Our Pyrolysis Burn-Off oven has now been in action for 12 months and it has been a huge success. We go above and beyond what the competition offers for a holistic, multi-stage cleaning process using the oven and some supporting processes. The results have been fantastic and we have many satisfied customers from the past year.
Over this time, we have cleaned everything from filters and spinnerets to jigs, extruder screws and over parts – we have even cleaned baking trays with superb results. The industrial parts cleaning process removes baked-on paints and plastics, as well as stubborn food residue that cannot be removed any other way. Some of the jobs completed have left items looking as good as the day they were bought.
The importance of clean industrial parts
When your industrial parts are kept clean to the highest possible standards, your business saves time and money, not to mention a lot of hassle. Our holistic approach with varied cleaning techniques will vastly reduce your spend on consumables and allow you to focus on productivity. Whether your contaminants are paints, plastics, food or anything else, we have a solution with our pyrolysis burn-off oven and complementary processes that will work for you.
We do it all in-house with our cutting-edge equipment and guarantee fast results that will impress right down to the finest detail. We also bring a wealth of expertise and experience to the table to ensure even the most challenging contaminants will never cause delays.
What makes the Sonic Solutions pyrolysis burn-off special?
Most companies offering this service focus on a quick burn in the oven followed by a basic clean with a jet wash. Our process involves a much slower burn in the oven, aimed at protecting the underlying metal via slower heating and cooling. We have a wealth of understanding about the temperatures required to tackle different contaminants on the items, so we will tailor the process to your needs.
After the heating process in the oven is complete, we undertake various complimentary cleaning processes such as:
Ultrasonic cleaning, perfect for removing contaminants like oil and carbon on your items.
Vapour blasting, where compressed air is mixed with an abrasive media in a water solution, removing more contaminants whilst leaving a smoother finish after completion.
Jet washing, using a state-of-the-art top-loaded Vixen jet wash to clean different sizes and shapes of parts.
We find that through balanced combinations of those complimentary cleaning methods, we can get the best possible results whilst cutting down on the time taken and the chemicals used.
A year of high-quality pyrolysis burn-off
The introduction of this burn-off oven has been a huge success for Sonic Solutions. We have developed our own processes to maximise efficiency and can offer significant cost savings against many other methods of cleaning. Plus the lack of hazardous chemicals or waste disposal makes it a very eco-friendly solution.
We are passionate about delivering nothing but the highest standards with our thermal stripping service. When you outsource this process to us, you are guaranteed fast, high-quality results and you will free up your own skilled workers to focus on the core tasks for your business.
Inferior cleaning can harm the performance of your equipment. It can also lead to problems that cause downtime and loss of your income. The last 12 months have shown that our processes are highly effective for a wide range of equipment and materials – the results speak for themselves and we have glowing testimonials from countless satisfied customers.
Contact our expert team at Sonic Solutions today and book a free trial clean to get a taste of what we can do for you.
Keeping industrial parts cleaned to the highest standards means your business can save time, hassle, and money. With the right cleaning techniques, you can eliminate excess spend on consumables, reduce downtime and improve both productivity and quality. At Sonic Solutions, we are specialists in cleaning key parts and machinery in the paint industry and we’ve put together this expert guide to handling paint contamination and the solutions available.
The Paint Contamination Problem
Manufacturing paint and polymer coatings involves many different parts, including pipework, nozzles, valves, mixing vessels, filters, conveyor belts, receptacles, and jigs. All of these parts will get dirty with time, as paint residue collects and accumulates on their surfaces. This accumulation of paint and polymer residue causes numerous problems and issues in production, quality, and finance. Some of the most common issues we see caused by this build up are:
The passage of the product or part can quickly become restricted, slowing throughput unless flow rates are increased.
To compensate for restricted flow, pressures and flow rates must be increased. In turn, this raises further issues of safety as pressures rise to potentially dangerous levels, and process control reduces as the flow rate increases.
As control reduces it means that quality begins to suffer, and solid particulate risks are introduced into the end product.
Any build up of organic material in the process risks the development of bacteria, which is both a health and a quality issue.
If the accumulation of residual product is not properly addressed and resolved, then it will lead to a complete shutdown of equipment.
It is inevitable that cleaning or replacement of these dirty parts will need to take place at some stage. However, not only can these parts be extremely expensive, but they are also often bespoke, manufactured abroad and on extremely long lead times, making their replacement a financial, logistical and production nightmare.
Ultimately parts need to be cleaned, can you do this in-house?
The short answer is yes and the majority of businesses will look to clean parts themselves as the first option, especially if the cost of replacement is high or the lead time on replacement is long. It might seem like the perfect solution, but in house parts cleaning operations are often not as simple and painless as people think. The problems and pains of in-house cleaning are plentiful, including;
Cleaning these parts is often a multi-stage process, employing a range of cleaning methodologies, equipment, and chemistry. To take on such cleaning in-house would require significant investment in both equipment and experienced personnel, together with making the space and services available to accommodate the additional process.
Each different part has different cleaning requirements, and these variable needs make the process even more challenging for an in-house team. Some parts require simple cleaning, while others need a more complex procedure to keep them running well.
Setting up and running a cleaning facility is usually outside the experience of most production personnel, with the result being that the cleaning results they deliver are disappointing.
Outsourced Parts Cleaning For The Paint Industry
A sub-contracted cleaning operation, particularly when part of a planned maintenance programme, can be extremely effective in both time and money compared to the alternatives of replacement parts or in-house cleaning. Paint can be removed by a number of methods, including pyrolysis (also known as burn-off), chemical stripping (usually either solvent based or highly caustic), or media blasting (using sand, glass, a metallic oxide or soda crystals, either in dry form or within a water jet).
Pyrolysis: This method essentially burns off the paint from the parts. It Involves gradual heating of the part in an oxygen deprived environment to reduce the paint or polymer to an inert ash, the volatile hydrocarbon elements evaporating and reducing to carbon dioxide and water.
Harder metals like steel and copper will not be adversely affected by this and there is complete removal of the contaminant with only inert residual ash being left. This can then be removed using jet washing and/or ultrasonic cleaning.
Metals may be discoloured by exposure to high temperatures, although their physical and chemical properties are unlikely to be adversely affected by this. Of course, if there are a variety of metals within a part, or some non-metallic attachment like seals, linings and electrical components these may be damaged by the process.
Chemical Stripping: Most paints can be removed by either solvents or caustic based solutions. Through a combination of dissolving and lifting the paint from the metallic surface they can remove paints and polymers satisfactorily.
However, most modern paints are designed to be relatively resistant to water and common day chemical substances so increasingly strong and aggressive chemistry is needed to remove them. This has clear implications for their handling and usage, with special precautions and procedures required to comply with health and safety regulations. This often creates issues within the process plant itself where the necessary chemical cleaning regime conflicts with the core production process.
Media Blasting: Blasting small particles at high velocity and pressure is a popular way of removing paints from a hard surface. The media used can vary from silica, sand, metallic oxides, glass beads, baking powder, or dry ice/frozen carbon dioxide pellets. The media will be chosen to be aggressive enough to remove the paint coating but without damaging the underlying material. It may be applied “dry” propelled by compressed air, or “wet” carried within a waterjet.
This is a hard call, especially as paints become more durable, requiring ever greater force to remove. The other big issue with media blasting is actually reaching all the surfaces that require cleaning. Complex geometry and internal openings and channels often mean the contaminating paint cannot be fully removed.
At Sonic Solutions, we offer all the above cleaning solutions. For the removal of paint, our specialists’ preferred method would usually be pyrolysis, unless there is a specific reason not to. Done correctly it removes all contaminating paint without damaging the item itself, leaving the bare metal for any future process.
It should be added that the majority of the time, the burning is only the first stage of the complete cleaning process, usually followed by a combination of jet washing, ultrasonic cleaning or even a further media blast, to leave a completely clean metal surface. At Sonic Solutions, we are able to offer a unique cleaning process compared to both in-house cleaning and other subcontract cleaning operations as we use a variety of cleaning processes to achieve the desired level of cleanliness.
Our cleaning expertise and experience combined with our flexibility and desire to deliver what the customer wants, when they want it, explains why some of the biggest and most demanding paint manufacturers like PPG, Dow, and Dupont rely on us to get rid of their unwanted paint residue from working parts.
To see how the process works, watch us in action.
At Sonic Solutions, we are experts in industrial parts cleaning and we are here to help! We are more than happy to explore, advise and assist with whichever option works best for you and can offer hire or finance options. Contact our expert team today to discuss your requirements in more detail.
It has been an interesting couple of months at Sonic, and indeed for most of the world! Apart from surviving Covid-19 (so far !!) we are proud to announce that we now offer a pyrolysis/Burn-off/thermal stripping service, which will allow us to serve you EVEN better. More on this subject later. For those who don’t know what pyrolysis is I will try to explain what it is, and more importantly what benefits it gives you.
What actually is Pyrolysis? 🤔
Pyrolysis is the thermal decomposition of materials at temperatures between 310 and 540 C (depending on the contaminant to be removed) in an inert, oxygen-deprived atmosphere. Undergoing this process organic substances like paints and plastics are decomposed to produce volatile organic compounds, hydrocarbons and a solid inert ash residue. These volatile products and hydrocarbons are then reduced to inert gases and vapour through exposure to temperatures of 700 to 900 C in an “afterburner” normally placed on top of the pyrolysis oven. The solid ash residue is normally either left on the floor of the oven or lies on the surface of the item and can be easily removed through jet washing or ultrasonic cleaning.
What benefits does burning give? ✅
Where heavier metals need to have coatings of paints, polymers or plastics removed it is a far quicker, safer, cheaper and more effective way of bringing them back to bare metal than the alternatives of chemical and abrasive treatments. The controlled rise, holding and then reduction in temperature over an extended period in the absence of oxygen reduces the risks of combustion and the stresses on the metal due to rapid expansion and contraction. This means the coating is completely removed WITHOUT DAMAGING the item itself.
What can burning actually clean? 🔥
Pyrolysis is typically used to clean products or production components like extruders, spinnerets, static mixers, pipes, valves, even rejected parts that need re-coating, that are coated in paints, polymers or plastics such that they cannot perform their function.
We will be releasing more information over the coming weeks regarding our new service, helping us serve you better for years to come. Sonic Solutions are the UK’s leading ultrasonic cleaning service and following our extension of cleaning services to include jet washing and vapour blasting we are now offering thermal cleaning 👍.
Welcome to the Sonic Solutions Knowledge Center. This is the Go-To resource for Industrial Ultrasonic & Parts Cleaning and is updated regularly. If we haven’t already written about a particular aspect of Industrial Ultrasonic Cleaning, Pyrolysis, Thermal Stripping, Media Blasting or Jet Washing that you’re interested in, then please submit your enquiry here and one of our Industrial Cleaning Experts will take a look.
We approached Sonic Solutions after our parts manufacturers let us down and wasted precious time by supplying oily parts. Not only were they friendly, helpful and happy to rush our parts through - the quality was unbelievable! They arrived back at our factory just in time to not hold up production and we couldn't recommend them highly enough.
Our company AssetCool found the entire team at Sonic Solutions to be responsive and incredibly supportive of a new project. Their technical knowledge is superb, and they delivered exactly what they promised. We're very happy to recommend them to anyone with ultrasonic cleaning needs, and look forward to working with them again in the future.
I reached out with a problem to various companies prior to talking with Sonic Solutions, most were unhelpful. These guys insisted on the first trial being for free! The job was excellent and the turn around time very impressive. We are now setting up a monthly cleaning regime with them. A joy to deal with.
The 2021 Ultimate Guide to Industrial Ultrasonic Cleaning
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