Industrial Cleaning of Heat Exchangers, Cleaner Systems, Better Performance

Business Need

Heat exchangers are vital to industries ranging from energy and manufacturing to food processing and HVAC. But over time, even the most robust systems suffer from scale build-up, fouling, and contamination that reduce efficiency and increase running costs.

A range of clients recently approached Sonic Solutions for help maintaining and restoring their heat exchangers. In each case, operational performance was being compromised by internal deposits, from stubborn mineral scale to baked-on hydrocarbons.

Time was a critical factor. Cleaning needed to be fast, thorough, and safe, with minimal disruption to the client’s schedule.

Our Role

Using tailored ultrasonic cleaning methods, we removed hard deposits and fouling from even the most awkward internal surfaces. Our systems reach deep into tubes and crevices that traditional cleaning can’t, without the need for disassembly or aggressive chemicals.

Whether working with small precision units or large industrial-scale heat exchangers, our approach delivered consistent, high-quality results.

The Outcome

In every case, the cleaned heat exchangers were returned to service with improved thermal efficiency, extended lifespan, and lower risk of unplanned downtime. Clients reported measurable performance improvements and reduced maintenance overheads.

From preventative maintenance to emergency restoration, Sonic Solutions delivers the cleaning power heat exchangers need, with no mess, no damage, and no delays.

Business Need

One of the UK’s leading leather manufacturers based in Peterborough approached Sonic Solutions with a major challenge – 147 dust filters, all heavily packed with leather dust and residue from high-volume production.

In a manufacturing environment where cleanliness directly impacts product quality and workplace safety, these filters needed a thorough clean to keep the site running smoothly and to meet hygiene standards.

Our Role

We arranged for batch collection and applied a tailored ultrasonic cleaning process designed to break down and lift embedded leather dust from deep within the filter material and housings.

Our cleaning method ensured complete removal of fine particulate matter without damaging the structure or integrity of the filters – a key concern when dealing with specialised equipment used in premium goods manufacturing.

The Outcome

The filters were returned in pristine condition, helping our client maintain a clean production environment and avoid costly replacements. With quick turnaround and reliable results, they can continue crafting high-end leather products with confidence.

Whether you have 1 or 147 filters needing attention, Sonic Solutions is ready to help.

Business Need

Our client recently sent in a batch of precision-stamped stainless steel components that had become marked during the drying process. Although freshly manufactured, the parts arrived with stubborn water stains that affected both their visual appearance and overall finish quality.

As these parts were headed for further assembly or possible end-use, a spotless presentation was essential. The goal was to remove all residue without damaging the surface integrity or requiring manual abrasion.

Our Role

We assessed the level of surface staining and opted for a fast, non-contact solution using our ultrasonic cleaning tanks. The parts were submerged in demineralised water and treated with our proven ultrasonic process to lift and disperse the marks evenly.

This approach avoided any scrubbing or harsh chemicals, preserving the stainless finish while eliminating all water spots and residues.

The Outcome

In just one cycle, the parts were fully restored to a clean, polished condition, ready for packaging, dispatch, or onward use.

The client received consistent, contaminant-free results with zero risk to part geometry or finish. It’s another example of how ultrasonic cleaning delivers fast, effective results without compromise.

Business Need

Our client Ian Bartlett, a private collector and restorer of antique musical instruments, initially approached a professional instrument restorer for help with a 200-year-old Schwieso Grecian concert harp, crafted primarily from brass. He was quoted £1,500 for the cleaning alone.

Seeking a more cost-effective but equally careful solution, he reached out to Sonic Solutions, trusting our reputation as industrial cleaning specialists to handle the delicate restoration of this rare artifact — one of only around 900 ever made.

The harp was heavily tarnished and corroded due to centuries of exposure, with surface contaminants that required removal without damaging the original metalwork or intricate detailing.

Our Role

We designed a bespoke two-step cleaning process tailored to the harp’s brass components. First, we applied a controlled acid treatment to break down oxidation and corrosion from the surface, safely revealing the underlying brass without aggressive abrasion.

Then, using our ultrasonic cleaning technology, we gently removed all loosened residues and contaminants from the detailed brasswork and delicate fittings. This method ensured a deep, thorough clean while protecting the harp’s structure and craftsmanship.

The Outcome

The restoration revealed the original brilliance of the brass and preserved the fine historical details of this rare musical instrument. The client was delighted to have the harp cleaned and stabilized for just £350 — a significant saving compared to the £1,500 quoted by traditional restorers.

Our work provided a museum-quality result at a fraction of the cost, ensuring this unique piece of history can now be appreciated for generations to come.

Business Need

Calderdale Museum in Halifax, a volunteer-run institution, reached out to Sonic Solutions as part of their mission to restore a 300-year-old wool comb machine — set to become the only working one of its kind in the world.
At the heart of this restoration was one of the machine’s large circular combs, a key component covered in decades of grime and oxidation, with hundreds of razor-sharp pins that made handling and cleaning both hazardous and delicate.
With limited funding and a strong commitment to historical preservation, the museum needed a cleaning partner who could balance expert care with cost-effectiveness.

Our Role

We were proud to support this heritage project by offering our ultrasonic cleaning services at a specially reduced rate, recognising the museum’s volunteer-led nature and the cultural value of the restoration.
Using our ultrasonic cleaning systems, we carefully removed built-up contamination from the comb without damaging the fine brass structure or the sharp metal pins.
Special safety protocols were followed to clean around the pins, which were sharp enough to easily pierce skin, requiring precision handling and non-invasive cleaning techniques to preserve both staff safety and the component’s integrity.

The Outcome

The cleaned comb was successfully refitted into the wool combing machine, and we’ve since received images from the museum showing the machine fully assembled and running for the first time in centuries.
This restoration didn’t just bring a historical artifact back to life — it restored a piece of living industrial heritage, made possible by volunteers and supported by our specialist cleaning team.
We’re proud to have played a part in preserving British textile history and helping the museum make it accessible for future generations.

Client Testimonies

Some words from Roger swift…
“We used Sonic Solutions a few weeks ago to clean one very large wool combing circle and four small ones at the Calderdale Industrial Museum, they were virtually impossible to clean by hand as they were very intricate and easy to damage and no replacements were available at all. We contacted Ryan at Sonic Solutions and he was happy to undertake the job. He arranged the collection and delivery as we didn’t have a vehicle large enough to accommodate them. We were all so impressed with the quality of the finished job, they look like new, and as we are an industrial museum it is very important to us. We hope to have the machine up and running shortly and we believe it will be the only Noble Comb still running in the country, possibly in the world. Many thanks to Ryan and the team at Sonic Solutions, great job!”

Some words from Ian Christie…
“Sonic help led us out at the calderdale industrial museum, great thanks to them, as we struggled to find a way of cleaning the old parts of a 19th century wool combing machine, very professional and friendly service”

Business Need

Our client Clearfield Envirotech who are a plastics recycling company, urgently needed specialist cleaning for their unbranded plastic filtration sets used in an EREMA system. Upon inspection, we found an unprecedented level of metal contamination — screws, nails, and wire were embedded within the blade housing.

The volume of contamination was far beyond typical levels, posing serious risks to operational efficiency, product quality, and equipment lifespan. With two sets sent to us at a time, it was crucial to fully restore the housings to safe, clean, and functional condition to keep their recycling processes running smoothly.

Our Role

Sonic Solutions tackled the extreme contamination challenge with a two-stage specialist process. First, we used pyrolysis to safely and effectively burn off all residual plastic material from the blade housing. This crucial step exposed the deeply embedded metal contaminants like screws, nails, and wire.

Following pyrolysis, we applied our ultrasonic cleaning processes, using precision cleaning techniques to loosen and manually remove all remaining metal debris(we are able to scoop out the contamination

The Outcome

We successfully restored the blade housing to its original working condition, ensuring it was clean, safe, and fit for purpose. Our intervention prevented potential damage to the client’s machinery and significantly reduced the risk of downtime and costly repairs.

The client can now confidently maintain production quality and efficiency, backed by the reassurance of a thoroughly decontaminated and restored set.