Costs of testing failures are now minimal, saving tens of thousands of pounds, and improving delivery reliability to customers. Our relationship with this Company continues to thrive as we work with them to support their ambitious growth and development going forward.

Business need

One of the UKs leading Rail operators had an issue regarding the large electronic cables, power sockets and internet lines that run between the train carriages. The parts need maintenance to continue functioning safely and efficiently but are so incredibly covered in contaminants of all sorts that the engineers couldn’t work on them.

Our role

This type of job, where the parts have layered soiling on a variety of materials often requires a variety of treatments, involving soaking and jet washing as well as ultrasonics to remove the dirt trapped in the grooves and small apertures. Also with electrical use complete drying inside and out is essential, requiring a prolonged and multi stage drying process involving compressed air and drying cabinets.

The outcome

One of our favourite before and after picture jobs as the results are so incredible. It is quite a shock to see how well they do come out and something we are very proud of here at Sonic Solutions. We now receive weekly shipments of the parts and the rail company is one of our best customers. The engineer’s feedback was incredible, they can now work on and maintain the electronic parts restoring highly complex and expensive parts to full working order, saving over a hundred thousand pounds a year.

Business need

One of the largest oil companies had a problem with one of their oil wells. This oil well had a very high sulphur content which made the separation of oil from sea water using hydrocyclones very difficult. The solution created a thick sludge inside the hydrocyclones that built up over time to such an extent that they could not perform the job at all, requiring an expensive replacement of the hydrocyclones to avoid bringing the entire multi-million dollar operation to a standstill.

Our role

At the time the oil company called Sonic Solutions, we hadn’t heard of a Hydrocyclone before, but after explaining the problem, material type and the contaminant we had a good idea of how we could help. They sent around 50 Hydrocyclones, all heavily contaminated and the problem was clear. We hadn’t quite expected just how difficult this greasy sludge was going to be to remove, but after a little trial and improvement we got the chemistry and cleaning process perfected, and managed to free up the parts from all the sulphur ridden oily contaminant.

The outcome

The highly expensive and niche parts no longer needed replacement when soiled, saving valuable time and money, estimated in the tens of thousands of pounds. The oil company now has a way of dealing with this issue and can rely on Sonic Solutions for anything else they should encounter down the line. As always from new situations we have also gained new knowledge and techniques for future work.