Large-scale automated ultrasonic cleaning targets high standards of aluminium surface-cleanliness and quality bonding.

The new capability has been integrated into Powdertech’s  4-meter by 2-meter by 0.6-meter tanks with a 4,800-litre volume and currently processes thousands of aluminium parts a day. 

This investment has an enhanced ability to clean complex aluminium components at scale, achieving surface cleanliness levels of 56 Dynes and above. 

The ultrasonic cleaning system has been set up at Powdertech’s Bicester facility, providing manufacturers and suppliers of automotive, defence, aerospace and medical sectors with access to repeatable, high-volume cleaning for large, complex aluminium components.  

Aluminium ultrasonic cleaning tank at Powdertech's Bicester facility.

The system improves the ability to remove contaminants from surfaces, cavities and difficult-to-reach areas, helping to improve coating adhesion, structural bonding, component appearance, coating consistency and the long-term reliability and durability of finished aluminium components. 

Jimmy Phillips, Head of Sales and Marketing, Powdertech Surface Science said, “We know our customers are seeing more demanding cleaning specifications that call for testing to higher Dyne levels; with this new system we can offer them measurably cleaner aluminium at scale. We see this as an investment in better aluminium bonding for our customers, and their customers.  

“We think this is the biggest ultrasonic cleaning system of its kind from a specialist provider in the UK. It gives us the capacity and control to deliver consistently high standards of cleaning on thousands of parts a day, strengthening the value we can bring to customers with increasingly demanding aluminium applications''. 

Ultrasonic cleaning system generators

As lightweight materials, advanced coatings, and structural adhesives become more widely used across various industries, the need for exceptionally clean component surfaces is increasing.  

Standards such as ISO 16232 are also placing greater emphasis on controlling particulate contamination, helping manufacturers achieve strong adhesion, reliable bonding, and consistent product performance. 

OEMs in performance-critical sectors are increasingly finding that even small amounts of contamination can affect function, coating adhesion, or long-term reliability. This makes achieving consistent, repeatable cleanliness increasingly important. 

Further building on Powdertech's established expertise in advance aluminium powder coating and surface pretreatment, this investment expands and strengthens Powdertech’s surface finishing capabilities for customers across the automotive, EV battery, medical and precision-engineering sectors.  

Ultrasonic cleaning uses high-frequency sound waves to generate microscopic bubbles within a cleaning solution. This method provides a rapid, non-abrasive method for deep cleaning aluminium components.  

As these bubbles collapse, contaminants can be removed from surfaces, cavities, and difficult-to-reach areas without damaging the component. The process is energy-efficient and environmentally friendly, requiring no harsh chemicals. 

Powdertech have two automated up to 15-stage cleaning and pretreatment lines for aluminium components, offering best-in-class optimised TiZr passivation using the Gardobond and Gardoclean systems.  

Jimmy Phillips said: “The installation of our ultrasonic cleaning line builds on our established expertise in advanced aluminium powder coating and pre-treatment, enabling customers to access an even broader range of specialist manufacturing services from a single, trusted supplier. 

We expect demand for cleaner, more reliable and higher-performing aluminium components will increase, particularly within the automotive and other precision-engineered sectors.  

This investment ensures that we are well positioned to support both today's production requirements and the manufacturing challenges of the future.” 

With over 40 years of experience, Powdertech Surface Science is the most technically advanced provider of aluminium powder coating and chrome-free pre-treatments in the UK.  

Established in 1984, with a clear aim to provide high-quality professional chemical pre-treatment, powder coating, and bonding services to specialist niche market sectors to leading-edge manufacturers in automotive, aerospace, medical, battery electric vehicles (BEVs), and other specialised industries.