Filters are designed to be disposed of when full of contaminants. Although they're not considered environmentally friendly, manufacturers are coming up with new ways to make them kinder to the planet. This includes filter technology to reduce carbon emissions, waste initiatives, and accreditations such as ISO 14001:2015 for environmental management.
Here are some things to look for when assessing the sustainability of your filtration processes.
Reducing waste
An obvious but crucial step – wasting less and recycling more. From production and packaging waste to PPE and office resources, small changes can make a big difference. More sustainable manufacturers will use waste-to-energy schemes, a lean production methodology, and other popular waste reduction programmes.
Waste to energy
Energy recovery plants incinerate old filters and other waste products to produce power. This energy is harnessed using water and steam turbines. The process is similar to how coal and nuclear plants produce energy. Incineration also prevents how much waste goes to landfill.
Lean production methodology
Applying lean manufacturing principles ensures companies maximise quality and productivity while minimising waste.
Waste is defined as anything the customer doesn’t get value from. The eight most common causes of waste are:
- Excess inventory
- Overproduction
- Over-processing
- Product defects
- Idle people or equipment
- Unnecessary motion (people, equipment, machinery)
- Unnecessary transportation
- Unused talent or ingenuity
Renewable energy
Look for a reduction in reliance on fossil fuels, whether that’s through installing solar panels on company buildings or buying from renewable suppliers.
Optimising processes
Filter lifetime
The longer a filter can run for, the better. If your process isn’t optimal, operating costs and downtime increase. Using quality solutions that cost more upfront but last longer can make a huge difference. In some cases, filters that once needed replacing daily only need changing monthly.
You can extend filter lifetime by using:
- Cartridges with antimicrobial and anti-algal coatings to slow the development of biofilm
- Prefilters to remove larger particles and extend the life of membrane filters downstream
- The correct filter type to prevent blockages and higher pressure drops
Filter sizing
Correctly sized filters remove unwanted particles while minimising system pressure drops and maximising filter on-stream life. This:
- Increases efficiency and production rates
- Minimises downtime
- Reduces waste
Packaging
Packing methods can produce a lot of excess waste. Making simple swaps like bleached card for brown card, PVC tape for paper tape, and PU foam for paper packaging make a big difference - especially at scale. As does packaging more efficiently, for example bundling products to save space or reducing packaging thickness.
The future of filter technology to reduce carbon emissions
Pyrolysis
Turning used filters into biofuel makes use of plastic waste when it can’t be recycled. It also reduces the reliance on fossil fuels. Pyrolysis works by heating waste without oxygen so it thermally decomposes into combustible gas. This gas is used to power the pyrolysis process, generate electricity for the local grid, and more.
Filter materials
Most filters are made from plastic because this is still the most practical and cost-effective way to filter fluids and gases across many industries. But new materials that are better for the environment and don’t compromise on performance are emerging.
Monomers used to make polymers for polypropylene are usually derived from fossil fuels. But new materials, like Bornewables™, are made from vegetable oils.
These new materials are used to make biodegradable polypropylene melt blown cartridges. Replacing one tonne of conventional polypropylene with the new sustainable material will remove 2.1 tonnes of carbon emissions, reducing carbon emissions to 1kg for every 30" melt blown filter.
Greener filtration processes
A great way to make your own processes more environmentally friendly is to choose your suppliers carefully. Ask how they reduce carbon emissions through their sustainability practices. Look for industry certifications for environmentally conscious production, clear information on filtration materials, and in-depth industry knowledge to support you in reducing waste. Get in touch to learn more about our sustainability initiatives.
