- Carolina IAQ
In polymer fiber manufacturing, filtration is critical in removing contaminants from product streams and preventing process downtime from line breaks. In candle filtration, overtime contaminants may become embedded in the media resulting in a loss of functionality and may negatively impact process flow. Regular cleaning and testing provide a way to ensure the filter elements continue to perform optimally. Additionally, it serves as an alternative to throwing away and replacing expensive filters.
Carolina Filters partners with producers of a variety of different polymer fibers including Polypropylene (PP), Polyester (PET), Polyamide (PA-66), Polyethylene (PE), and others. Polymer fiber producers often utilize candle filters along with pack filtration media. Pack filtration media includes shattered metal, woven wire mesh screens, porous metal discs, sand/bauxite, and glass beads. In many cases, there could be mixtures of the various filtration media in the packs. Manufacturers of the candle filters include, but are not limited to Pall, Asco/Mott, Maag, Parker, and John Crane. Shattered metal suppliers include Hoganas, and Ametec.
Carolina Filters reclaims shattered metal media for reuse in the packs which allows for the elimination of landfilling spent metal plugs and provides a lower cost alternative to virgin metal.
In some cases, spinnerets may be the root cause of production difficulties. Build ups inside the spinneret capillaries may lead to line breaks and “dog leg” extrusion defects. As with filters, our cleaning technologies have the capability of removing such buildups and returning the equipment back to optimal functionality.
Along with spin pack cleaning, Carolina Filters also supports the polymer fiber industry in the cleaning of spin beams, pumps, and other ancillary equipment.
From upstream candle filtration to pack filtration, to best accommodate customer needs, Carolina Filters considers the specific equipment and contaminant to tailor design an optimal cleaning process. Our wide range of technologies allow the cleaning to go beyond surface level contaminant removal to target deeply embedded residuals.
When designing a cleaning process, we target three different levels of contaminant; surface, deeply embedded, and molecularly bound. Surface level contaminant is the most easily removed and is the target of traditional cleaning technologies. Deeply embedded contaminant consists of both organic and inorganic particulate that has become lodged in the pathways of the filter medium. Embedded contaminants are typically responsible for poor filter performance. For removal of these contaminants, Carolina Filters employs a variety of chemical, physical, and thermal methods. Lastly, molecularly bound contaminants consist of oxidation and scale which can create points of weakness in the filter media, as well as propagation points for corrosion and buildup of particulate. Removal of these contaminants is the final step in returning filter elements to like-new condition.
When a large manufacturer of synthetic fibers needed a solution for the continuous and expensive replacement of their shattered metal filter media, Carolina Filters was able to provide a solution. By creating a cleaning process for the media and utilizing a sieving system for separating out metal that no longer met specification, we created a significant savings opportunity for the user by using reclaimed metal instead of virgin metal, along with the elimination of associated disposal costs. Trials of the recycled metal showed no difference in performance versus virgin metal.