Case Study: Upgrading Project of Precision Filtration System in a Chemical Additive Factory in Southeast Asia

Project Background

In the fourth quarter of 2025, a medium-sized manufacturer in Southeast Asia, specializing in industrial surface treatment additives (alkaline cleaning agents and emulsions) for automotive electroplating customers, experienced product quality fluctuations. Over the prior three months, downstream customers consistently reported visible suspended particles (approx. 5–20 μm) in the liquid, which caused pinhole defects in electroplated layers and drove the return rate up to 4.7%.

Pain Points of the Original Filtration Solution

The factory’s legacy wound-type filter cartridge system exhibited three critical failures:

• Rapid filtration accuracy decay – Differential pressure surged after only 40 hours of operation, while actual filtration accuracy degraded from the nominal 5 μm to over 50 μm.

• Severe bypass leakage – The outdated end‑cap seal design allowed unfiltered coarse particles to enter the finished product tank directly through bypass paths.

• Uncontrolled maintenance costs – Each unit housed 12 cartridges; replacement took 2 hours per cycle, and spent cartridges were expensive to dispose of as hazardous waste.

Our Proposed Solution

Following technical assessment (medium temperature: 45–55°C, operating pressure: 0.45 MPa, flow demand: 6 m³/h), we recommended and installed the JYSF-2#-304 single-bag filter, featuring multi-core adaptability.

• Material & surface treatment – Constructed of 304SS with sandblasted finish, resisting intergranular corrosion from alkaline media. The sandblasted surface is less prone to scratches and dirt accumulation than polished surfaces, improving CIP cleaning efficiency by 30%.

• Sealing system – Equipped with NBR (nitrile rubber) seals, compatible with the plant’s petroleum sulfonate additives; tests confirmed no swelling or deformation at 60°C, completely eliminating bypass leakage.

• Filter element – Utilized 1‑micron PP filter bags with 304SS steel rings. The large‑format design (180×810 mm) provides an effective filtration area of 0.24 m² – 1.8 times that of the original cartridge bank.

• Pressure rating – Designed for 1.0 MPa, well above the actual 0.6 MPa operating pressure, leaving ample safety margin for future pump pressure increases during production expansion.

Quantitative Results After Three Months of Operation (Data from January to March 2026)

Additional benefit: The sandblasted housing proved highly resistant to fingerprint corrosion in the humid workshop environment, maintaining a like‑new appearance. The customer highlighted this case as a benchmark for “small‑investment, significant‑impact” technical improvements during their monthly production meetings.

Customer Feedback

The production manager stated in the acceptance email:

“We had doubted whether a single‑bag filter could handle continuous production, but the JYSF-2# proved with data that correct selection matters more than expensive equipment. Now our finished product light transmittance is stable above 98%, and spare parts inventory has been simplified from three cartridge types to just one filter bag – this is true cost reduction and efficiency improvement.”