Author: Richard Juskowiak, Donaldson process filtration division
The growth of production needs at modern plants requires increasing the efficiency of sterile filters for gas and liquids. Over the past thirty years, filtration technologies have not undergone significant changes.
However, over the past two years, a team of 40 engineers and materials-science specialists, in close cooperation with large food and beverage producers, has been solving problems in the field of microfiltration. The results of this work were significant improvements in the following filter characteristics.
- Throughput.
- Integrity and service life.
- Filter replacement frequency.
In 2016, the production of the improved Donaldson LifeTec™ filter line was launched in Europe and North America. Let us look in more detail at the problems that the LifeTec filters solve.
Industry: Spring water Problem: A producer may claim that its water has «natural purity» only if it meets certain requirements and…
Throughput
The high throughput of standard-size filter elements (diameter 2.75 inches and length in 10-inch increments) has always been accompanied by a high pressure drop requiring additional energy costs. To increase output, throughput must be increased. To solve this problem, the developers of the LifeTec filters created a pleated cartridge with a dense packing of polyethersulfone (PES) filter material. The asymmetric pore structure of the membrane retains particles in the size range required for sterilization and has an increased throughput compared with a symmetric membrane.
A standard-size cartridge holds 20 percent more filter material, and the increase in free space to optimize the passage of the flow ensures an increase in throughput of up to 20 percent in existing filter housings.
Industry: Spring water Problem: A producer may claim that its water has «natural purity» only if it meets certain requirements and…
Integrity and service life
Under the harsh conditions of processing, cleaning and sterilization in food and beverage production, filters are subjected to significant loads. In addition, through carelessness, filters can be deformed during installation. Since the filter material is a fragile and precise structure, any damage to the cage must be prevented.
LifeTec elements have a lattice structure with diamond-shaped or triangular cells, resembling the design of bridge supports. Such a design withstands loads that can damage or reduce the efficiency of the element, and also provides increased resistance to the pressure drop in the filter during the daily filtration of a large volume of liquid.
A filter that withstands carelessness during installation and heavy operating modes provides increased safety, has an extended service life and reduces costs.
Filter replacement frequency
The third problem in liquid filtration is supply. The huge number of unique sizes and ratings of filters and their components has led to users having to wait weeks for spare parts that are produced irregularly.
Donaldson solved this problem by launching single-flow production of LifeTec filters. We can quickly make the components of each 10-inch module to order, including variants of a specific length or a version with end caps. All elements are assigned serial numbers to ensure full traceability. This production method speeds up delivery and can minimize manufacturing defects.
General advantages of the technology
LifeTec is a truly revolutionary technology for the filtration of liquids and gases. It sets a new standard in water bottling and other liquid applications. The first enterprises where the new filters began to be used were the plants of a well-known European soft-drink producer and two other companies that took part in their development. The new technology can increase productivity and safety when modernizing filtration systems in food and beverage production.
