One of the most common practices found in air filter change outs is to replace the used filter with a new filter. Unfortunately, repeatedly changing out old filters with new air filters is an expensive practice and one that will actually cause equipment to consume excessive amounts of harmful debris.

This excessive consumption will lower your equipment’s operating efficiency, significantly increase particulate emissions and increase the risk of equipment failure.

Most of the dirt that passes through an air filter’s media does so during the early part of the new filter’s usable life when it’s filtering efficiency is the lowest. In fact, it is not until after the first 5%-15% of a filter’s useful life has passed that the filter begins to develop an important filtering shield, called the “pre-coat.” The “pre-coat” is formed as microscopic dirt particles begin to build up on the surface of the filter media producing a light contaminant layer. Once formed, the “pre-coat” enables the filter to operate at its maximum efficiency, preventing dust and other contaminants from entering the engine.

Industries have long since recognized that constantly replacing air filters is an expensive practice. In addition, with increasing environmental awareness, industries are now realising that this practice is having a detrimental effect on valuable landfill space. With a very fine balance between environmental goals and the corporate goals of ROI, production costs, equipment readiness and quality there are few, if any, alternatives to the common practice of new-for-old air filters. Except for one.

The patented Sonic® Air Filter Dry Cleaning System automatically dry-cleans and recycles cartridge air filters, significantly reducing operational costs and helping to minimize equipment downtime while maximizing equipment readiness. At the core of the system is a completely automatic, patented air filter dry-cleaning machine that is capable of cleaning virtually any cylindrical air filter in as little as 4 minutes. The components: the patented Sonic® Dry Clean Machine, Inspection Booth, the SDC Finishing Table and the SDC Waste Collection System.

Patented SONIC SYSTEM®

The Sonic® Machine uses internationally patented technology to safely and effectively clean virtually any cylindrical air filter up to 37” in height and 20” in outside diameter. With “push button” operation the Sonic® Machine is the only completely automatic system on the market today.

For maximum cleaning effectiveness, the air filter cleaning chamber is completely sealed and under constant vacuum. Inside the cleaning chamber, are three strategically placed vacuum nozzles; one nozzle for the main cleaning chamber and two nozzles located on the inside and the outside of the air filter. The vacuum nozzles are designed to work closely together with two sets of air nozzles to ensure that every inch of the air filter is cleaned. The vacuum and air nozzles are engineered to work in sync which enables the Sonic® Machine to clean both inside/outside and outside/inside air filters with the flick of a switch.

SDC Manometer Station

The Manometer Station is used to test dirty air filters before and after the Sonic® Dry Clean process. This station allows the operating technician to accurately measure the amount of pressure drop for the air filter. The operating technician can then use this measurement to compare against baseline data on the air filter to determine the operational status of the air filter. This process ensures that the air filter is returned to service with the required filtering efficiency.

SDC Inspection Booth

The Inspection Booth allows the operator to accurately determine the integrity of the filter media. The inspection station utilizes a custom manufactured 750-watt halogen light source center, which allows the operator to easily and safely inspect the air filter's media for damaging effects, ranging from large tears in the media to microscopic pinholes that are not readily visible to the naked eye.

SDC Waste Collection System

The SONIC SYSTEM® is a completely self-contained cleaning unit with a waste disposal system that allows the particulate matter to be collected and sealed in bags or cans for safe disposal. The non-biodegradable material and waste collected is reduced in volume compared to more traditional methods. Standard for all Sonic Systems® is a three or six bag rack collection unit. The bag rack unit is specifically designed to meet both the airflow requirements and collection requirements of the customer's application.

Sonic C-Containers

Stationary, transportable filter cleaning centres are ideal for applications with changing or unpredictable environments. Regardless of your environment, the Sonic® C-container provides you with a controllable, stable and friendly operating environment for your dry-cleaning system.

  • Combines Sonic's® patented filter dry-cleaning technology with durable, transportable c-containers.
  • Weather proof.
  • Controllable internal environment.
  • Self-contained designs.
  • Field proven!

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The Sonic® Cleaning Process

The operating technician simply determines if the filter is dirty on the inside or outside, flips a switch to the proper inside/outside setting and then presses the “start” button. Once the “start” button is pushed, a self-adjusting arm lowers down and locks the filter into a proper and secure position activating the vibration cycle.

From start to finish the total time duration for the vibration cycle is approximately 17 seconds. During the vibration cycle, the air filter is rotated on special “clicks” while the angled air nozzles blow controlled, compressed air inside and outside the air filter. The combination of vibration, rotation and compressed air allows the machine to loosen and remove any heavily impacted dirt or debris that may be located in the filter element. Any dirt or debris loosened during the cycle is quickly vacuumed away to the Dust Collection System. After the vibration cycle stops the air nozzles are activated and the clean cycle begins. The clean cycle begins with specifically engineered air nozzles moving in and onto the air filter, automatically adjusting to both the inside and outside surfaces of the air filter. There are two sets of air nozzles, one on the inside of the air filter and the other set located on the outside of the air filter. The two sets of air nozzles are specifically designed to mirror each other causing the compressed air to glance off of the filter's media. The particulate matter is never blown through the media where damage can occur, but back against the original path of travel. This part of the cleaning process removes the remaining amount of dirt and debris from the filter. The time duration of the clean cycle is approximately 5 minutes. Upon completion, the Sonic® Machine automatically stops and releases the air filter, signaling that the cleaning process is done.

When the automatic clean cycle is finished, the technician then removes the clean filter cartridge from the machine and places it on the SDC Finishing Table for end cap cleaning of the filter and final wipe down. The operator then takes the filter to the SDC Inspection Booth where the filter element is checked on a 750-watt light source. Here the filter is slowly rotated around the light source while the operator inspects the media for any pinholes.

The operator then places the filter on the SDC Manometer to check the airflow (this is also done prior to cleaning). Finally, the operator treats the filter gasket with a rubber preservative or replaces the gasket altogether. The rubber preservative ensures that the gasket is kept in good condition and is not used to clean the filter. If the gasket cannot be repaired or replaced, the filter is rejected.

Sonic System Features

NS Komatsu, a Komatsu Dealer located throughout Australia uses a Sonic System® to clean and reuse cartridge filters, both in-house and for their customers.

  • A standard Sonic System® will clean cartridge air filters 7” to 37” in height and 3.5” to 24” in outside diameter. Systems can be manufactured to accommodate any size air filter application.
  • Patented design can repeatedly clean filters to 99.96% of maximum filtering efficiency without damaging the filter's “pre-coat” – guaranteeing you an air filter that will out perform any new filter right from the start!
  • No chemicals, liquids, solvents or agents are used anywhere during the filter cleaning process!
  • State-of-the-art electronic hardware and computer chip technology produce replicated sequences of compressed air, vacuum, vibration and rotation cycles. This fully automatic process is easily operated at the push of a button, enabling the operator the free time to work to complete other projects.
  • The system can clean cartridge filters in as little as 4 minutes.
  • Top hooks and removable rollers make in-house moving a cinch.
  • Every square inch is primed and coated with Endura Millenium Grey and Millenium Blue quality coatings.
  • Convenient re-settable cycle-timers will help you keep a physical count on your cartridge filter cleaning.
  • Simple design of the frame and the smart-style placement of the working components allow the operator to perform maintenance duties in a fast and trouble free manner.
  • Every component is stringently tested for defects before it is sent to assembly. Each system that is completed undergoes a final SDC inspection process before they are shipped out to the customer.

Obsolete Methods: Wet Washing

Located at each end of the metal frame are either metal or plastic end caps. The airflow entering the filter can come from either the outside-in or inside-out directions. In either case, the media fibers entrap incoming dirt and form a “pre-coat.” With the aid of this “pre-coat”, the air filter cartridge is able to operate at its maximum filtering efficiency.

Wet Washing

Over the last twenty years, from lack of better methods, the air filter cleaning industry has primarily tried to clean air filters through wet washing techniques using both water and detergents. Washing filters using water and detergent techniques has proven deleterious to air filters, as the liquids are known to dissolve the resins and paper elements, thereby destroying the integrity of the media. The direct result is a less than acceptable level of protection and filtration.

Generally, air filters can only be washed with water 1-2 times before they have to be replaced with a new filter. If the filter is washed more than 2 times the risk of having the air filter break apart as a result of damaged resins increases significantly. In fact, each time a filter is washed with water, the filter loses 20% or more, of its filtration efficiency. It has not been uncommon to trace the failure of an end user's equipment directly to a damaged, wet washed air filter.

Manufacturers of new air filters are well known for discrediting wet washing as a viable cleaning alternative for many of their filter products. In fact, some manufacturers will not continue their warranty on filters after they have been washed. Their reasoning is as follows:

The Donaldson Company

The washing process can weaken the filter's media because washing leaches out the resins. The resins hold the fibers together in the filter media. If they are leached out, the fibers will float free, causing a drop in the filters efficiency. Donaldson also concludes that thirty percent of an [air] filter's efficiency can be lost each time the filter is washed.

Fleetguard

Washing has an effect on the filter's capacity. After washing the (filter's) capacity can drop as much as ten percent. The loss of capacity continues at a greater rate after that point.

Evidence is overwhelmingly against wet washing filters. In a study by Allied Automotive, “Does Filter Washing Make Sense” it was concluded that, “…the economic advantage of filter washing compared to the purchase of new (air) filters are marginal at best. Moreover, we learned that a high percentage of reputedly acceptable cartridges returned from washing contained damages that were not readily perceptible to the naked eye.”

Sonic Dry Clean: Environment, Health and Safety for the Economy and the Environment

Sonic Dry Clean is a valued partner in any companies maintenance program. The SDC System enables businesses to safely and effectively clean thus recycle their dirty air filters at a significantly reduced cost. The SDC System is a proven, tested process that also saves landfill space, and is environmentally superior to all other cleaning options. The SDC System demonstrates how environmental technology can improve the environment and the economy at the same time!

To protect employees, the environment and reduce operational costs, WesTrac Equipment, a Caterpillar Dealer in Western Australia uses a self-contained Sonic System® at one of their mine sites to safely clean highly hazardous asbestos from cartridge filters.

Scribante Construction using the Sonic System for their fleet in Witbank, South Africa.

Technical Specifications

Automotores Gildemeister Chile S.A. a Hyundai Dealer has eliminated the costly practice of purchasing and installing new filters by using a Sonic System® to clean and reuse their existing cartridge filter inventory.

Warranty

Seller warrants that the equipment of items sold hereunder shall be free from defect in material or workmanship for a period of 12 months from the date of shipment from factory. This warranty comprises the sole and entire warranty pertaining to the equipment or items sold provided hereunder. Seller makes no other warranty, guarantee or representation of any kind whatsoever. All other warranties, including but not limited to, merchantability and fitness for purpose, whether expressed, applied or arising by operation of law, Trade Usage, or course of dealings are hereby disclaimed.

Not withstanding the foregoing, there are limited warranties on equipment or items built or acquired wholly or partially, to buyer's design or specifications.

Limitation of Remedy: Seller liability arising from or in any way connected with equipment or items sold or this contract shall be limited exclusively to repair of the equipment or replacement of the items sold. At seller’s sole option. In no event shall seller be liable for any incidental, consequential or special damages of any kind or nature whatsoever, including but not limited to lost profits arising from or in any way connected with this agreement or equipment or items sold hereunder, whether alleged to arise from breach of contract, expressed or implied warranty, or in tort, including without limitation, negligence, failure to warn or strict liability.

Cockburn / Corefleet is the mine contractor for BHP’s Mt. Newman Mine in Australia. Corefleet uses the Sonic System to clean cartridge filters, significantly reducing the mines cost per ton.