Imagine a one-mile race on a four-lap track. Before the race begins, the track must be properly conditioned—this is equivalent to precoat formation in a filtration system.
Flux rate considerations:
A common industry mistake: Under-sizing filters to reduce upfront costs.
Some manufacturers promote smaller filters at lower prices, leading to :
Studies show that undersized filtration systems increase long-term operating costs by > 40% due to :
Accurately determine solids percentage or volume to properly size :
Batch Filtration :
Continuous Filtration :
Proper cake formation management allows for :
✔ Production Demands
✔ Quality and Clarity Requirements
✔ Repeatable Discharge method and cycle times
✔ Reliable System uptime
✔ Preventative Maintenance schedules
✔ Capital considerations and operational costs
Meeting customer objectives is our primary goal when sizing a new filter. As a manufacturer, we understand that process and throughput control is a crucial factor in filter selection.
Key process parameters impacting throughput :
Partnership with Sparkler Filters always includes a full review and confirmation of objectives, starting with a completed application data sheet.
Constant-flowrate filtration :
Constant-pressure filtration :
Centrifugal pump driven processes can be effective when properly sized :
Any and all methods have advantages and disadvantages that can impact or improve cycle time, throughput, and overall efficiency.
Absolute Rating : Captures 100% of particles at the specified micron size.
Nominal Rating : Captures most (typically 90-95%) of particles at the specified size.
Manual vs. Automatic Cake Discharge :
Beyond the initial hardware investment, long-term operational efficiency is the true cost determinant.
The biggest cost of ownership is the ability to repeatably and reliably produce your desired output on demand.
“Prevention of failure is always lowest operational cost by any unit of measure”
- Scott Mishler
Applications Engineer
The costliest inefficiencies and poorest economic ROI could arise from improper filter selection and under-sizing, leading to:
Selecting the optimal filter media and change-out frequency minimizes long-term consumable costs by :
✔ Improving flow rate and cycle times
✔ Decreasing precoat recirculation times
✔ Enhancing clarity for consistent product quality
✔ Maximizing washability in automatic applications
✔ Peak performance
✔ Operator safety
✔ Consistent filtration quality
Many competitors have gone out of business, leaving customers scrambling for replacement parts to keep operations running.
Click here to learn more
Now that we've covered the importance of proper sizing and discharge timing, let’s break down the key factors that determine the best filtration system for your process.
Material of construction should be determined by your process compatibility. Common options include Carbon Steel, Stainless Steel (304, 304L, 316, 316L) and Hastelloy. Alternative options include Monel, Duplex 2205 and Titanium. Stainless options are best for long term use and part availability if compatible and 304 is the lowest first cost.
Material of construction can be separated by wetted material (the portion of the filter that has direct contact with process fluid) and non-wetted material (the exterior sections of the filter that do not have direct contact with the process fluid).
Standard gasket options include Buna-N, Neoprene, EPDM, Teflon, Viton and Silicone.
Click here for a complete list of design specs and options.
A scavenger plate (heel filter) can be used to maximize throughput for high value products, corrosive or hazardous environments, to assist in cleaning and drying or prevent cross contamination of multiple products.
Cover removal options can be lifting handles, hooks for hoist or forklift removal, handwheel and davit arm or hydraulic lift assist.
Filter mounting can be a standard 3-4 pipe legs with floor flanges, girth mounted, portable pharmaceutical style base with casters, base with forklift pockets and/or casters or a cart style with handlebar. Mounting on MCROs are I-beam only.
Port type and size are custom for each filter specific to your facilities needs. Options include NPT, flanged, DN and sanitary (tri-clamp).
Click here for a complete list of design specs and options.
Design pressures of the filter and jacket are dependent upon the material thickness and verified by ASME calculations and third party approval. Filter design pressure starts at 60 psi and goes up to 150+. Jacket design pressure starts at 14.5 psi and goes up to 150+
Design temperatures are depending on metal expansion limits and gasket limitations. Standard design is -20F-350F with higher ranges available upon request.
Steam/Heat Jackets can be added to ensure temperature variation remains constant.
Differential pressure is typically determined my screen thickness. Standard pressures begin at 50 psid and can go to 100+ if requested.
New filters can be rated for full vacuum upon request.
Click here for a deep dive into design specs and options.
To achieve the highest filtration efficiency, product quality, and operational reliability, follow these key principles :
Determine application process parameters – Understand critical variables like flow rate, viscosity , solids loading , and pressure requirements. Click here to view our Viscosity and Solids Loading Visualizers
Define process goals and objectives – Establish clarity standards, throughput targets, and discharge requirements.
Select the right equipment and filter media – Ensure proper sizing, cake spacing and media selection for optimal separation efficiency.
Optimize system design – Balance throughput capacity, pressure drop, and cycle times to maximize efficiency.
Monitor pressure drop and filtration performance – Prevent inefficiencies, media blinding, and process disruptions through proactive system monitoring
Click here for more process tips.
With nearly a century of expertise, Sparkler Filters exemplifies :
Application-specific, precision-engineered filtration solutions in +24,000 installations
Optimized solutions that maximize throughput and efficiency for decades
Industry-leading product quality and generational reliability – Made in the USA
Cost-effective filtration systems designed for long-term profitability and ROI
Genuine OEM parts availability for decades
Expert consultation included and access to our library of applications
At Sparkler Filters, we don’t just supply high-quality, American-manufactured and engineered filtration equipment—we deliver tailored, application-specific solutions designed to enhance your process, improve efficiency, and maximize profitability for long-term success.
Your partnership with Sparkler ensures your manufacturing process receives the most effective, dependable, and high-performance filtration solution in the industry.
Contact us today to discuss your application and see how Sparkler Filters can help optimize your filtration system.
