The Misonics process language
Every study is built from these stages
Not every part needs every stage — each case study names the stages its process card uses, in this order. Each stage has a job, and the order matters.
Every new study starts with the customer’s actual parts and cleaning requirements. We develop and validate the process, then specify the chemistry, ultrasonic parameters and system configuration needed to reproduce the result.
Sixteen cylinder heads timed at 15/30/45/60 minutes in MetalTek 100 — combustion faces and exhaust ports to bare cast iron, no media anywhere near them.
Timed photographs · full process cardAviation · airfield MRO2,500+ fixtures at a major Australian airport. Cooked tyre rubber off the optic in a 20 minute dual-frequency cycle, with photometric numbers either side.
Before & after · process cardProcess cleaningA three-station Sonos L-130 built and commissioned on our own floor — dual-frequency 25/45 kHz, DI rinse and hot-air dry, basket moved on the clock.
Video · photographs · the setupDefence & law enforcementCarbon, unburnt powder, lead and copper wash out of the whole action in a 15-minute 40 kHz cycle — armoury-scale throughput.
Photos · full process cardManufacturingSwarf, cutting oil and pastes — critically clean in a 20-minute UltraWash cycle with Brulin 1990 GD.
Photos · full process cardEngine rebuildingCoked carbon out of the ring belt in 815 QR-NF at 70 °C — dimensions gauged unchanged.
Photos · full process cardEngine rebuildingRust, carbon and paint stripped in one 1–2 hour immersion — water jackets included.
Process cardTransportThe ash regeneration leaves behind — and the RegeniK second bath that removes it, flow-tested.
Process cardMining · marineWhole-core recovery for Mesabi-class coolers and marine finned-tube exchangers.
Process cardEnergy+67% service life on an MSX30 bench — machine payback under 12 months.
Photos · results dataEnergyCandle filters and demister pads recovered on rotation for a major generator — ΔP per element.
Program studyPolymer recyclingErema-class discs from consumable to rotating stock — £75,328 calculated annual saving.
Savings analysisAerospaceCooled ultrasonic wash, cavitation rinse, IPA dip and air dry on a 5–10 minute platform cycle.
Engineered systemAerospace · medicalAMS 2700 / ASTM A967 conformance without nitric — NASA-validated, cost-modelled.
Standards studyElectronicsIonic residues below the IPC 6 µg/in² limit with Electro chemistry at 40 kHz.
Process cardFoodCM-800-class installation cleaning racks and equipment to export-plant standard.
Install photosMore in production — the full pipeline is mapped in our case-study production list. Photography and client permissions are being added as they clear.
Not every part needs every stage — each case study names the stages its process card uses, in this order. Each stage has a job, and the order matters.
Where an application warrants a controlled trial, we clean, photograph, gauge and document — and the process card stays with the customer.