The compressor is one of the main electricity consumers at a plant. A dirty filter makes it even more expensive

Find your situation

What industrial enterprises come to us with

Click a situation – we will show where the problem comes from and how Donaldson filtration solves it.

Pneumatics and valves break too often – there is condensate in the pipeline

Machine building, assembly lines, any production with pneumatic drives

The compressor compresses not only air but also the moisture it contains. As it cools in the pipeline, it condenses. Water in the air line destroys the seals of valves and pneumatic drives from the inside – unnoticed until they start to fail.

A typical situation

Valves and pneumatic tools are rated for 3–5 years but are replaced every 6–12 months. No one links it to air humidity until an engineer checks the system. After a dryer is installed, the service life recovers.

Dryer down to dew pointRemoves moisture from the air down to −40…−70 °C – no condensate in the line

Moisture separation and filtrationCuts off droplets and aerosol before the point of use

Pneumatics life ×3–5Valves and drives last their rated life instead of 6–12 months

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Craters and defects in the coating – the cause is in the air, not the paint

Paint shops, varnishing, powder coating, automotive

The problem appears randomly – not on every batch, not on every part. They change the paint, check the operator, adjust the temperature. But the source is oil aerosol or silicone from an ordinary filter's seals, which gets into the air and settles on the surface before application.

It is about silicone

One microgram of silicone per square meter of surface – and the whole paint layer craters. Standard filters contain silicone seals. A paint shop needs special ones – silicone-free.

Silicone-free filtersA special series for painting – zero silicone contamination

Oil aerosol removalCoalescing oil filtration down to 0.01 mg/m³

Air class for paintingConsistent coating quality from batch to batch

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The electricity bill grows – the compressor runs, but its efficiency drops

Any production with a compressor station – hidden energy losses

The compressor is one of the main electricity consumers at any plant. When a filter in the system clogs, flow resistance rises. The compressor has to work harder to maintain pressure. This is invisible on any given day but clearly seen in the annual bill.

Simple math

Every extra 0.1 bar of resistance on the filter adds about 0.5–1% to the compressor's electricity consumption. Donaldson filters have 40–60% lower resistance than standard equivalents. On a large compressor station that is a noticeable saving.

Pressure drop −40…−60%Lower resistance on the filter – easier for the compressor

Electricity savingsEvery 0.1 bar is 0.5–1% of the electricity bill

Payback in monthsOn a large compressor station the difference shows in the annual bill

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Filters are changed too often – each change stops the system

Any production – unplanned stops, emergency element replacements

At an industrial plant, changing a filter means stopping part of the system, waiting for the pressure to bleed off, a mechanic's work, and starting up again. If this happens every 2–3 months instead of a planned once a year, the loss of time and money accumulates quietly but steadily.

Why this happens

Cheap filters trap contamination only on the material's surface. It clogs quickly, pressure drops – and it has to be replaced early. Donaldson Ultrafilter filters work through the whole depth of the material and trap 47% more dirt.

+47% service lifeDepth filtration through the whole material – fewer replacements

×2–4 service lifeOne element replaces 2–4 generics under the same load

Planned replacement once a yearFewer unplanned system stops

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Aggressive media, high pressure or non-standard conditions

Chemicals, oil and gas, energy, gas turbine air intakes – when there is no standard solution

Not all industrial production is a standard compressor and pneumatics. Chemical media, high pressure in gas mains, aggressive gases, low temperatures – such conditions require different materials and designs.

Donaldson covers any conditions

Housings for pressure up to 400 bar – for gas transport systems and oil production; chemically resistant materials – for acids, alkalis and solvents; special dryers for extreme temperatures.

Pressure up to 400 barHousings for gas transport and oil production

Chemically resistant materialsFor acids, alkalis and solvents

Extreme temperaturesSpecial dryers for operation in freezing conditions

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Did not find your situation? Describe the task – a Profair Solutions expert will suggest a solution.

Why Donaldson

Not just filters, but concrete results

+47%

Works longer without replacement

Donaldson filters trap 47% more contamination. Fewer stops – more output.

−27%

Cheaper over a year

One Donaldson cartridge replaces 2–4 generics. The purchase price difference pays off within 1–3 months.

−40…−70°C

For any conditions

From standard drying to extreme cold, from 7 to 400 bar – Donaldson covers the entire range.

How we work

With production facilities – from diagnostics to support

Step 1

We listen to your task

No technical briefs – you just tell us what is happening.

Step 2

The expert analyzes

We study the process and find the risk points.

Step 3

We propose a solution

A specific protection scheme – nothing extra.

Step 4

We supply and support

Equipment, documents, installation if needed.

Step 5

We stay by your side

Consumables, audits, questions – a single call.

Related challenges

Common situations in industrial production

Moisture in compressed airCondensate, pneumatics fail Line downtimeThe filter clogged early Energy lossesThe compressor runs idle

Industrial production – where compressed air is everywhere, but no one thinks about its quality

What industrial enterprises come to us with

Pneumatics and valves break too often – there is condensate in the pipeline

Craters and defects in the coating – the cause is in the air, not the paint

The electricity bill grows – the compressor runs, but its efficiency drops

Filters are changed too often – each change stops the system

Aggressive media, high pressure or non-standard conditions

Not just filters, but concrete results

Works longer without replacement

Cheaper over a year

For any conditions

With production facilities – from diagnostics to support

We listen to your task

The expert analyzes

We propose a solution

We supply and support

We stay by your side

Common situations in industrial production

Not sure which filter protects your production?

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