The 6‭ ‬Key Challenges
of Process Filtration

1. Knowing your system and when to make changes

The first consideration for your filtration needs is choosing the right filter to suit your process demands‭. ‬Hhow do you use that filter in a way that ensures optimum performance‭? ‬

When choosing a filter‭, ‬it is important to think about it in line with your process‭. ‬The parameters may look right in the catalogue, but consider what happens both upstream and downstream of the intended filter‭. ‬Considering those may alter your decision‭. ‬Filters aren't created equal, so it’s crucial you choose the correct filtration system for your specific process and business need‭. ‬

Remember to use the expertise of your supplier‭ ‬‮–‬‭ ‬they are there to help solve your problem‭, ‬digging deep into your needs and expectations‭. ‬Rely on your supplier's filtration expertise to help you choose the right filter‭. ‬

It might be that your current filter works fine‭. ‬But when did you last optimise your processes to check you're getting the most out of your system‭?‬ A large proportion of filters in use today could be improved on or optimised‭, ‬but often they're left to operate without review‭.‬‭ ‬

It may feel like a risk‭ ‬‮–‬‭ ‬if your filter is working‭, ‬why change it‭? ‬But a fully optimised filtration process will result in a more consistent product quality and reduce your filter usage‭ ‬and running costs‭.‬

Without optimisation‭, ‬there could be variability in the final product, leading to unhappy customers‭. ‬Or you might not be getting‭ ‬full capacity out of your filters‭, ‬which will inevitably cost you more‭. ‬

2. Cost

The adage‭ ‬‘buy cheap‭, ‬buy twice’‭ ‬has never been more relevant than when choosing a filter‭. ‬Consider two different filter suppliers‭; ‬Supplier A charges 3x the price than Supplier B‭, ‬but the filter from Supplier A will last 10x as long and improve the quality of your‭ ‬product‭. ‬More expensive is not necessarily better‭ - ‬choosing the correct filter selection is the priority‭. ‬However‭, ‬cheaper suppliers may not have the quality systems or technical support required‭.‬

Let’s examine the ways you reduce the costs associated with filtration‭.‬

Start by optimising your filtration train‭ ‬‮–‬‭ ‬you might be using multiple stages of filtration because it’s always been done that way‭. ‬A review could see that number drop‭, ‬or a review of the type of filter, could see a later specification of product offering longer onstream life‭, ‬therefore reducing the cost of filtration and the labour involved in changing each‭ ‬stage‭. ‬But don’t be afraid to lean on the expertise of your filter supplier‭ ‬‮–‬‭ ‬they can help you reduce your costs‭. ‬

The overall costs of production will often involve more than one person‭.‬ The person responsible for buying the filter will naturally want to pay less per item‭, ‬but that may be at odds with the person in production whose main concern is using a filter that lasts as long as possible‭, ‬to eliminate the need to replace it‭. ‬While it‭ ‬may be hard to get different departments to agree‭, ‬consider higher-quality filters regardless of your job function‭, ‬because of the long-term benefit optimised process filtration offers to your business‭.‬

3. Regulation

It’s important to keep regulation at the forefront of your mind‭. ‬Choose a filter supplier who has a deep understanding of the legislation for your sector‭. ‬This will ensure they supply you with the filtration solution you need to meet those regulations‭. ‬The best filter suppliers don’t just understand the filtration process‭,‬ but also the demands of that application in relation to the regulatory framework‭. ‬

Don’t underestimate documentation‭. ‬The suppliers who understand the legislation pertinent to your sector‭ ‬will provide the right documentation i.e‭. ‬Certificate of Conformance‭. ‬There is also the requirement to use appropriate materials of construction approved to international standards‭, ‬depending on the industry‭.‬ For example‭, ‬pharmaceuticals must conform to FDA regulations; in the water industry‭, ‬the DWI‭. ‬This will give you confidence that you're using the right product‭. ‬Log that in your systems‭, ‬so that if there are any problems further down the production line‭, ‬your filter can be fully traceable‭. 

The higher the risk‭, ‬the greater demand for testing and validation will appear, and with it, an increased level of documentation‭. ‬And with more testing‭, ‬comes more documentation‭. ‬On paper‭, ‬a low-cost filter may look attractive‭, ‬but it’s the correct‭, ‬relevant documentation that matches the demands of the process that you pay for‭. ‬

Traceability on materials of construction is paramount in ensuring a product will always perform to specification‭. ‬Where appropriate, you can use the filter serial number to trace source materials and manufacturing process details to give you the necessary‭ ‬confidence in supply‭. ‬

4. What happens if something goes wrong?

No one wants to halt their process for any reason‭; it incurs costs and limits the amount of product you can produce‭. ‬Reducing the risk of unscheduled stops is imperative‭. ‬A reputable filter supplier who has quality systems in place will vastly reduce this‭ ‬risk‭. ‬

5. Environmental factors

Producing any product can have a serious impact on the environment‭. ‬Businesses are increasingly required to demonstrate how they‭'re mitigating this impact‭. ‬Choosing an environmentally friendly filter supplier who considers this in their approach is important‭. ‬Amazon Filters is currently investigating three initiatives‭.  

1. Waste to Energy programmes‭ ‬run by companies like Veolia and Biffa‭. ‬Plastic waste is incinerated to produce heat/energy‭.‬
2. Investigating the manufacture of filters from waste plastic‭.‬ Amazon Filters are constantly evaluating making filters from more environmentally responsible materials such as polymers derived‭ ‬from vegetable or starch sources‭, ‬or from recycled materials‭.
3. Packaging materials
   1. Reducing packaging by supplying multiple filters in a box rather than boxing each filter individually.‬
   2. Reducing the gauge of carboard used‭.‬
   3. Recycling all the packaging we receive from our suppliers‭.‬
   4. Looking at new materials for the bags which are manufactured from renewable, plant-based sources‭.‬
   5. Replacing plastic-based packaging e.g‭. ‬filler and sealing tape‭, ‬with paper-based material‭.‬

We also store and sell the waste produced in the filter manufacturing i.e‭. ‬off cuts ‬of filter material etc‭, ‬and recycle them for use in lower spec products such as coat hangers‭, ‬crates‭, ‬etc‭. ‬We've installed solar panels that generate energy for the National Grid‭, ‬reducing our reliance on conventional energy sources and our carbon footprint‭. ‬We’re even reducing how much energy we use in our factories and offices by installing LED lights‭, ‬insulation and new compressors‭.

6. Safety

The tragic explosion at the‭ ‬Nypro UK chemical plant in Flixborough‭,‬‭ ‬changed the industry‭. ‬Now safety needs to be at the top of everyone’s agenda‭. ‬

Does your filter supplier comply with the appropriate codes‭? ‬Do they adhere to and follow national and international standards‭? ‬Does your supplier know and follow industry guidelines‭? ‬

Amazon Filters is accredited with the ISO 45001‭ ‬system which demonstrates the safety features within our own production environment and our products‭ ‬are designed to ATEX requirements‭.   ‬

Preventing contamination or product contact with the operators is also an important consideration‭. ‬Depending on your industry‭, ‬you may be filtering something unpleasant and/or harmful‭. ‬The last thing you want is for your operator to come into contact with‭ ‬an unpleasant substance when they are replacing filters‭, ‬for example‭. ‬Operator Exposure levels must follow the strict guidelines‭ ‬set by the Health and Safety Executive‭. ‬Amazon Filters can support this with products targeted at contamination control‭, ‬with the environment and operator safety in mind‭.‬

Does your supplier prioritise design control to lessen the health and safety risks‭? ‬Preventing injury and minimising risk must be taken in to account when designing a pressure vessel‭ (‬and any part of process filtration‭). ‬Design features, such as quick release clamps‭, ‬hydraulically operated closures‭, ‬and retained location devises to minimise parts falling in to a vessel‭, ‬are all part of the care that should be in a good vessel design‭. ‬