- Carolina IAQ
Within the sphere of polymer film manufacturing, filtration plays a crucial role in ensuring the production of quality products while minimizing process downtime. Over time, these critical elements become plugged with contaminants and additives from the polymer stream, resulting in increased online pressures and compromised product quality. Proper cleaning and testing can return filter elements to optimal performance and minimize the risk of defects reaching extruded film and blown film products.
Carolina Filters services a range of polymer film manufacturers including producers of polyester (PET), polypropylene (PP), Polyethylene (PE), and polyvinyl butyral (PVB). Polymer film manufacturers often utilize leaf discs and candle filtration elements constructed of woven wire mesh, sintered fiber, and porous metal. Manufacturers of these elements include, but are not limited to: Pall, Maag, John Crane, Purolator, Baekart, PTI, US Filters, and Porvair.
Carolina Filters also supports the polymer film industry in the cleaning of precision extrusion, coextrusion, and blown film dies, and critical heat exchanger assemblies ensuring peak process performance and product quality. Our capabilities include turn-key filtration cleaning services which include the disassembly, cleaning, and reassembly of entire filtration systems including the filter vessel and tubesheet.
To best accommodate customer needs, Carolina Filters considers the specific equipment and contaminant of their operation to tailor design an ideal cleaning process. Our wide range of technologies allow our cleanings to go beyond surface level contaminant removal and target the deeply rooted contaminants responsible for losses in functionality.
When designing a cleaning process, we target three different levels of contaminant; surface level, 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 filters. This type of contaminant is most usually the root cause of poor filter performance. Carolina Filters employs a variety of chemical, physical, and thermal methods for their removal. 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 buildup and embedding of particulate. Removal of these contaminants is the final step in returning filter elements to like-new condition.
We have assisted many companies in the industry to eliminate filter related issues. When one of the largest PET film manufacturers in the US struggled with drastic decreases in on-stream life of their pre-extrusion filters, Carolina Filters was able to provide a cleaning solution which returned their filters to functioning like new. Working with their engineers, a process was created which targeted removal of their PET, additives, and embedded dry solids. Utilizing our DEECOM technology, porosity was greatly improved, and their filters returned to functioning like new.