
Project Reference
The Challenge
The client needed maintenance work for their kiln furnace to remove existing kiln bricks of 229mm thickness and were harder than normal concrete. The kiln is confined in a cylinder shape with a 3.5m diameter, exceptionally long at 30m and operated under extreme conditions due to its use in processing acid. Temperatures within the kiln were so high that the bricks became sticky when touched, even with gloves, resembling the texture of gum. These extreme conditions would require an immense amount of manpower and a suitable solution for a level surface to make way for replacements.
Our Approach & Result
Sonicon deployed Bumblebee, robotic hacking system for an increase of 20x efficiency compared to traditional manual hacking. The machine was selected for its ability to navigate the confined and elongated kiln while delivering precision and vibration-free results. The use of robotic hacking reduced the need for extensive manpower, requiring only two operators to complete the task, significantly minimizing human exposure to the harsh environment. The planning included anchoring and positioning strategies tailored to the kiln’s dimensions, minimizing disruption.

Kilns are integral to a range of industries, yet their maintenance often poses unique challenges. With their confined and extraordinarily deep long spaces, combined with hardened and sticky brick structures due to extreme heat, even routine work demands innovation and expertise.
For this project, the stakes were high: the existing bricks needed to be removed to maintain operational efficiency, but traditional methods simply wouldn’t suffice. Enter Bumblebee, a robotic hacking solution that redefines precision and productivity.
Operating in a space where every move counts, Bumblebee transformed what would have been a grueling manual task into a streamlined process 20x faster. Its ability to navigate the compact and extended environment while tackling the hardened bricks highlighted how technology could elevate industrial maintenance to new heights. Even when exposed to the high heat in the kiln, Bumblebee efficiently maneuvers in the confined kiln for only 12 days to complete the task.
Sonicon’s range of advanced solutions, including Bumblebee, ensures we’re equipped for every unique challenge. But this project wasn’t just about technology—it was about understanding the client’s needs and delivering results that exceeded expectations, paving the way for better and more efficient kiln operations.
Discover how Sonicon is revolutionizing industrial maintenance with innovative, tailored solutions.