The Art of Meltblown: Decoding Filter Machine Operations

In recent years, since melt-blown filter elements play an important role in the coarse filtration of water and beverages, the demand for melt-blown filter elements has been growing steadily. With the global supply chain crisis caused by the pandemic, more and more companies are choosing to produce their own filter elements in order to ensure the safety of the supply chain, but they don’t know how to produce them. So, today we are going to talk about what beginners should know if they want to enter the production industry of melt-blown filter elements.

Meltblown Filter Materials

Firstly, you should choose the right materials for meltblown filters. Generally speaking, there are approximately 90 percent of meltblown filters made from PP. The advantages of PP material are lightweight, good toughness, good chemical resistance, low water absorption, and good chemical resistance in various acids and alkalis. Of course, there are other materials that can be used as melt-blown filter elements, such as PBT material. PBT is generally used for oil filtration and oil-water separation in high-temperature environments and aggressive hydrocarbon fuels and oil. If you have a sufficient budget and high environmental protection requirements, you can consider PLA material. This material is 100% biodegradable and very environmentally friendly. In addition, in biological and medical aspects, other materials or different material mixtures are also used to make filter elements. However, those materials are all targeted materials adopted after a thorough analysis of the chemical substances to be filtered and are not used widely, so we will not discuss them.

 

Meltblown Filter Production Process

Secondly, we will introduce the process of melt blown filter production.

Step 1: Pour PP plastic particles into the feeding barrel. Our melt-blown filter machine adopts an automatic feeding system, so you don’t have to worry about the capacity of the barrel and the downtime caused by not loading the material in time.

Melt Blown Filter Machine

Step 2: The plastic particles enter the extruder and are heated and melted. Our extruder is heated internally in stages, which will not cause the internal temperature to be too high and cause serious carbonization of some plastics. There is a temperature sensor to control the internal constant temperature.

Step 3: The plastic liquid is extruded from the mold.

Step 4: The blower blows the molten plastic into plastic threads. The blower is connected to the oven and hot air blows the plastic to prevent premature solidification of the plastic threads.

Step 5: The rotating rod receives the plastic threads and is wound into a melt-blown filter element.

Receiving Rod Of Melt Blown Filters

Step 6: The filter element is cut to the required length. Our equipment allows the combination of rotating rods and cutting equipment to achieve automatic cutting.

Produced PP Melt Blown Filter

Step 7: Weld the end caps or fins on both ends of the filter element. In order to adapt to the welding of filter elements of different sizes, we recommend our infrared welders for melt-blown filters.

spun bonded filter end cap welding melt blown filter end cap welding

servo control melt blown filter IR welder

In this process, the extrusion pressure of the extruder, the distance from the extruder to the rotating rod, and the rotation speed of the rotating rod determine whether the plastic threads are fine and dense, and how dense the filter element is. This requires not only precise control of the machine but also operator experience and repeated adjustments.

 

Finally, we would like to talk about energy consumption. In the production system, extruders and blowers are the main power-consuming devices. When the machine is turned on, it needs to be heated to a specified temperature before it can start normal operation. Therefore, the machine needs to run at full power for about a quarter of an hour to half an hour each time it is turned on. After running smoothly, a set of extruders and blowers consume an average of 20KWH per hour. Under standard circumstances, two sets of extruders and blowers are generally used for production. After smooth operation, the power consumption per hour is about 35KWH. But power consumption is also related to the temperature of the working environment. If the machine works in a cold area, the machine’s heat preservation capacity will decrease and it will continue to heat, so energy consumption will increase. In general, for the sake of energy saving, we do not recommend frequent shutdown of the machine. Continuous operation of the machine can reduce energy consumption.

 

For the filter end cap and fin welding machine, we highly recommend using the IR welding machine. The infrared welding method can prevent the heating plate from contacting the plastic, thereby preventing the remaining material from sticking to the heating plate. And there is no need to preheat the machine, saving time and energy. The maximum power of our machine is 10KW, but for welding PP materials, it does not need to be turned on to the maximum power, so it does not consume a lot of power.

Banner for all Melt Blown Filter Cartridge Machines

In general, making PP filter elements is not very complicated. Knmtech melt-blown filters making machine lines are highly automated, so a lot of trivial manual operations are eliminated. If you have any technical-related questions, feel free to consult us.

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