For industrial facilities, having the right air filter is critical to preventing downtime and maintaining a safe work environment. In this blog post, we’ll explore how these manufacturers design and create custom air filters to meet the specific needs of their clients. From the materials used to the size and shape of the filter, there are many factors that go into the design process. Read on to learn more about how industrial air filter manufacturers create custom industrial air compressor filters for their clients.
Industrial air filter manufacturers' guide to custom filters
What are industrial air filters and their different types?
Industrial air filters are used in a variety of settings, from manufacturing plants to office buildings. These filters are responsible for maintaining indoor air quality. There are many types of industrial air filters. Check out some of the most common types below:
1. Pleated Filters
Pleated air filters are one of the most popular industrial filters because they offer a high degree of filtration while still allowing for good airflow. They are made by pleating a piece of filter media (usually paper or cloth) into a series of accordion-like folds. This increases the filter's surface area, which captures more particles. However, they have to be replaced regularly for optimum performance.
2. Fibreglass Filters
Fibreglass air filters are another popular type of industrial air filter. They are made from a sheet of glass fibre that is woven into a mesh. The tiny pores in the fibreglass trap particles as air passes through them. Fibreglass air filters can be used in various applications and are often used as pre-filters to extend the life of more expensive pleated air filters. They are perfect as pre-filters as these are usually inexpensive and are capable of capturing larger debris like lint and dust.
3. Carbon Filters
These air filters are made from activated carbon, which is a form of carbon that has been treated to make it very porous. These pores trap particles as air passes through them, making carbon filters an effective way to remove contaminants from the air. Carbon air filters can be used on their own or in conjunction with other types of filters to provide even better filtration. Activated carbon filters can capture VOCs (Volatile Organic Compounds) and are also capable of removing odour. They can successfully trap liquid and gaseous particles present in the air.
4. HEPA Filters:
HEPA stands for "High-Efficiency Particulate Air" filter. Made of fibreglass or synthetic material tightly aligned together to create a mesh, these filters are capable of trapping particles that are up to 0.3 microns in size. Industrial HEPA air filters are mostly used in domestic and commercial applications. These filters are known for creating a breathable indoor environment. Many consumer products like air purifiers, HVAC/AC, vacuum cleaners and automobiles use industrial HEPA air filters. These filters are highly recommended for individuals who have health troubles like asthma or allergies.
How are custom air filters different?
Each industry has different requirements when it comes to the type and efficiency of air filters. A reputed industrial air filter manufacturer will work with you to determine the best type of filter for your specific application. From low-cost solutions to high-efficiency units that can remove even the smallest particles from the air, they can advise, design and suggest the right type of custom air filter for you. This detailed level of customization sets these air filters apart from their OEM counterparts.
Common Applications of Industrial Air Filters
High safety standards are a must for the automotive industry. Automobile manufacturers also have to adhere to numerous quality standards set by the government in terms of quality checks. Among various parameters, the air-quality check is considered to be of utmost significance. This is where industrial air filters come into the picture. These manufacturers use air filters to create custom air boxes to control the airflow into the engine and thus, reduce/muffle the noise of the engine. They are also used in the vehicle's air conditioning system.
Manufacturing industries have to ensure optimum indoor air quality. This is because the outside impurities can negatively impact the health of the employees and also interfere with the manufacturing process. Clean air is a necessity no matter what kind of manufacturing plant it might be. Also, many manufacturing units are peculiar in their process, ingredients and methods. Impurities like dirt, debris, lint, and even viruses and bacteria can interfere with the process and lead to heavy production loss. Hence, manufacturing units ensure they install high-quality industrial air compressor filters to reduce or avoid downtime and maximize output.
Food & Beverage:
Just like the manufacturing industry, the food and beverage industry demands superior air quality as well. Food and beverage manufacturers have many compliances to follow and consumers' safety is arguably the most significant one. Any mishap in the process could be potentially hazardous for the end consumers. Hence, this industry usually gets industrial filters installed by a reputed provider and also maintains them regularly. Additionally, the industrial air filter systems also guarantee the good health of the employees who work around the clock.
Who needs HVAC systems? To begin with, offices, building complexes, shopping malls, homes, hospitals, schools, the list just goes on. We can find HVAC (Heating, Ventilation, and Air Conditioning) almost everywhere. Apart from their major functions, which are facilitating indoor heating, ventilation and air conditioning, they also serve an important role in keeping indoor air quality high. The role of air filters in HVAC is indispensable.
The pharmaceutical industry constantly works around drugs, chemicals and other components. These units are always occupied by scientists, doctors, manufacturing plant employees, storage tanks, and various drug manufacturing machines and equipment. To ensure the well-being of the personnel and to keep the medicinal ingredients, drugs and other components free of any outside impurities, the pharmaceutical industry heavily relies on industrial filters. They mostly depend on industrial HEPA air filters to meet their requirements.
The process of creating custom industrial air filters
Air filter manufacturers use a variety of methods to create custom air filters for industrial applications. The most common method is the pleated panel process, which involves creating a pleated panel of media and then attaching it to a frame. Other methods include the use of rolled media, which is fed through a series of rollers to create a pleated panel; and the use of pre-pleated media, which is stored on a roll and then cut to size as needed. Industrial filters can be made from a variety of materials, including paper, fibreglass, and synthetic media. The type of material used will depend on the application for which the filter will be used.
The pleated paper or fabric is usually glued or stapled onto a metal frame. This frame provides support for the filter and helps it fit snugly into the housing unit. Once the filter is assembled, it’s time for testing. The filter is placed in an aerosol and runs through a series of tests that measure its efficiency in trapping particles. These tests help ensure that the finished product will meet the specific needs of the customer. These air filters come in a wide variety of shapes and sizes, each designed to meet the specific needs of the application.
The benefits of using custom industrial air filters
When it comes to industrial settings, having clean air is crucial. This is why air filter manufacturers create custom industrial air filter systems - to make sure that the air in your factory or warehouse is free of contaminants. There are many benefits to working with custom industrial air filter manufacturers. One of the most significant benefits is that they can create filters that are specifically designed to meet the needs of your facility. Some other benefits are listed below.
Improved Air Quality:
By removing contaminants from the air, industrial filters can improve the overall air quality in your facility. This can lead to a healthier work environment for your employees and reduced absenteeism.
Reduced Maintenance Costs:
When your equipment is not constantly covered in dust and dirt, it will require less maintenance. This can save you money on repairs and upkeep.
Dust and other contaminants can clog machinery and reduce its efficiency. By keeping the air clean, industrial filters can help keep your equipment running at peak performance.
How to choose the right industrial air filter manufacturer for your needs
Choosing the right industrial air filter manufacturer for your needs is a critical decision. There are many factors to consider when making this choice, and the wrong decision could result in significant problems down the road. Here are a few tips to help you choose the right manufacturer for your needs:
1. Do your research:
It's important to learn as much as you can about the different manufacturers before making a decision. Read online reviews, talk to other businesses in your industry, and get input from anyone else who has experience with industrial air filters. This will help you narrow down your options and choose a manufacturer that has a good reputation.
2. Consider your specific needs:
Every business is different, so it's important to find a manufacturer that can create custom filters that meet your specific needs. Make sure to discuss your unique requirements with potential manufacturers to ensure they can provide what you're looking for.
3. Compare pricing and warranties:
Once you've narrowed down your choices, it's time to start comparing prices and warranties. Be sure to get quotes from multiple manufacturers so you can compare apples to apples. Pay attention to both the price of the filters and the warranty offered by each manufacturer. The right choice will offer high-quality filters at a reasonable price with a long warranty to back it up.
4. Ask about customer service and support:
After you've made your purchase, you'll want to know that you can rely on the manufacturer for customer service and support if needed. Aftersales service can make or break a relationship with a customer, so manufacturers who focus on this aspect are more trustworthy.
Industrial air filter manufacturers have to take a number of factors into account when creating custom filters for their clients. By understanding the specific needs of each client, they can create a filter that will work effectively for them. This attention to detail ensures that each industrial air filter manufacturer produces high-quality products that their clients can rely on. Dynamic Filtration is your one-stop solution for custom industrial air filters. We boast years of experience and a large base of satisfied clients. Speak to us today!