Our Hardest Challenge Yet – Aluminum Rods for a Major UK Baked Goods Manufacturer

Business Need

One of the UK’s largest baked goods manufacturers contacted us with a particularly tough problem: their tiny aluminum baking rods had become completely coated with hardened, carbonized dough residue (see image below). This buildup was preventing proper use, risking contamination, and slowing down production.

This was the most challenging contamination we have ever faced ,hundreds of narrow rods, each clogged with thick, baked-on material that standard cleaning methods couldn’t touch.

Our Role

We offered a free trial of our service to prove what we could do. Our approach was methodical:

• Pyrolysis Treatment – We first ran the rods through our high-temperature pyrolysis process to break down the bulk of the contamination.
• Ultrasonic Cleaning – Next, we used ultrasonic cleaning to remove loosened carbon deposits.
• Manual Finishing – Even after these two steps, extremely stubborn carbon still clung to the insides. Our team painstakingly cleaned each rod by hand using steel brushes to completely clear them without damaging the aluminum.

This was a labour-intensive and highly detailed job, requiring precision and patience , but we were determined to succeed.

The Outcome

The rods were fully restored, inside and out, and returned to the client ready for production. The result spoke for itself:

• Every rod completely cleared of baked-on carbon
• Zero damage to the aluminum surface
• Production downtime minimized thanks to our multi-step process

This project was not only a success but also proved our ability to tackle the most extreme cleaning challenges — even with components as small and numerous as these.

Client Testimonial

“We genuinely weren’t sure if these rods could be saved. The level of work your team put in — pyrolysis, ultrasonics, and manual cleaning — was outstanding. We’re very impressed with the results and will absolutely use your services again.”

📞 Want to work with us? Get in touch today!

Business Need

Candle filters are essential for maintaining system performance, but over time they become clogged with stubborn contaminants, this is most commonly heavy carbon buildup and particulate debris.

This fouling restricts flow, reduces filtration efficiency, and forces equipment to work harder, leading to higher maintenance costs and increased risk of downtime.

Our Role

We applied our ultrasonic cleaning techniques with a combination of carefully picked chemicals to restore the filters to optimal condition. The filters were placed in the tanks with slight agitation, where high-frequency sound waves create microscopic bubbles that implode against the surface of the filter elements.

This cavitation action safely but effectively breaks down and removes carbon deposits and embedded contaminants, The filters have deep channels within them but this is not a problem for our ultrasonic cleaning methods as we were able to get them spotless inside and out.

The Outcome

Following ultrasonic cleaning, the candle filters were transformed from clogged and inefficient to crystal clear and fully operational. The restored filters provided improved flow and filtration performance, extended the service life of the equipment they protect, and significantly reduced both downtime and ongoing maintenance costs.

Instead of costly replacements, our customer achieved spotless results through our service proving that regular parts cleaning is cheaper, faster and more efficient than buying new

Business Need

Anilox rollers are critical to delivering consistent, high-quality print results. Over time, ink and coatings become trapped deep within the roller cells. While a roller may look clean to the naked eye, microscopic inspection often reveals residues that compromise performance.

One of the UK’s largest plastic bottle manufacturers recently faced a challenge: a sleeved anilox roller due for repair required precision cleaning. Unlike traditional rollers, sleeved rollers don’t include the side mechanisms that normally support them, making the job far more complex.

With many years of experience cleaning rollers from 30 cm up to 5 m in length, our team brought both skill and adaptability to the task. We applied our proven 5-step cleaning process:

1. Chemical coat to loosen hardened deposits
2. Ultrasonic cleaning to penetrate deep into microscopic roller cells
3. Internal flush to clear contaminants from within
4. Rinse and rub for a controlled, residue-free finish
5. Careful packaging to ensure the roller was protected during transit

Despite the missing support hardware, we engineered a safe, effective method for the sleeved roller and executed each step with precision.

The Outcome

The result was a roller that was not only visibly spotless but also validated under microscopic inspection, proving it was fully cleaned and ready for repair. This successful outcome reaffirmed our ability to handle even the most unusual and demanding roller-cleaning projects.

Client Testimonial

“We were impressed with the precision and care shown in cleaning our sleeved roller. The ultrasonic process gave us complete confidence that the roller was ready for repair—saving us time and ensuring production quality down the line.”
— Senior Production Manager, UK Plastic Bottle Manufacturer

📞 Want to work with us? Get in touch today!

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.