Plastics & Recycling
The plastics and plastics recycling industry is one of the largest manufacturing sectors in the world and relies heavily on specialist machinery and processing equipment to maintain consistent production.
Industrial Parts Cleaning for the Plastics & Recycling Industry
For these systems to operate efficiently, it is essential that industrial components and processing equipment are kept clean and free from contamination.
At Sonic Solutions, we specialise in industrial parts cleaning for the plastics and recycling industries, using advanced cleaning technologies such as:
- Ultrasonic cleaning
- Pyrolysis and thermal stripping
- Industrial jet washing
- Vapour blasting
By using the correct combination of these industrial cleaning processes, we help plastics manufacturers and recyclers to:
- Improve production efficiency
- Reduce costly downtime
- Extend the lifespan of expensive machinery components
- Maintain high product quality
Why is cleaning your dirty industrial parts better than replacing them?
Breaker and screen – before
Breaker and screen – after
Erema blade housing – before
Erema blade housing – after
Cleaning Solutions for Plastic Processing Equipment
Plastic manufacturing and recycling processes depend on a wide range of precision engineering components, all of which can accumulate contamination over time.
During production, equipment can become contaminated with:
- Polymer residue
- Oils and grease
- Carbon deposits
- Inks and pigments
- Wax and resin vapours
- Rust and scale
If these contaminants are not properly removed, they can build up on critical components and cause serious problems for production efficiency and product quality.
Using our specialist industrial cleaning services, Sonic Solutions can safely remove these contaminants from a wide range of components used in plastics manufacturing and recycling.
Common Problems in the Plastics Industry
Contaminated Extraction System Filters
Extraction filters and condensers used in plastics processing often become contaminated with wax and oil vapours released during heating and drying processes.
These components are often:
- Difficult to clean effectively
- Expensive to replace
- Custom-built with long manufacturing lead times
Professional industrial cleaning can restore these parts and avoid costly replacements.
Restricted Airflow and Process Inefficiency
Contamination inside filters and extraction systems can significantly restrict airflow.
To compensate, operators may increase pressure or flow rates, which can create:
- Reduced process control
- Increased safety risks
- Higher energy consumption
Cleaning contaminated components restores airflow and helps return systems to optimal operating conditions.
Expensive Replacement Components
Many parts used in plastics recycling and extrusion are bespoke components manufactured overseas, often with long lead times.
Replacing these parts can create serious challenges including:
- Production delays
- Increased operational costs
- Supply chain disruption
Professional cleaning services can extend the lifespan of these components, saving both time and money.
Risk of Production Shutdown
If contamination is not addressed, the accumulation of residue can eventually lead to equipment failure or production shutdowns.
Preventative cleaning helps ensure equipment continues operating efficiently and reduces the risk of costly downtime.
Reduced Product Quality
Dirty equipment can introduce solid contaminants and impurities into the final product.
This can result in:
- Poor product consistency
- Reduced material quality
- Increased product waste
Maintaining clean equipment is essential for consistent polymer processing and high-quality finished products.
The Sonic Solutions Approach
At Sonic Solutions, we specialise in removing organic contamination from plastics processing equipment using advanced industrial cleaning methods.
Many components used in plastics manufacturing are made from steel, copper or other durable metals, which are well suited to thermal cleaning processes.
Our preferred cleaning method for many plastics industry applications is pyrolysis (thermal stripping).
During the pyrolysis process:
- Organic contaminants such as polymers, oils and resins are completely broken down by controlled heat.
- Only a small amount of inert ash remains.
- This ash can then be easily removed through ultrasonic cleaning or jet washing.
This process allows us to fully remove stubborn polymer contamination without damaging the metal component.
While some metals may become slightly discoloured due to high temperatures, their structural and chemical properties remain unaffected.
Multi-Stage Industrial Cleaning for Maximum Results
In most cases, pyrolysis is only the first stage of the cleaning process.
For optimal results, it is typically followed by additional cleaning methods such as:
- Ultrasonic cleaning
- Industrial jet washing
- Vapour blasting
By combining multiple cleaning techniques, we ensure that components are left completely clean both internally and externally.
This multi-stage industrial cleaning approach is what sets Sonic Solutions apart from many in-house cleaning operations or single-method cleaning services.
Trusted by Leading Plastics Recycling Companies
Sonic Solutions provides industrial cleaning services to some of the UK’s leading plastics recycling and processing companies, including:
- Berry Global
- Luxus
- Jayplas
Many of these companies previously operated their own in-house cleaning systems but found that they could not achieve the same level of cleanliness and efficiency as our specialist cleaning processes.
In one example, our cleaning solutions helped a client save over £73,000 per year on replacement parts.
Why the Plastics Industry Chooses Sonic Solutions
- Specialists in industrial parts cleaning for plastics and recycling companies
- Advanced processes including ultrasonic cleaning, pyrolysis, jet washing and vapour blasting
- Ability to remove polymer, resin, wax and carbon contamination
- Extend the life of expensive extrusion and recycling equipment
- Reduce downtime and production disruption
- Parts collection and return service available
By combining experience, advanced cleaning technologies and flexible service, Sonic Solutions delivers reliable cleaning solutions for the plastics manufacturing and recycling industry.
Parts We Clean for the Plastics Industry
Laser Filters
Various types of laser filters are used in the plastic recycling industry, including Erema, MAS, FIMIC, and Ettlinger laser filters, all used to remove contaminants from plastic recycling processes. Unlike the disposable wire mesh filters that need constantly changing, “continuous melt” filtration uses blades to skim off the majority of contaminants that hit the filter.
Sintered Filters
Sintered filters are used in the production of blown moulding to keep contaminants out of the end product by purifying air before the moulding process. Over time these become trapped with particulate and must be cleaned or replaced. The slow build-up of particulate raises pressures in the system and can lead to major problems.
Heat Exchangers
The air heat exchangers keep the blow moulding air at a constant temperature, meaning products such as plastic bottles are manufactured in an identical and repeatable way. Over time these air heat exchangers gather up deposits from the heating of plastic that leave a sticky layer on the surface, reducing the effectiveness of the equipment.
Condensers
Condensers used in the production of blown moulded products are designed to catch and remove the volatile vapours released in the heating of plastics in the extrusion stage. Over time this sticky “wax” builds up reducing the effectiveness of the “cooler”.
Dust Filters
Dust filters are found in a number of different areas of the plastics industry. In recycling they are used in the grinding process to catch airborne particulate that could affect the health and safety of the workforce and contaminate products. When producing blown film, it’s imperative no airborne particulate is present, so extraction is key.
Pelletising Heads
Pelletising heads are usually cleaned when switching products or if there has been a failure in the filtration process allowing contaminants to block the fine holes. Being that this equipment is almost the last stage of production the tolerances are extremely important and must be kept clean for best results.
Proud Members of…
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.
Knowledge Centre
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Latest Case Studies
Berry BPI Group
Annual Savings of at least £75,328 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...
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