Why the Pleated Filter Cartridge Is the Best Option for Filtration

Pleated filter cartridges, used as filtration devices, help to eliminate suspended solids and other fine contaminant materials from liquids and gases. The distinctly manufactured pleat configuration or fold on the filter element allows for the largest amount of filtration area to be contained in a more compact cartridge product.

Due to their construction, pleated filters tend to be selected for applications that need a higher rate of flow, along with a consistent micron control and a highly efficient means of surface filtration. These components can most often be found in applications where the stability of the system's peak performance, along with the ease of servicing and correcting any issues with filtration accuracy, are equally critical.

In this blog, we will learn about the definition and working principle of pleated filter cartridges, the available types of pleated filter cartridges, and why they may be regarded as the best option today for meeting the filtration needs of a variety of industries.

What Is a Pleated Filter?

Pleated filters have become so popular because of their fundamental concept. Whereas depth-type filters filter through the entire length of the cartridge, pleated style filter cartridges capture impurities through the outside of the cartridge.

A pleated filter cartridge is a cylinder of folded filter media, evenly spaced apart. The construction of these filter cartridges increases the surface area available for filtration while keeping the cartridge itself compact.

The additional surface area allows the pleated cartridges to accommodate larger flow rates, while still providing low-pressure drop, and will retain the same amount of particles from the water being filtered.

The characteristics of pleated filters are:

• increased surface area due to a folded filter media
• surface filtration rather than depth loading
• micron-based performance rating
• ability to operate efficiently at higher flow rates

How Pleated Filter Cartridges Work

The mechanism of pleated filter cartridges is simple, and this contributes to their ubiquity in many industries. By utilizing controlled surface capture for the removal of contaminants, as opposed to depth loading, they are able to achieve micron-rated performance.

The pleated filter media compresses and spreads across the area of the filter housing when the fluid flows into the filter. As a result, particles that are larger than the rating specification of the media "capture" on the surface, and clean fluid passes through the pores of the media.

Using a surface filter enables users to predict and measure their performance with greater certainty throughout its life cycle.

In operation:

• Fluid enters the housing under pressure.
• Flow distributes evenly across the entire pleated filter face.
• Contaminants build up on the filter media's surface.
• Filtered fluid leaves the system.

Types of Pleated Filters According to the Materials and Usages

Different types of materials can be used for pleated filters based on the requirements and specifications of the operating environment. Chemical compatibility, temperature tolerance, and filter cartridge lifespan are all influenced by the material chosen.

A properly selected material ensures that a pleated filter will provide consistent performance in real-world conditions.

Examples of Common Types of Pleated Filter Media:

• PP pleated media cartridges have chemical resistance and a low price point.
• Polyester pleated media filters are suitable for high-temperature applications.
• Glass Fiber pleated media filters are for highly critical and fine micron filtration.
• Stainless Steel pleated media filter for extreme pressures and temperatures.

Key Features of Pleated Filter Cartridges

Pleated filter cartridges have an outstanding reputation for performance due to numerous design characteristics that affect their efficiency, service life, and operating costs.

The advantages of these cartridges are not based on one single advantage, but rather the cumulative effect of several combined performance benefits.

The most important of these include:

• A large effective filtration surface area.
• High flow rate capability.
• Low & Stable Pressure Drop.
• Uniform & Consistent Micron Filtration.
• Easy Installation & Replacement.

Pleated Filter Advantages Over Other Filter Cartridges

In terms of cartridge design, pleated cartridge filter designs are generally superior for applications with a strong focus on efficiency, control, and predictability. These types of cartridge filters, which operate by means of surface filtration, provide several advantages over depth filter cartridges when used in systems with consistent contaminant loads.

The way that pleated filters capture contaminants is similar to a depth filter, with the contaminants being placed on the surface of the filter, versus filtered through the whole thickness of the media.

Pleated filter cartridges provide the following benefits:

• Consistent and better particle retention over the entire life of the filter cartridge.
• Higher flow rate for a given size cartridge.
• Easy identification of blocked or fouled filters.
• Increased time between filter cartridge changes.
• Decreased long-term operating and maintenance costs.
• Improved operational stability and system control.

Pleated Filter Cartridges Applications in Different Industries

The versatility of industrial pleated filters enables them to be utilised throughout numerous industries. Their ability to provide repeatable filtration performance allows for both critical and everyday applications.

In a number of cases, pleated filters are used in the final polishing stage of many processes and provide protection from contaminants to sensitive downstream equipment.

Pleated filter cartridges are commonly used in various applications, such as:

• Removal of sediments, rust, and fine particulates from water like a water treatment.
• Filtration of fuels, lubricants, and process fluids in the Oil and Gas industries.
• Chemical processing to eliminate the presence of solid contaminating particles that may interfere with chemical reactions or compromise equipment.
• Pre-filtration and non-sterile process filtration of Pharmaceuticals.
• Process consistency, ingredient water, and product clarification in Food and Beverage applications.

Choosing Pleated Filters: Factors to Consider

Choosing pleated filter cartridges isn't just about selecting a micron rating. To provide a reliable system and a predictable maintenance cycle, you should ensure that you select the correct cartridge for your application.

Taking an overall view of the operating conditions provides better long-term results.

Here are some things to consider:

• Recommended micron rating
• Operating temperature and pressure
• Compatibility of the chemical being filtered with the cartridge
• Flow rate, including the type of system being used
• Regulatory and industry standards for the application

How Pleated Filters Improve Operational Efficiency

The use of cartridge filters with pleated designs directly improves the efficiency of all operations by reducing how often maintenance needs to be done and how much time is lost due to unplanned downtime. The design of these filters allows for consistent filtration operation during the entire range of possible fluctuations in operating conditions.

By having consistently lower and stable pressure drop than standard bag-style filter systems, pleated filter cartridges also provide for improved pump and overall system efficiency. This efficiency typically results in reduced power consumption over time.

When properly selected, a pleated filtration cartridge system also effectively protects the equipment downstream from excess buildup of contaminants and results in more consistent processing of products.

Operational efficiency advantages include:

• Decreased pressure drop variability across the lifespan of a cartridge
• Extended life between cartridge service
• Reduced Maintenance and Replacement Costs
• Reduced Unscheduled Downtime
• Improved Protection of Pumps, Membranes, and Mission-Critical Defined Equipment

Many users at this point find value in collaborating with knowledgeable filtration manufacturers who possess an understanding of the unique challenges in specific applications. mmp filters provides support by concentrating on Compliant Designs for Consistency (for example, what materials are used), and offering real solutions to meet practical needs in multiple industries and across Global Markets, as well as ensuring continuous process consistency.

Conclusion

The many industries using today’s filtration solutions can include, but are not limited to, those using a pleated filter cartridge as part of their engineered solution. A pleated filter cartridge has become a staple in filtration design due to the many benefits it offers, including the ability to provide a larger surface area to capture contaminants at all flow rates and consistent micron-level performance with low pressure drops.

Pleated filter cartridges have a unique advantage over other types of filtration systems; in addition to having the highest efficiency ratings, they provide predictable results. Due to surface filtering, all contaminants are captured evenly on the filter media, allowing for easier tracking of performance and simpler planning for future maintenance. In the long run, pleated cartridge filters save users time and money by reducing downtime, decreasing operating costs, and protecting the equipment downstream from contamination.

As manufacturers are increasing demand for "cleaner" industrial fluids with higher quality control and improved efficiency, pleated cartridges are a scalable and practical option. When properly selected based upon the right media, micron size rating, and operating conditions, pleated cartridges will help generate long-term reliability for a variety of applications, including water treatment, Chemical, Pharmaceutical, Oil & Gas, and food processing.

Evaluating filtration upgrades or new designs of systems requires a detailed understanding of the various strengths and limitations of Pleated Filters is critical for achieving uniform, effective, and Sustainable Filtration Performance by any organization.