Let Sonic Solutions handle your Pyrolysis, Burn-off and Thermal Stripping
Effectively different names for the same process; the removal of unwanted organic material contamination (paints, plastics, food process waste etc) through heat. Organic materials decompose rather than combust at high temperatures in the absence of oxygen. Heat converts the organic solid into inorganic ash and organic gases. The inorganic ash can then be removed from the item through a wash, and the organic gases reduced to carbon dioxide and water vapour by exposure to very high temperatures in an afterburner.
Sonic Solutions offers 2 options for thermal cleaning:
1: Burn-Off Oven
Our burn-off oven is gas powered and comprises a main burn off chamber, an afterburner for decomposition of waste gases, and a water suppression system to douse any combustion. These 3 elements are managed via a control panel allowing for varied times and temperatures to accomplish the removal of the contaminant without damage to the metal part or the environment. It manages the temperature at all times and maintains the set pyrolysis cycle with little or no operator intervention. Temperatures will typically be set between 420 and 450 centigrade although harder thermosetting materials like PTFE (Teflon) may require higher temperatures. Cycles will generally last for a total of 6 to 8 hours with the oven held at the set temperature from 3 to 5 hours depending upon the volume of contaminant on the items. Heating up is gradual (2-3 hours) to prevent stressing the underlying metal, and likewise cooling down. The main burn off chamber is 3 metres long, 2 metres wide and 2 metres high so can accommodate both large individual items and large volumes of smaller items.
Vacuum ovens use pyrolysis in a vacuum avoiding uncontrolled combustion inside the cleaning chamber. It is the only thermal cleaning method that applies pyrolysis and oxidation consecutively. In two-chamber versions like ours, molten plastic drains into an unheated chamber to capture the bulk of the polymer to reduce the fumes. It is electrically powered and ideal for the quick and careful removal of plastics soiling extrusion tools and filter parts. It is smaller than the burn-off oven so perfectly suited for cleaning smaller parts like the hot melt filters from plastics recycling and pelletising operations, or nozzles from plastics or paint processes. Parts like Erema, MAS, Ettlinger or Starlinger extrusion filters. All such filters, screens, nozzles and parts can be quickly turned around with the use of our vacuum oven.
Pyrolysis Benefits Include:
- Improved product quality – It provides a consistent and high cleaning result
- Only sure way of completely removing contaminating organic matter – With many parts, especially items with variable detailed surfaces it can be the only way to completely remove contaminants.
- Efficient – It uses automated systems that are safe, reliable, and fast providing a controlled, repeatable process
- Economical – Significant cost savings compared to other methods
- Environmentally friendly – Requires no hazardous chemicals and waste disposal. Waste products are inert ash, water vapour and carbon dioxide
Widely used for the removal of paints, plastics, polymers and food residue from any item made of a heavy metal like steel or iron. Parts such as filters, extruder screws, spinnerettes, jigs, baking trays and oven parts, can all be successfully cleaned through thermal cleaning.
Sonic Solutions are also able to offer complimentary cleaning processes such as ultrasonics, jet washing and vapour blasting which can enhance the cleaning results obtained solely from thermal stripping. Through our experience of all these methods, we are able to turn your costly item into a valuable part.
Why outsource pyrolysis, burn-off and thermal stripping to Sonic Solutions?
We pride ourselves on delivering the highest quality thermal stripping service and our client testimonials speak for themselves.
Burn-off of industrial parts and components can be a drawn-out, time-consuming task and leaving this to your own team of skilled people isn’t always the most effective or best use of their time. Ineffective cleaning can lead to poor performance, costly downtime and lost sales, so why not ensure peace of mind with our “done for you” thermal stripping service.
BAE, Cummins, Airbus, British Sugar, Shell
Andrew briefly explains how your Free Trial works
Book Your FREE Trial Clean...
- Enter some basic details about your part.
- We’ll get in touch to arrange pick-up & delivery.
- You get cleaned part(s) sent back to you.
- That’s it!
What’s the catch?
In short, there isn’t one. You’re not obligated to do anything with us after your free trial clean. The truth is that we do pick up some great customers by offering select businesses a trial clean, but only when it’s a great fit and makes sense for all involved. Outsourced industrial parts cleaning isn’t for everyone and if it doesn’t make clear business sense for you to use us, we don’t expect you to. Simply put, we’re passionate about what we do and know that not everyone is aware of how effective, affordable and stress-free our service is which is why we offer this free trial from time to time to spread awareness.
Annual Savings of at least £75,328
“All in all a massive win for us, reducing costs and increasing revenue simultaneously in a very competitive market.”
Simon - Engineering Support Manager
Berry BPI Group
How we saved Simon £75,328 - Simon’s calculations were based on the following;
- An average 13 filters a month were cleaned in 2019. Erema laser discs in Simon’s case, but this process also applies to Ettlinger, MAS or other hot melt filters.
- Our multi-stage cleaning process means that each filter now lasts at least twice as long as they would’ve done otherwise
- Any hot melt filter costs well in excess of £1,000
- Total cost of cleaning, carriage, packing etc.. costs in the region of £100 per filter.
Simon’s conservative calculation of an annual saving of £75,328 was based purely on replacement costs. He also benefited from higher throughput, longer runtime and less downtime.
We often work with
Plastics Recycling & Processing
Oil & Gas
Click onPress the button to open our enquiry form and we’ll come back to you ASAP (usually within the hour) with answers, options, prices and services or call us today on 01924 495 975
What Our Customers Say About us
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.
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Hi. I’m Andy, owner of Sonic Solutions for 14 years. Our aim is simple, to get your dirty parts clean, as efficiently and effectively as possible, so you can get on with your business.
We provide a cleaning service, cleaning chemicals, and ultrasonic cleaning equipment, so whether you want to do the job in-house or just let someone else sort it out we can help.
So if you require any cleaning of your equipment to help maintain your parts, increase production and reduce money loss, why not get in touch with our friendly and professional team.
We look forward to hearing from you.