Featured melt filter elements, stainless steel screen mesh, and plastic recycling granulating systems engineered by Pujiang HG Plastic Machinery Co., Ltd.
An in-depth engineering assessment of metal fiber felt technology, gel retention mechanics, and fluid dynamics in high-viscosity polymer extrusion.
In modern high-speed polymer processing—encompassing BOPP/BOPET packaging films, technical synthetic textiles, and post-consumer resin (PCR) upcycling—the filtration unit is no longer a passive consumable. It is a critical line-stabilization asset. Historical reliance on plain-woven wire mesh disc packs or coarse powder-sintered elements has introduced operational bottlenecks: rapid pressure differential ($\Delta P$) spikes, frequent line shutdowns, shear degradation of high-MW polymers, and poor retention of sub-micron micro-gels.
Technical Consensus: Integrating Bekaert-grade non-woven sintered metal fiber felt (Bekipor® standard) into custom ODM filter candles and leaf discs increases dirt-holding capacity by 200% to 350% compared to traditional woven wire mesh, while maintaining structural porosity up to 85%.
Sintered Bekaert metal fiber media is manufactured by multi-stage bundle drawing of austenitic stainless steel (primarily SUS 316L, Hastelloy C-276, or alloy 600) into micro-fibers ranging from 1.5 to 80 microns in diameter. These ultra-fine metallic filaments are layed into a 3D non-woven random matrix and subjected to high-vacuum solid-state diffusion sintering. This metallurgical bonding locks fiber intersections without occluding interstitial voids.
Unlike two-dimensional wire mesh—where filtration is strictly surface-constrained and aperture-limited—sintered fiber felt presents a high-depth 3D maze. As high-viscosity polymer melts pass through this tortuous path, shear stresses alter the flow lines of deformable gel particles, capturing them within the depth of the medium without triggering premature pore clogging.
| Filtration Media Type | Porosity % | Dirt Holding Capacity ($g/m^2$) | Initial $\Delta P$ (Pressure Drop) | Gel Retention Efficiency | Thermal & Pressure Limit |
|---|---|---|---|---|---|
| Bekaert Sintered Fiber Felt (316L) | 75% - 85% | Highest (180 - 260 g/m²) | Very Low | Superior (Depth Filtration) | 350°C / 250 bar |
| Multi-Layer Sintered Wire Mesh | 45% - 55% | Moderate (60 - 90 g/m²) | Medium | Good (Surface Filtration) | 300°C / 200 bar |
| Sintered Metal Powder Media | 35% - 50% | Low (30 - 50 g/m²) | High | High (Rigid Particles) | 400°C / 300 bar |
| Plain Woven Screen Mesh Packs | 30% - 40% | Lowest (15 - 30 g/m²) | High to Rapid Rise | Poor (Gels Pass Through) | 250°C / 150 bar |
Combining 20+ years of precision metallurgy, automated pleating robotics, and integrated machine building to deliver unmatched cost-efficiency and technical agility.
Utilizing ultra-high vacuum sintering furnaces operating under $10^{-4}$ Torr to eliminate oxidation, guaranteeing pristine metallurgical alloy bond strength and long-term chemical resistance.
State-of-the-art CNC pleating lines generate uniform cylindrical geometry, maximizing active filtration surface area up to 300% per candle element while maintaining structural pleat spacing.
100% quality inspection protocol. Every ODM Bekaert filter element undergoes non-destructive bubble point testing and pore size distribution verification prior to export dispatch.
How ODM Sintered Bekaert Filters solve complex operational challenges across global manufacturing plants.
In biaxially oriented polypropylene (BOPP) and polyester (BOPET) film extrusion, minute carbon specks or gel pinholes cause film web breaks at high stretch ratios. Our ODM Bekaert leaf disc filter assemblies (hard rim / hub-and-spoke) remove particles down to 3μm, ensuring optical clarity and eliminating costly line stoppages.
High-speed continuous polymer filtration (CPF) systems demand uniform melt viscosity before entering spinnerets. Sintered fiber felt candle filter elements provide low initial pressure drop, preventing polymer thermal degradation while filtering fine particulate contaminants that plug spinneret capillary holes.
Recycling post-consumer plastic flakes (rPET, rHDPE, rPP) involves heavily contaminated melt streams containing paper, aluminum, and cross-linked gels. Paired with Pujiang HG's plastic recycling machines, our reinforced ODM sintered Bekaert screen belts and filter cartridges provide high-burst-strength filtration under dynamic backwashing.
From technical drawing consultation to high-vacuum sintering and quality delivery.
Analyzing polymer viscosity, operating pressure, temperature range, and target contaminant micron rating (3μm - 100μm).
Selecting Bekaert fiber diameter, multi-layer mesh support, core tube perforation specs, and end-cap adapter fittings (DOE, NPT, Threaded, Bayonet).
High-vacuum thermal fusion sintering of fiber media followed by robotic TIG seam welding of end adapters to prevent media bypass.
Bubble point testing according to ISO 4003, pressure burst validation, cleanroom ultrasonic washing, and international vacuum export packaging.
Review our comprehensive series of custom polymer melt candle filters, screen mesh elements, and granulating equipment.
Addressing key technical queries from plant managers, procurement specialists, and filtration systems design engineers.
Bekaert sintered metal fiber felt features an open, 3D non-woven structure with porosity up to 85%, compared to 30-40% in woven wire screens. This high porosity translates to a significantly lower initial pressure drop ($\Delta P$), a dirt holding capacity up to 3.5 times higher, and depth filtration capabilities that capture soft, deformable polymer micro-gels that would otherwise shear through two-dimensional mesh openings.
Yes. Stainless steel (SUS 316L/304) sintered fiber candle elements are engineered for thermal and chemical cleanability. Common industrial regeneration procedures include TEG (triethylene glycol) boiling, pyrolysis burn-off ovens, ultrasonic bath agitation, and chemical solvent flushing. Properly cleaned Bekaert elements can undergo 10 to 20 cleaning cycles before requiring replacement, substantially lowering operational expenditure (OpEx).
We provide comprehensive ODM customization: micron filtration ratings (1.5μm to 100μm), structural outer diameters (OD) and lengths (up to 1500mm), adapter end-cap fittings (threaded, DOE, bayonet, double O-ring, custom flange), internal support core thickness, pleat count density, and metallurgy (AISI 304, 316L, Hastelloy, Inconel).
Our ODM filter elements incorporate high-strength perforated stainless steel inner cores and outer protective mesh guards. Combined with solid-state vacuum sintering, the media layer withstands differential pressures ($\Delta P$) up to 210 bar (3,000 PSI) without structural collapse or media displacement, ensuring steady polymer flow in high-viscosity CPF systems.
Every shipment includes a comprehensive Quality Assurance Dossier: ISO 4003 Bubble Point Test Certificate, Material Test Reports (MTR) confirming 316L chemical composition (EN 10204 3.1 certification), pressure drop performance curves, and dimensional inspection reports.
