Baghouse filter media is an essential component of many industrial dust emission control systems. The manufacturing process of needlefelt filter media can vary depending on the specific requirements and materials used. However, here is a general step-by-step process:
Raw Material Selection and Preparation
Different types of fibers are chosen based on the desired physical, chemical, and filtration properties of the finished products (filter media and filter bag). These fibers can be natural (such as wool, cotton, or silk) or synthetic (such as polyester, polypropylene, PPS, aramid, nylon, or PTFE).
Fiber Opening
The selected fibers are opened using machines like a picker or opener. This process breaks up compressed fiber bales and opens the fiber tufts into individual fibers, facilitating better blending in the following production process.
Blending
The opened fibers are mixed to create a homogeneous blend. This process is usually done by using a blending machine. The aim is to evenly distribute different fiber types to achieve desired properties, such as strength, softness, filtration efficiency, or color variation. By selecting fibers carefully and blending them appropriately, manufacturers can create needlefelt products suitable for various filtration applications in various industries.
Carding
The opened and blended fibers are fed into a carding machine, which uses a series of rollers covered in wire teeth to comb and align the fibers in parallel and form a continuous thin layer of fiber web. The carded web ensures an even distribution of fibers and creates a uniform thickness.
Crosslapping
The carded fiber web is then layered multiple times on top of one another, crossing the fibers in different directions. This process improves the strength and stability of the final needlefelt.
Pre-needling
The carded web passes through a pre-needling machine, which lightly interlocks the fibers with barbed needles. This provides initial strength and improves the web’s stability during the subsequent needling process.
Needling
The pre-needled web enters a needling machine where thousands of barbed needles pierce the web. The barbs on the needles entangle and interlock the fibers, creating a coherent felt structure. This process further binds the fibers together and increases the strength, porosity, and filtration efficiency of the felt.
Heat Setting
The needled felt is passed through a heated oven or chamber to stabilize the structure. Heat setting helps in locking the fibers together and improving dimensional stability.
Filter Media Treatment
Different fibers provide each media with different dust filtration characteristics. Filter media can be further treated to improve their filtration efficiency and performance, such as lengthened filter media life cycle, better dust cake release, reduced valve pulsing, more consistent airflow, reduced differential pressure, and reduced downtime and maintenance. Such treatments include calendering, singeing, napping, hydrophobic treatment, and membrane lamination.
Finishing
The edges of the filter media are trimmed to achieve the desired dimensions for the filter bag production process. In addition, the finished filter media is inspected for any defects.
For More Information
It is vital to note that the specific manufacturing process may vary based on the specific requirements of the needlefelt filter media, such as thickness, density, porosity, and filtration operating conditions under which the filter media will be used.
Aokai is enthusiastic about helping customers achieve high and long-lasting filtration efficiency. This is exactly why we insist on manufacturing filter media in-house. As a leading filter media manufacturer and supplier in China, we custom design and manufacture dust filter media that best suits customers’ unique dust collection requirements. Aokai provides filter media solutions for abrasive, corrosive, high-temperature, and explosive dust filtration, and specializes in dust collection processes in asphalt mixing, chemicals, cement, metals, power generation, waste-to-energy, renewable energy, woodworking, and many other demanding industries. Contact Aokai for more information about our filter media manufacturing process and product offerings.
