Air filtration failure in high humidity environments
Customer pain points:
A North American frozen food plant (with an annual production capacity exceeding 100 million pounds) used three air handling units (total air volume of
170,000 CFM) in a critical processing area and faced severe filtration failure issues:
Pre-filter clogging: Bread crumbs and high humidity in the return air caused the Merv 8 (G4) densely pleated pre-filter to clog every 1-2 weeks,
restricting airflow.
Main filter efficiency degradation: The original Merv 11 (M6) synthetic fiber electrostatic filter's efficiency plummeted after static electricity
dissipated. The shallow 4-inch filter bags had insufficient dust holding capacity and a lifespan shorter than expected.
High operating and maintenance costs: Frequent filter replacements resulted in annual labor and disposal costs exceeding $42,000, and unstable airflow
impacted product quality.
Precision filtration solution design:
Reconstruction of the two-stage filtration system:
Components
Technical parameters
Innovation
Camfil 30/30 Pre-Filter
Merv 8 (G4) · U-shaped pleat structure
High-strength, moisture-resistant design, 200% increased filter media utilization
Camfil Hi-Flo ES Main Filter
Merv 13 (F7) · Deep-bed bag structure
Electrostatic enhancement technology, 40% higher efficiency stability
Intelligent Monitoring System
Third-party data logger · Real-time resistance/kWh monitoring
Meets utility rebate program certification standards
Technological breakthroughs:
Moisture-Resistant and Corrosion-Resistant Materials: The pre-filter utilizes hydrophobic-coated glass fiber, extending its lifespan to 6 weeks in environments with a relative humidity (RH) greater than 80%.
Doubled Dust Holding Capacity: The main filter features a deep gradient filter media design, holding up to 535g of dust (exceeding its own weight).
Energy Recovery Mechanism: Utilizes fan exhaust pressure to drive the backflush system, reducing energy consumption by 12%.
Implementation effect and quantified benefits:
Comparison of key indicators before and after the transformation:
Indicator
Before renovation
After renovation
Improvement
Pre-filter Life
2 weeks
6 weeks
↑300%
Main Filter Life
6 months
12 months
↑100%
Average Daily Energy Consumption per Unit
$42.67
$37.86
↓11.3%
Annual Comprehensive Operation and Maintenance Cost
$42,000
$26,600
↓36.7%
Economic benefits:
Direct Savings: Annual savings of $33,000 for the three units (labor, energy, and disposal costs).
Tax Rebate Benefit: Received a $28,500 utility tax rebate, effectively giving the filters "free".
Implicit Value: Clean air increases product quality by 1.2%, avoiding $1.5 million in annual losses.
Industry application expansion scenarios:
This solution has been verified to be applicable to:
Dairy: Dual 10 filters reduced annual cheesemaking costs from $42,000 to $26,600 and reduced landfill volume of dirty filters by 67%.
Juice production line: Flottweg belt filter press increased apple juice production by 400% in three years and reduced labor costs by 50%.
Meat processing: Steam filtration system (5μm accuracy) passed USDA approval, avoiding $1.2 million in annual production downtime.