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Manufacturing Considerations in Nonwoven Fabric Filtration


When nonwoven fabric filters are needed for your engineering application, you can’t afford to go with an inexperienced manufacturer. In addition to having chemical expertise, your provider should be able to problem solve the best cost-effective solution for your project. That includes factors such as exposure to temperature or chemicals, filtration particle size, material selection and alternatives, die cutting shapes and sizes, prototyping, and even when to bring in your consultant for the most efficient project roadmap. Mueller, Sur-Seal and SpecTex offer a strong union of chemical experts with a large global reach, ensuring your manufacturing process will result in the best possible product for your application. 

The base for our filters are nonwoven fabrics. The characteristics of each manufactured filter will vary depending on the needs of the application. First, let’s define a nonwoven fabric. 

 

What is a Nonwoven Fabric? 

The INDA: Association of the Nonwoven Fabrics Industry, offers the following description:  

“Nonwoven fabrics are broadly defined as sheet or web structures bonded together by entangling fiber or filaments (and by perforating films) mechanically, thermally, or chemically. They are flat, porous sheets that are made directly from separate fibers or from molten plastic or plastic film. They are not made by weaving or knitting and do not require converting the fibers to yarn.”

Source: INDA

 

 

 

What separates a nonwoven fabric from a woven fabric is that, rather than weaving or knitting fibers together, the fibers or filaments are entangled together through a mechanical, thermal or chemical process. 

LEARN MORE: Custom-Cut Nonwoven Solutions 

Die Cut Filters, Mesh, Vent Fabrics and Membranes 

Nonwoven fabrics are a base material for many common functions, including barriers to dust, dirt and moisture, as well as acoustic applications. 

In the industrial world, filtration is an encompassing marketplace. Filters can be cut into many different shapes and sizes and can be comprised of a large variety of materials. 

When engineering a nonwoven fabric filter, the design and material selection must meet the performance needs for its intended application. 

“Filtration is pretty pervasive in the industrial world. It’s a big marketplace that uses a lot of materials. There’s quite a large variety of cuts and shapes for many different applications. Because there’s so much material used, there’s a lot of engineering content within the materials that allow it to perform the way it’s supposed to perform. It really is a science. “ 

Steve Rossi, General Manager at SpecTex

The Two Main Types of Filtration 

In regard to filtration, nonwoven fabrics serve one function: to control the flow of either liquid or air through a fabric medium. 

There are two main types of filtration:  

  • Air/Dry Filtration 
  • Liquid/Wet Filtration 

Factors to Consider in Nonwoven Fabric Filtration Manufacturing 

 

When engineering your filtration product, there are some important considerations to account for in the design process: 

  • Temperature Exposure: What temperature will the product be exposed to? Is it internal, external, part of a furnace or HVAC component? Choosing the wrong material for high temperature exposures, such as polypropylene or polyester, will result in the filter melting. 
  • Chemical Exposure: What chemical environment will the filter be in or around? Be sure to select a media that will not degrade when exposed to its surrounding chemicals. 

The common medium Teflon, for example, has both temperature and chemical limitations to consider. 

  • Particle Size: What is expected to be filtered? Particle size, opening size and micron rating need to be considered in order to determine the most efficient flow. 
  • Pathogens: Do bacteria and microbes need to be filtered for this application? 

Engineering, Design, Die Cutting and Manufacturing Services 

As a die cutting manufacturer, the umbrella organization of Mueller, Sur-Seal and SpecTex can take your engineered design and manufacture it to your specifications. 

Many engineers come to us with design in hand, material already determined and a thorough understanding of what to expect during the manufacturing process. 

But did you know that our expert chemists can help you much earlier in your engineering and design process

In fact, the earlier our team gets involved, the better. We love to problem solve, and we welcome your challenges. By consulting with us in your early design stages, our team can help streamline your overall product design to make it optimally efficient as well as cost-effective. 

LEARN MORE: Engineering and Prototyping Services 

Why Choose Us? 

Our newly aligned organization combines the strengths of each company into one cohesive team, shoring up our areas of chemical and manufacturing knowledge and expertise as well as our strong global sourcing arm. 

Here are a few reasons to choose the Mueller-Sur-Seal-SpecTex advantage: 

Prototyping 

We offer prototyping without tooling. We can print your prototype to the exact shape and specifications of your product. By offering all types of prototyping, we can fulfill your specific sequence of data requirements, and deliver on first article of inspection. 

LEARN MORE: Die-Cut Prototyping with Mueller Custom Cut 

Diversity of Shapes and Ability to Handle Volume 

Our volume processes include rotary press, camera and imagery driven checks. We offer one of the largest variety of shapes and cuts in the die cutting industry. 

Unmatched expertise and team collaboration 

Our expert team has aligned the industry’s best in chemistry, manufacturing, and international supply sourcing to offer you the best and brightest problem solvers with nearly unlimited solutions. 

By working with our team through the design and chemical engineering process, you can feel confident that your product challenges, goals and needs are thoroughly understood and that the best available solution will be presented and delivered. 

You have many choices when it comes to selecting a filtration product manufacturer. Let us earn your trust by showing you that we can help you solve your most critical project roadmap challenges with our collective team, bringing you over 40 years of expertise in chemical engineering and die cutting solutions. 

To request a quote or simply learn more about how our expert engineering services can streamline your design and maximize cost-efficiency, contact our team today

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