Industrial filter cartridges are an important component of most manufacturing and production processes, used to remove contaminants from liquids and gases. However, they face common problems that affect their efficiency and effectiveness.
In this guide we look at the five main problems with industrial cartridge filters for water filtration and how to solve them.
1. Poor filtration efficiency
Poor filtration efficiency can have many causes, such as:
- incorrect filter selection or installation
- clogged filters
- damaged filters
To solve this, select the right filter cartridge for the specific application and make sure installation and maintenance are correct. Depending on the contaminants being removed, this may mean choosing a filter with a finer micron rating or a different filtration medium.
If the filter is not removing enough small contaminants, the micron rating should be reduced. If the contaminants or the liquid are damaging the current filter medium, it should be replaced with another. Regular replacement and cleaning also help prevent efficiency from falling. If you have filtration efficiency problems, contact the experts at Keiken Engineering.
2. Short filter life
Excessive particle loads, dirt or chemical damage can shorten a filter’s life. To extend it, it is essential to select the right filtration materials, use pre-filtration and maintain regular cleaning and replacement routines.
Strategies to extend filter life:
- Ensure the filter material is compatible with the process liquid.
- Choose filters with a high dirt-holding capacity.
- Use pre-filtration to capture larger particles before the main filter.
- Use a coarser pre-filter (e.g. 10 micron) to protect finer filters (e.g. 1 micron).
- Clean filters regularly and replace them on time.
- Consider pleated depth filters for higher particle retention and fewer replacements.
- Consult a filtration specialist to find the best solution.
3. Filter bypass
Filter bypass occurs when fluid passes around the filter cartridge instead of through it, resulting in incomplete filtration. It can be caused by damaged seals or gaskets, incorrect installation or high flow rates. After several cleaning cycles, filter integrity can also be compromised if the filter is not changed, leading to bypass.
To solve this, make sure the filter is installed and maintained correctly: check that seals and gaskets are undamaged, keep flow rates within the filter’s range and follow proper cleaning procedures.
If bypass is not due to installation, seals or replacement practices, contact a water filtration professional to help resolve the problem.
4. Contaminant release
Contaminant release is a serious concern in the pharmaceutical, food and electronics industries. Even small amounts of contamination affect product quality and safety and can lead to recalls and even legal action. It may be caused by incorrect filter selection, degradation of the filter medium or improper installation.
To prevent it, select the right filter cartridge and ensure correct installation and maintenance. Regular filter replacement and testing also help detect any contamination problems.
5. High maintenance costs
High maintenance costs — cleaning, filter replacement and downtime — are a challenge for industrial cartridge filter systems. To reduce them, select a cartridge with a longer service life and higher dirt-holding capacity, and consider pre-filtration to remove larger particles before they reach the main filter.
Correct installation, maintenance, regular replacement and cleaning also help reduce costs. Sometimes reducing filtration costs is as simple as switching to another cartridge type; at other times it may involve installing upstream pre-filtration.
If you want to reduce your filtration maintenance costs, work with a reliable water filtration company.
The essentials
Industrial filter cartridges help remove contaminants and ensure product quality and safety. By addressing these common problems, manufacturers can improve the efficiency and effectiveness of their filtration systems.
To keep your cartridge filters performing at their best, the experts at Keiken Engineering can help. Contact us today.
