Author Archives: Andrew Knapp

Using A Walnut Shell Filter As An RO Protection Filter

The purity of boiler feed water can be a critical part of the manufacturing process. This water needs to be free from contaminants in order for the boiler to operate correctly, without frequent shutdown for maintenance. For this reason, a membrane filtration train is frequently used. Unfortunately, the exposure of plant water to the manufacturing process means that the feed water can be contaminated with both high levels of oils and solid material. Frequently, the membrane filtration will need an upstream filter, to extend the life of the filters and protect membranes.

The STiR walnut shell filter was selected by a global tire manufacturer to solve issues related to its’ membrane filtration train. This train includes reverse osmosis and nanofiltration, and was made unviable by high levels of oil in its’ boiler feed water. Oil levels were high enough that the train was taken offline until a solution could be found, and the recirculated water could not be used in the boiler.

Walnut shell media was selected because of its’ ability to remove free oils and greases without causing damage to the media bed. Sand filters and carbon filters may blind prematurely when exposed to free oils, necessitating frequent bed changes. Walnut shells catch oil droplets on their surface, which are easily removed during backwash cycles. This means that a walnut shell media bed does not need to be replaced when exposed to oil, and has a lifespan of approximately 20-25 years.

The walnut shell filter was able to protect the RO system and nanofiltration membranes, significantly reducing the oil load to them. The free oil concentration were reduced from as high as 85 ppm, to less than 1 ppm. This reduced frequency of membrane fouling, reducing the total purchasing cost. It also reduced the maintenance requirement of the membrane filters, while protecting the RO system from oil slugs which had caused it to rapidly foul. Additionally, water heating costs were reduced, as water could now be sent directly back to the boiler.

How To Choose The Best Industrial Water Filtration System For Mining Applications

Over the course of the past few decades concern for the environment has brought about a large number of new regulations concerning the use of water in mining operations. These include how it is accessed, and how it is treated, using industrial water filtration to ensure all waste water generated meets with acceptable standards of cleanliness.

In the mining industry, things like overburden, waste rock, and tailings are considered by many to be among the largest forms of waste generated. However, another major pollution source is the water directly discharged from the mining process, proving that proper industrial water filters are vital to protecting the environment.

The Need For Industrial Water Filtration By The Numbers

According to the latest statistics, over 70% of all pollutants produced by the mining industry (this includes both open pit and underground mining) are emitted via the water used in the process. This water must be processed through high quality industrial water filters in order to avoid the release of toxic materials into the environment. Heavy fines may be levied against those who fail to meet required standards.

Filtra-Systems Offer Superior Industrial Water Filters

There is more to choosing the best industrial water filtration system than cost. The first, and perhaps most important of these is the ability of the industrial water filters you choose to remove the contaminants from the water.

Operating and maintenance costs must also be factored in. Filtra-Systems STiR filter uses a highly efficient mixer and backwash method, while utilizing walnut shells as a filter media to remove contaminants from the water. Walnut shells were chosen for their ability to remove sticky solids and oils from the water, and for their ability to be used for longer periods of time between cleanings. Not only does this increase the effectiveness of our industrial water filters, it also served to reduce operation and maintenance costs.

The STiR system is capable of removing up to 95% of all suspended solids and insoluble hydrocarbons without the addition of chemicals. A single industrial filtration unit can process between 50 and 6500 gpm based on the application, making the STiR filter one of the most effective and efficient industrial water filters on the market today.

If you would like to learn more about Filtra-Systems and our STiR Industrial Water Filter, contact us today. We look forward to hearing from you!

Should You Select Bag Or Cartridge Filters For Your Industrial Application?

When it comes to industrial filtration, there are several different filter types to choose from when working with industrial grade liquids, including both bag filters and cartridge filters. Ultimately, however, the final choice comes down to choosing the right filtration technology to meet the performance demands of your facility, while remaining within your projected operating costs. Both bag and cartridge style filters offer removable media, but the final decision should be based on the application, as each type of media has its advantages and disadvantages.

Bag Filters

Bag filters are often the best choice for any number of industrial applications. These types of filters use a wide range of filtration media based on the application, such as activated carbon, needle felt, and nylon monofilament mesh. The operate by trapping waste solids inside the bag and are considered to be a relatively low-cost form of industrial filtration.

However, these filters have a smaller surface area than most cartridge filters. The low overall operating cost makes bag filters an excellent choice for small batch operations where the cost of a self-cleaning system would not be justified. Along with this, small operations will not have a high bag replacement frequency leading to lower disposal costs. Bag filtration systems tent to produce less solid waste than cartridge filters, making them an excellent choice for applications where the user wants to minimize their volume of waste.

Cartridge Filters

Cartridge filters capture solid contaminants on the outer surfaces of the filter media. These types of filters run the gamut from inexpensive bonded units to more expensive models made from a variety of high-capacity pleated types of media. These filters can be used for a wide range of applications where sub-micron filtration is needed. These include beverage and food production facilities, chemical and paint plants, and applications where the filtration of acids and bases is required. Cartridge filters are also ideal for pharmaceutical applications as well as those in which ultra-pure water filtration is required.

How Industrial Water Filtration Can Improve Efficiency And Save You Money

Over the course of the past couple of decades, industrial water filtration has become one of the most important considerations for the average manufacturing facility in North America. These concerns have only increased as water supplies have dwindled and wastewater contamination standards have become more stringent. All of this has led to the need to choose the right industrial water filters and filtration systems to increase overall system efficiency and keep costs to a minimum.

Here at Filtra-Systems we understand how important the right industrial water filtration system is to your facility’s efficiency and operating costs. We are proud to offer our STiR technology, or industrial water filters with superior performance. These filters have been designed to maximize water filtration, reduce solid waste disposal costs, and decrease your overall expenses. The right filtration system can help your facility in three ways:

1) Reduced Filtration Media Fouling

Depending on the nature of your business, the wastewater you produce or the cooling water you reuse can quickly become contaminated by a wide range of solid waste contaminants. While most filter systems can remove a high percentage of contaminants in wastewater, they may not be capable of restoring the purity of your cooling water sufficiently. When your filter media becomes fouled, water flow is reduced, resulting in decreased cooling effectiveness and productivity.

Our STiR industrial water filtration system removes the maximum quantity of contaminants during each backwash cycle, significantly improving water flow throughout the system. This in and of itself will make a significant improvement in your overall manufacturing efficiency and operating costs.

2) Reduced Waste Disposal

Many industrial waste filters use sand as the filtration media to remove contaminants such as oil and grease from water. The problem with this type of filtration is that these substances tend to create solid balls of mud from the sand media. In turn, this reduces the efficiency of the filter and the flow of water throughout the entire system. The net result is that you end up replacing these filters frequently at a significant cost.

3) Reduced Waste Disposal Costs

If your industrial water filters are more efficient and effective at removing contaminant particles from your water supply, your filter media is going to last longer. This in turn means that you will not have to replace the filter media as frequently. Since you have to pay to dispose of the filter media, by extending it’s lifespan you can significantly reduce your filtration costs.

No matter which of the Filtra-Systems industrial water filtration systems you choose, you can count on them to improve your facility’s overall efficiency and reduce your overhead operating costs. If you have any questions about our STiR filtration unit or any of our other industrial water filters, contact our team of professionals and let us help you find the perfect filtration system for your business.

Why Coolant Filters Are A Must For CNC Machining Applications

There are several reasons why your shop floor should be using the latest in CNC coolant filtration systems to help keep the coolant system working properly. Most in the industry are well aware of how much money coolant filtration systems can save a company over the course of a year, and the lifetime of each machine. But this is only the beginning, as filtration companies such as Filtra-Systems move towards the creation of systems that are more effective and efficient using a wide range of filtration mediums.

Poor Filtration Costs Money

The simple reality is that in today’s manufacturing environment of ever-tightening budgets, the use of a poor-quality CNC coolant filter can lead to a range of problems. Among the worst of these are the risk of metallic fines ending up in the coolant, and the growth of bacteria. A buildup of metallic fines within the coolant not only reduces the quality of machined parts, but also leads to accelerated wear throughout the machinery, causing damage to the pump, nozzles, and potentially the machine tool.

Doing Things The Right Way

Today’s machine industry is running machinery that operates faster than ever and is working with metals that are more abrasive than those cut in the past. All of this places a huge demand on the coolant, and therefore the CNC coolant filter system. It has become more necessary for modern coolant filtration systems to provide extremely stable and reliable performance.

There was a time when a machining facility might be able to get away with a CNC coolant filtration system that was cobbled together using parts from a variety of manufacturers or systems. In today’s high pressure, high speed machining environment where extreme precision is more important than ever, this type of system is no longer good enough.

At Filtra-Systems, we offer turnkey chip processing and coolant filtration systems designed to provide your facility with continuous operation. Whether you are manufacturing engine blocks, camshafts, axles, or any one of thousands of other products, our CNC coolant filters are designed to provide your machines with the cleanest possible coolant at all times.

Your Company, Your Coolant Filtration System

At Filtra-Systems we understand that no two of our clients have the same needs. To ensure that we meet the needs of every customer, we offer both central coolant systems and stand-alone units built to meet your requirements. Our CNC coolant filter systems can be customized to meet your needs using pressure, vacuum, magnetic, and bag filters to ensure every drop of coolant sent back to your machines is as pure as possible.

Our goal is to help our clients keep their operating costs under control by reducing the wear on their machinery. We accomplish this by providing the highest level of coolant filtration possible at all times.

Filtra-Systems Receives Ford Supplier Achievement Award

Ford Excellence Award Photo
Filtra-Systems Vice President Keith Bratten receives the Supplier Achievement Award from Ford Executive Engineer

Filtra-Systems has received the Ford Achievement in Supplier Efficiency Award for Manufacturing and Engineering Excellence.

This is the culmination of a long working relationship with Ford, which has resulted in the delivery of many filtration systems around the world.

Featured projects that have been completed with Ford Motor Company can be seen here:
Aluminum Machining



How You Can Benefit From A Professional Review Of Your Industrial Wastewater Filtration Requirements

When your facility generates industrial wastewater, you must have at least some form of industrial water filtration system to ensure that you are not pumping industrial waste into the environment. Over the past few decades in the US, the EPA has imposed increasingly strict rules with regard to the release of industrial waste into streams, rivers, lakes, and waterways.

If you are not using the right wastewater filters, you could find yourself in a violation of a number of regulations. The implementation of a professional review of your filtration requirements is the best way to ensure that you are in full compliance.

Benefits of a Professional Review: Where is Your Waste Coming From?

Do you know exactly how much wastewater your facility produces, and where it is coming from? It is important to have a professional inspector come to your facility and examine your entire operation and all processes in order to determine the source of your waste.

How Much Wastewater Are You Producing?

It is your job to know exactly how much industrial wastewater you are producing at any given moment. You should know exactly how much clean water is coming into your facility and how much wastewater is leaving it. An inspector can work with you to determine these figures down to the gallon. They can ensure that your industrial water filtration system has the required capacity to fully treat all of the wastewater that your facility generates.

Are You Using the Right Filtration Media?

Perhaps the most important factor to consider with wastewater filtration is ensuring that you have the right industrial water filtration media for your process. At Filtra-Systems our industrial water filtration systems make use of a wide range of filtration media, including pressure, vacuum, and bag filters. These can be used to remove a variety of contaminants such as oils and suspended solids.

During your water filtration review our representative will go over your complete system and identify areas that need improvement, not only to ensure your facility meets the latest regulations, but that it is operating at maximum efficiency. We can provide your facility with a custom built, state of the art industrial water filtration system that meets your needs now and can be adapted to meet them as they change in the future.

See How 3 Industrial Processes Benefit From Filtration

The best way for you to see how our industrial filtration systems can benefit your business is to look at three different situations where our products have made a major impact on the efficiency and cost-effectiveness of particular companies. We have found that in this industry it very easy to make claims regarding the abilities of your products, but what really counts is the ability to prove that your products work exactly as described.

Eastman Kodak

Eastman Kodak has been one of the leading names in imaging for decades, going back to the original personal cameras. At the Eastman Kodak facility located in the northwestern US, the company produces chemicals that are used to process a wide range of health imaging films. Eastman Kodak had been using a rotary drum filtration system to filter, wash, and dewater their products. However, the company conducted a study to find a more effective and efficient process. Their research found that a vertical tower filter press would make a major difference. The one chosen was the Filtra-Systems Verti-Press as it offered superior efficiency and the ability to operate with any arrangement of chambers offline (for maximum maintenance versatility).

The Modern CNC Machine Shop Floor

For decades the average CNC machine shop used a central coolant system that utilized trenches in the floor as a way to transfer contaminated coolant from the various machines to a central pit. The filters were located at the end of a sloped trench No only was this highly inefficient, but in many instances routine maintenance was very difficult and costly.

Today, CNC facilities are installing a centralized machine tool coolant filtration system that is located on the floor rather than under it. Not only does this system do away with the need for trenches running under the floor, it also allows management to modify the number of filters, and in fact the entire system as their needs change.

The STiR Industrial Water Filter

Achieving the highest possible level of wastewater filtration is more important than ever, as regulations have become more stringent. While industrial water filter using sand, anthracite, and carbon media have their uses, they have always been susceptible to media failure due to fouling. This leads to increased downtime and expense, as the filter media must be changed on a regular basis.

Our patented STiR technology can remove up to 95% of suspended solids, and 90% of insoluble hydrocarbons from your wastewater. More importantly, our STiR industrial water filters do need the addition of chemicals to achieve these results. We can provide you with individual units that can process fro 50-6,500 gpm, and will build complete systems that are ready to be installed.

Over the past 40 years, we have found that there is no such thing as one size fits all when it comes to industrial wastewater filtration. We offer a complete range of custom water filtration systems that can be used to improve your business’ efficiency and reduce your operating costs. Contact us today and let us work with you to solve your wastewater problems!

Why Your Company Needs A Mist Collector

From large machinery air quality, successful companies understand that pragmatic safeguards are necessary in order to protect their workers from the dangers that are inherent to industrial environments. Oftentimes, these safeguards not only protect workers’ health, they have a significant positive impact on the efficiency of the process. Companies that choose to invest in these safeguards help keep their employees safe and can make more money in the process.

Improved Workplace Health

When coolants and oils are sprayed onto parts during cutting, honing, and grinding processes, oil mist is released into the air. If good mist collectors are not installed, this oily mist will leave the machine and escape into the air. As can be easily deduced, this mist is not healthy for humans to breathe. Limiting lung exposure to this byproduct of CNC machining has a measured benefit on workers’ health. In addition to the respiratory issues that can result from the inhalation of oil mist, long term exposure can cause skin disease. The current OSHA standard for mineral oil in air is 5 mg/m3. Air passed through HEPA filters generally has 0.5 mg/m3 of oil mist, 10X below OSHA standards.

Mist collectors are commonly mounted to the cutting machine, and prevent oil mists from entering shop air. HEPA filters can prevent this from happening by removing most particulate from the air stream.

Improved Maintenance & Efficiency

Filtra-Systems has designed coolant filtration systems for industrial applications for decades, which is why we understand the need for robust solutions that require little maintenance to ensure optimum output with little downtime. Systems that lack mist collectors must address maintenance problems with mist that accumulates on the walls, floors, and machines. Just as importantly, systems that lack mist collectors must spend money on additional coolant to add to the system in order to make up for the volume  that is lost to the air. Both of these issues can cost a company time and mone

The Filtra-Systems Advantage

Filtra-Systems Gen II Mist Collectors have several distinct advantages over competing collectors. The vast majority of coolant can be returned to the machine because it is mounted directly to the CNC machine, before any ductwork. The centrifugal separator protects the disposable HEPA filter, minimizing the cost of replacement media and downtime during change outs.

Designed with our customers in mind, our oil mist collector will improve your company’s bottom line and protect the health of your workers.

Customized Filtration Solutions: Mining & Chemical Industries

To ensure that all companies involved in the mining and chemical industries have access to the necessary industrial water filtration systems, Filtra-Systems has been working with their clients on a continual basis to promote accuracy and sustainability. Since no two clients’ needs are the same, Filtra-Systems offers customized filtration solutions that fit our customers’ needs.

Different Types Of Mining And Chemical Solutions

Filtra-Systems is a filtration company that has been seeing to our clients’ diverse needs by means of custom engineered filtration systems for years. Because of our customer’s fluctuating demands, Filtra-Systems has tailored our systems to be compatible with the systems of our clients, thus ensuring that every filter technology is used with its required applications. Available solutions include:

Customized Filtration Solutions And Its Many Perks

Solutions depend entirely on what filtration system is being used. The proper filtration solutions are necessary in order to optimize the unique needs of a company. Water filtration companies that create innovative technology based on current industrial filtration system trends are the companies that bear choosing when it comes to mining and chemical needs. Each product must be thoroughly tested and built with the most optimal information and technology; once the industrial water filtration meets that criteria, it can be customized to any company’s exact needs.

Improve Operating Efficiency Through Custom Filtration Solutions

Each filter will vary depending on the company in question. Filtra-Systems has worked with a broad range of clientele over a considerable span of time, and this has given us a thorough understanding of how to optimize workflow through the use of customized filtration systems. Understandably, certain companies have concerns about specific applications, all of which can be solved through the services of a custom filtration systems company like Filtra-Systems.

When used correctly and for specific purposes, an industrial filtration system can have a highly beneficial impact on the efficiency of an operation as a whole. Filtra-Systems understands this, which is why we tailor each of their filtration systems to our customer’s needs, using state of the art technology. For companies looking to optimize their workflow, Filtra-Systems is the company to call.