When it comes to liquid filtration in industrial processes, there are two basic types of filters that get used. First, there's the traditional and reliable melt-blown filter cartridges. These cartridges are basic in their design and straightforward in how they operate.
If you're looking for an alternative to standard filtration, you can also consider the advanced melt-blown filter cartridges, which offer a unique set of benefits alongside the reliability of pleated filters. Melt-blown cartridges are more technologically advanced than traditional high flow pleated filters, and are getting used more and more often.
It's important to understand the differences between these filter cartridges so that you can choose the one that's right for you. It's also important to understand the various advantages and disadvantages of pleated and melt-blown filters so that you know how to maintain and utilize them.
What are Pleated Filter Cartridges?
Pleated filters are considered by many to be the future of liquid filtration. They are made of synthetic materials, such as glass fibers, polyester, and polypropylene. Because of their pleated design, these types of filters cover a wide surface area and can trap large amounts of contaminants.
Pleated filters also utilize technology in their design, which adds to their filtration efficiency. They incorporate electrostatic charging, which allows them to catch more particles and use less energy to do so.
Pleated Filter Cartridge Benefits
Pleated filters are newer to the filtration industry than their melt blown counterparts. However, they're quickly becoming the standard for many industrial applications thanks to the following benefits:
- Generally, pleated filters are more efficient than other options, such as a melt-blown or string-wound filter cartridge
- Great flow rate
- Extremely durable and long-lasting
Pleated Filter Cartridge Applications
No matter what industry you're involved in, you can use pleated filters to get the job done. Because of the design and materials used to create pleated filters, they're compatible with most liquids, including:
- Solvents
- Chemicals
- Gas
- Oil
- Petroleum
- Water
From the chemical industry to water, petroleum, pharmaceuticals, and everything in between, pleated filters are versatile and comprehensive. They're especially useful as a pre-filtration option and are ideal at capturing tiny and minute particles. The only issue they have is in regard to larger particles, as it can increase the differential pressure.
What are Melt-Blown Filter Cartridges?
While pleated filters are the latest and greatest in industrial filtration, melt-blown cartridges are more traditional. Similar to spunbonded cartridges, melt-blown filters are a highly effective type of depth filter. As with pleated filters, melt-blown filters are typically made of polypropylene but also incorporate nylon.
While pleated cartridges are ideal when all particles are roughly the same size, melt-blown filters can handle contaminants of multiple shapes and sizes. This is because they have more depth than pleated filters, which means they have more surface area overall.
Melt-Blown Filter Cartridge Benefits
Here are some of the benefits of using melt-blown filter cartridges for your filtration needs:
- Fairly low maintenance
- High efficiency rating
- Compatible with many chemicals and particles
- Impressive flow rate
- Improves water and environmental safety
Melt-Blown Filter Cartridge Applications
Melt-blown filters are highly versatile and can be used in a wide range of industries, including:
- Solvents
- Chemicals
- Gas
- Oil
- Petroleum
- Water
Melt-blown cartridges are especially useful in wastewater and surface water filtration since they can handle particles of every shape and size without losing efficiency.
Main Differences Between Pleated and Melt-Blown Filter Cartridges
Now that you have a solid understanding of both pleated and melt-blown filter cartridges, let's compare the main differences between the two.
Cartridge Size
While pleated and melt-blown filter cartridges are generally similar in size, pleated cartridges are typically about 1/4 inch larger in diameter. This slight size difference allows pleated cartridges to hold more filtration media, which increases their dirt-holding capacity and makes them slightly more efficient in handling high contaminant loads. Both types of cartridges can fit into standard housings, but this added diameter in pleated filters can enhance longevity and filtration performance in demanding applications, making them ideal for long-term use without frequent replacements.
Efficiency
Both pleated and melt-blown filter cartridges have a high efficiency rating, which means they can capture even the tiniest particles. However, pleated filters are superior in terms of efficiency, as they have a micron rating of 0.5 to 75. Pleated filters also have a stronger dirt-holding capacity thanks to their multiple-layer construction.
Flow Rate
Pleated filters also take the cake when it comes to flow rate, as they have a superior rating compared to melt-blown cartridges. A 40" high flow pleated filter, for instance, has a flow rate of 30m3/h, while a melt-blown filter of the same size has a flow rate of 2m3/h. As such, pleated filters are a better option in high volume situations.
Initial Cost
If you're concerned with the initial cost of purchasing your filter cartridges, melt-blown cartridges are the way to go. Because of their simplistic design and straightforward operation, melt-blown filters are typically cheaper than their pleated counterparts.
Ongoing Maintenance and Maintenance Cost
While they're cheaper upfront, melt-blown filters may not be cheaper in the long run. This is because pleated filters have a longer service life, which means fewer replacements down the road. In terms of maintenance cost, however, both filters require roughly the same maintenance, and there isn't a huge difference between them.
Durability and Longevity
Pleated filter cartridges generally last longer than melt-blown cartridges due to their higher dirt-holding capacity. The pleated design maximizes surface area, capturing more contaminants and reducing replacement frequency. Melt-blown cartridges, with their dense structure, provide effective depth filtration but may wear out faster, making them better suited for single-use or short-term applications. Choosing the right cartridge based on durability needs can enhance filtration efficiency and cost-effectiveness.
Pleated Vs. Melt-Blown: Which Filter Cartridge is Right For My Industry?
As you can see, both pleated and melt-blown filters are excellent filter cartridges. They are both versatile, durable, long-lasting, and efficient, while also having a high flow rate. However, pleated filters are superior to melt-blown options in nearly every aspect, except for price.
Therefore, with the exception of the water treatment and filtration industry, pleated filters are often the best option for your filtration needs. The only caveat is if you need to capture particles of multiple shapes and sizes, as melt-blown filters still do a better job in that respect.