- Carolina IAQ
In polymer resin manufacturing, filtration plays a pivotal role in maintaining product quality and operational efficiency. These processes rely on clean filters to ensure smooth operation. Over time these critical elements become clogged with contaminants and additives from the polymer stream, resulting in increased pressures and compromised product quality. Proper cleaning and testing can return filter elements to optimal performance and minimize the risk of defects at end use customers.
Carolina Filters is a trusted partner for a range of polymer resin manufacturers including polyethylene terephthalate (PET), Polyamide 6,6, Polyethylene (PE), Polycarbonate (PC), Polypropylene (PP), Polylactic acid (PLA), Polyetherimide, and many others. Polymer resin manufacturers often utilize leaf discs and candle filtration elements constructed of woven wire mesh, sintered fiber, and porous metal. Manufacturers include, but are not limited to: John Crane Seebach, Maag, Pall, Mott, Parker, and PTI.
In addition to filter elements, we have assisted polymer resin manufacturers with the cleaning of heat exchangers, dies, pipes, breaker plates, and injection blocks to ensure that their line runs efficiently and without defects. Our capabilities include turn-key filtration cleaning services which included the disassembly, cleaning, and reassembly of entire filtration systems including the filter vessel and tubesheet.
Carolina Filters designs customized cleaning profiles to target each individual customer’s materials and additives. The cleaning process includes specified deep cleaning steps that target deeply embedded contaminants which allow for cleaned filters to perform in a like-new capacity when returned online.
When designing a cleaning profile for the manufacture of polymer resins, many factors must be considered. Carolina Filters has various options for depolymerization available to remove gross contaminates. After the polymer is removed, organic and inorganic contaminants will remain deep within the filtration media. Returning filters online without the removal of the deeply embedded contaminates will cause higher starting pressures and result in shorter filter life online. Carolina Filters has many different physical and chemical options for the removal of these contaminants.
We have assisted many companies in the resin industry to eliminate filter related issues. We have had the privilege of assisting a manufacturer who was producing a modified PET resin. They came to us with a problem of reduced filter life of filters cleaned by another company. The Carolina Filters technical team reviewed their cleaned filters and found that their current cleaning method was not targeting one key inorganic additive which was becoming embedded in the filter media. We were able to target the inorganic additive and remove it with technology available at Carolina Filters which resulted in longer onstream life of the filter set after cleaning.
Qualifying cleanliness and integrity are crucial to ensure that a cleaned filter returned online will result in good onstream life and high-quality produced product. Carolina Filters offers a diverse suite of cleanliness and integrity tests used to assess the quality of each filter after the cleaning process is complete.