Modern industrial filtration systems generate significant waste from spent cartridges and filter media. Specialized crushing and washing lines transform these complex composite materials into reusable resources through advanced separation technology.
System Components and Workflow
1. Pre-Processing Stage
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Metal end-cap removal station
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Automated dismantling for cartridge filters
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Magnetic separation (12,000 gauss)
2. Size Reduction System
Parameter | Specification |
---|---|
Shredder Type | Shear-type granulator |
Blade Configuration | Interlocking hooks |
Output Size | 10-30mm fragments |
3. Multi-Stage Washing
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Pre-rinse (40°C)
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Chemical soak (surfactant solution)
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High-pressure spray (80-100 bar)
Technical Specifications
Capacity Options
Throughput | Power | Water | Footprint |
---|---|---|---|
200 kg/hr | 30 kW | 3 m³/hr | 8×4 m |
500 kg/hr | 55 kW | 6 m³/hr | 12×5 m |
1 ton/hr | 90 kW | 10 m³/hr | 15×6 m |
Material-Specific Processing
Melt-Blown PP Filters
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Low-temperature processing
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Fiber preservation technology
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Anti-static treatment
Pleated Filter Media
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Gentle unfolding mechanism
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Adhesive separation
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Layer-by-layer processing
Contaminant Removal
Particulate Elimination
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Ultrasonic agitation (40kHz)
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Counterflow rinsing
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Centrifugal separation
Chemical Residue Treatment
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pH-balanced solutions
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Solvent recovery system
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Activated carbon filtration
Quality Standards
Output Specifications
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Particle residue: <100 ppm
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Oil content: <0.1%
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Moisture level: <0.3%
Industry Certifications
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ISO 16890 (Air filters)
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NSF/ANSI 42 (Water filters)
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EN 1822 (HEPA standards)
Environmental Benefits
Resource Recovery
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1 ton recycled filter media equals:
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600kg virgin plastic saved
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4,200 kWh energy reduction
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Waste Reduction
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95% landfill diversion rate
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80% water recycling efficiency
System Innovations
Advanced Features
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X-Ray Detection
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Composite material identification
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Layer separation guidance
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Electrostatic Separation
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Fine particulate removal
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Fiber realignment
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Closed-Loop Cleaning
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Zero-discharge water system
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Solvent recovery distillation
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Economic Considerations
Cost Structure
Capacity | Investment | Operating Cost |
---|---|---|
200 kg/hr | $95,000-130,000 | $35-42/ton |
500 kg/hr | $160,000-220,000 | $28-34/ton |
1 ton/hr | $280,000-380,000 | $22-28/ton |
Filter element recycling technology represents a specialized sector within plastic recovery systems. These tailored processing lines address unique challenges posed by composite filter materials through precision separation, advanced cleaning, and material preservation techniques. As industrial sustainability requirements intensify globally, these systems provide essential solutions for circular economy implementation in filtration industries.
Comments(12)
This recycling tech is seriously impressive! Saving 600kg plastic per ton recycled is a game changer.
Kinda pricey for small operations tho – $95k starting cost is steep.
Do these systems work for oil filters too? The specs mention HEPA but not automotive.
That 95% landfill diversion rate tho 👏 More industries need this ASAP
Wish my factory could afford the 1 ton/hr model… maybe next fiscal year.
Anyone actually using these systems? Would love real-world feedback.
The water recycling part is smart – 80% efficiency isn’t bad at all.
Is the ‘low-temp processing’ actually better or just marketing speak?
Finally some real solutions instead of just greenwashing!
That X-ray detection sounds overkill but I bet it helps with quality control.
Our sustainability manager needs to see this… *sends link*
How often do the blades need replacing on those shredders? Maintenance cost isn’t mentioned.