Farrleey Filtration’s Award-Winning Breakthrough

Innovation Spotlight: Transforming Filter Bag Media into High-Performance Pleated Cartridges

——Farrleey Filtration’s Award-Winning Breakthrough

The Challenge: Why "Soft" Filter Bag Media Was Deemed Unsuitable for Cartridges

Traditional wisdom holds that:

• Cartridge Requirements: Rigid structure to maintain pleat shape under pressure, high dust-load capacity.
• Filter Bag Limitations: Needle-punched nonwoven media (common in bags) lacks inherent rigidity and dimensional stability.

Conventional solutions involved adding metal wire supports or rigid backings—but these increased cost, weight, and complexity.

Farrleey’s Solution: Reinventing Material Science

Through patented Needle-Punching + Thermal Bonding Hybrid Technology, we engineered a game-changing media structure:

1. Core Innovation:
• 3D Fiber Interlocking: Multi-layered needle-punching creates a dense, self-supporting matrix without external frameworks.
• Controlled Thermal Bonding: Precision heating selectively melts polyester fibers at crossover points, forming rigid "welds" that lock pleat geometry.
2. Key Performance Metrics:

Why This Matters for Industries

• Cost Efficiency: Eliminates wire mesh/backing layers, reducing material costs by 35%.
• Sustainability: 100% recyclable polyester vs. mixed-material cartridges.
• Versatility: Adaptable to extreme conditions:
• High Humidity: Hydrophobic treatment prevents pleat collapse.
• Explosive Dust: Anti-static coatings meet ATEX/IECEx standards.

Proven Success & Recognition

• Case Study: Deployed in a Chinese steel mill’s sintering plant:
• Result: 18-month service life (vs. 12 months for wire-supported cartridges), reduced disposal waste by 40%.
• Award: 2023 Second Prize for Scientific and Technological Progress, China National Textile and Apparel Council – the highest honor in China’s filtration industry.

Applications Redefined

1. Cement & Mining: Handles abrasive dust (e.g., limestone, silica) with minimal wear.
2. Waste Incineration: Resists acidic flue gas (pH 2-5) at 180°C continuous operation.
3. Food & Pharma: FDA-compliant media for starch, sugar, or API powder recovery.

Technical FAQs

Q: How is pleat height controlled without wire supports?
A: Our Dynamic Pleat Forming Algorithm calculates fiber density and bonding points to optimize structural integrity for specific heights (10-100mm).

Q: Can existing cartridge housings use this media?
A: Yes! Retrofit kits available for Donaldson, Camfil, and Nederman systems.