Pleated Filter Bags

Not since the mid 1970’s introduction of Gore-Tex™ PTFE Membrane (by WL Gore Company) has our industry been more affected by the development of a new fabric structure than Spun Bond Polyester and the resulting success of Pleated Filter Elements — PFE’s (also referred to as Pleated Filter Bags). Since its first appearance in the mid 1990’s, the PFE market has grown to an estimated $50,000,000 per year segment of the estimated $300,000,000 US fabric filtration market. (For reference, the US membrane market, now forty years old, is also approximately the same dollar volume.)

Clearly, PFE’s have carved out a significant presence with proven application success stories throughout the filtration market. Aftermarket installations are now widely spread throughout the industries of:  Agricultural Products Processing (Grain, Ethanol, Milling), Chemical (Plastics, Paints, Pigments, Tire & Rubber), Consumer Products (Soaps, Detergents, Cosmetics), Food & Pharmaceutical Processing, Metals Processing & Fabrication (Steel, Foundry, Battery, Welding Fume, Cutting), Mining (Copper, Taconite, Soda Ash, Coal), Rock Dust (Cement, Lime, Gypsum, Ready-Mix), Utility (Boiler, Coal Handling, Fly-Ash Handling), Wood (MDF, OSB, Fabrication, Woodworking).

Similar to the eventual acceptance of membrane, the growth of PFE’s resulted directly from an interest by owners/operators of installed equipment to maximize bag house performance beyond that provided by traditional filter media and standard bag/cage configurations. Key solutions for problematic dust collectors grew out of the need to address, (a) fine particle emissions, (b) high differential pressure—loss of airflow, (c) installation problems—inaccurate and time consuming, (d) premature bag failures or shortened filter life due to abrasion, blinding or excessive emissions.  Initially—single bag, single compartment or small volume collectors provided a minimum ‘risk” environment for the participants involved. Once proven on a specific application, larger and additional trial installations were easily obtained given the documented benefits of PFE’s performance. Thankfully, the manufacturers have now progressed through a learning curve in both materials and processing to a point where successful application is now the norm. Those OEM’s that were active pioneers to the early trials developed an appreciation of how PFE’s performance could translate into future collector design modification and the resulting cost savings and performance benefits associated.  More recently, as end-users floor space has become a premium and new regulations associated with confined space and explosion prevention are taking center stage, the solutions provided by PFE’s will continue to proliferate in the market. Recent advancement in media and component construction have allowed for introductions of PTFE Membranes, Antistatics, Hydro-Oelophobic and high temperature pleatable filters.

For those collector manufacturers that have yet to venture into the application of PFE’s, we would suggest there is an application knowledge base that is available to you through the technical support staff of both Royal United and its PFE partner, iFIL. With a “state of the art“ manufacturing facility in Harrisonville, Missouri, iFIL USA (Innovative Filtration Technologies) is owned and operated by an industry veteran affiliated with iFIL AG Switzerland and specializes in the manufacturing and distribution of pleated filter bag technology. The combined talents of the US and European team brings vast design and application experience as well as manufacturing know how to the OEM market. Given the competitive marketplace of our OEM clients, there are significant opportunities for pleated technology that we can adderss: footprint and overhead height restrictions, improved air flow and efficiencies, lower total capital outlay on new projects, design optimization with respect to explosion and fire suppression. We are anxious to address your particular objectives or concerns.

Unlike the introduction of Gore-Tex™ membrane which was formerly patent protected, there is not a design patent covering the basic design of configuring spun bond media into a functional PFE configuration. This factor is probably responsible for the proliferation of designs and assembly techniques currently available in the market today. Clearly, competition among manufacturers continues with price and design features the primary criteria for long term success. Many of the specific design features are, in fact, patented designs of the respective suppliers active in this market.

For bag house manufacturers that are experienced in PFE application, we offer the following unique design features of our iFIL product line for your consideration:

TOP LOAD - Virtually all available top load PFE’s are designed with ease of installation and the creation of a gas tight seal with the tube sheet in mind. Very little consideration has ever been given to the difficulty of removal, which can be a nightmare of physical effort once the filters operating life is over. (If you are an active buyer of pleated “top load” bags, please try to remove just one of your current design from an installed hole!) Our unique and patent pending top load design offers the most user friendly installation and removal of any design on the market while maintaining a gas tight seal with the tube sheet. Please view the ease of installation on the adjacent video; removal is accomplished with equal ease. We will be pleased to forward a short sample, upon request, for purpose of comparison to your current design.

STAR BOTTOM - Our exclusive “Ledgeless” Star bottom has created quite a buzz from Plant Sanitation and Plant Management Personnel in the Food & Pharmaceutical industries where there has historically been concern in certain process applications of product being captured and accumulating on the ledge of a traditional bottom puck of the filter. iFIL’s Star bottom and bright white polyurethane, media and other components are intrinsically safe for food contact and are compliant with FDA 21 CFR Ch 1 (April 1, 2009 edition) & 177.1680.

TL SERIES (with BUILT-IN VENTURI NOZZLE) - The uniquely contoured top shape (Patent Pending) of our TL Series top-loading filters provides a high efficiency opening which minimizes pressure drop in the filtering mode while maximizing, or amplifying, the effect of reverse pulse cleaning. Independent laboratory testing has determined this unique profile is capable of increasing available cleaning pressure by more than 10% while providing 15% additional reverse air flow. The combined effect provides a 25% increase in total cleaning energy over currently available competitive designs.

CUSTOMER IDENTITY - Consistent with our Royal United business model to do all in our capacity as a supplier to enhance the ability of OEM customers to retain ALL aftermarket associated with their installed equipment base, iFIL has a unique capability to put their customers’ identity on all Pleated units. Through a unique mold/potting procedure; there are numerous opportunities to incorporate specific OEM identity (Company name, logo and/or phone number) into the molded parts of an iFIL manufactured product at no additional cost for volume users. YOUR IDENTITY ON EVERY UNIT!