We often need custom HEPA air filters to adapt to different filtration systems and achieve filtration goals.
However, only some manufacturers can realize the customization requirements of customers because there are many different process technologies and equipment requirements, so it is essential to find a professional air filter manufacturer.
Process of customizing HEPA filters
1. Inform the air filter manufacturer of the background of the project and the industry to which it belongs.
2. Tell the manufacturer the use scenario of the HEPA filter and what equipment or system it will be installed.
3. Send the product parameters, exact size, technical requirements, drawings, packaging requirements, and quantity of the air filters to be customized.
4. In-house technical discussions, proposals, and quotations from HEPA filter manufacturers.
5. Depending on the situation, decide whether a sample process is needed or place an official order for production.
6. Place the order, make payment, and the manufacturer does production and shipping.
Introduction of HEPA filter
Hepa air filters mainly filter air-suspended particles above 0.3μm and are the most effective filtering medium for pollutants such as smoke, dust, and bacteria. (Smoke particles produced by smoking are 0.5μm in diameter).
It is suitable for higher-level non-unidirectional flow projects with various purification equipment and clean plant end purification. It has high efficiency, low resistance, good uniformity of airspeed, etc.
In industrial air filtration, HEPA filter is suitable for higher-level non-unidirectional flow projects with various purification equipment and clean plant end purification. It has the characteristics of high efficiency, low resistance, good uniformity of airspeed, etc.
Hepa air filters can be widely used in the air conditioning end of the clean room in optics, electronics, LCD manufacturing, biology, pharmaceutical, precision instruments, beverage, food, PCB printing, etc.
HEPA filters are also heavily used in commercial air conditioning, HVAC systems, and household appliances such as air purifiers, floor sweepers, etc.
They remove allergens, germs, dander, and hair and improve indoor air quality.
Mini pleat and deep pleat
HEPA filters can be divided into a mini pleat and deep pleat based on the processing structure of the filter media.
The deep pleat hepa filter with an aluminum separator is mainly used in high-temperature or high-humidity environments.
The air volume for the deep pleat hepa filter is relatively large; its filter efficiency can only reach H13-H14 and can be used for high-temperature filtration after a specific production process.
The filter material of the deep pleat HEPA filter does not have the strict requirements of the mini pleat HEPA filter, and generally rarely use the deep pleat filter to do ultra-high efficiencies like U15 grade or higher.
Compact, small in size, with a large filtration area, and low resistance, the mini pleated HEPA filter is the first choice for commercial and residential HEPA filters. It is also used extensively in industrial air ventilation systems and hospitals.
How to make HEPA filters?
The HEPA filter is made of glass fiber or synthetic fiber as filter media; hot melt adhesive, aluminum foil, and other materials as a separator; sealed by polyurethane sealant and made of galvanized stainless steel, aluminum, and plastic as the frame.
Each component and function of the HEPA filter can be customized.
- Custom HEPA filter sizes according to measurements
- Custom filtration efficiency
- Custom weight
- Custom airflow and resistance
- Custom filtration materials
- Custom shapes
- Custom filters with unique properties such as high-temperature resistance, high humidity resistance, flame retardant, etc.
- Custom filter colors
- Custom protective fence
- Custom seal gasket
- Custom packaging and labeling
- Custom frames
Custom industrial HEPA filters and cleanroom HEPA filters
What we often call dust-free purification is not 100% dust-free as we perceive it. It is primarily based on the number of particles per cubic meter of air with a particle diameter greater than the classification criteria.
In a clean industrial environment, HEPA filters are used glass fiber as filter material.
This is because its filtration precision and stability are more in line with the industrial-level purification requirements.
For this reason, glass fiber media is used by default when customizing HEPA filters for industrial use.
Since glass fiber material is more rigid and easy to break, specific shapes of HEPA filters, such as HEPA cartridge filters, use synthetic fiber or glass fiber/chemical fiber composites as filter media for convenient production.
Custom deep pleat hepa filters for industrial purification or laminar flow projects
- Determine if the required HEPA filter’s actual size and mounting location match.
- Select the required filter efficiency according to the customer’s requirements and relevant standards.
- Determine the filter frame material. There are wooden frames, aluminum frames, galvanized and stainless steel frames, etc.
- Determine whether the required HEPA filter must be made with or without flanges (single and double flanges).
- Determine the separator material, and there are paper separators and aluminum separators (generally high temperature or humidity; choose aluminum separator). The paper separator is not used now because it is flammable.
- Determine whether the filter has a protective fence. If so, it can be divided into single-sided and double-sided protective fences. Protective fence material has aluminum diamond, hot-dip galvanized, stainless steel, cold plate baking paint(standard type), etc.
Custom combined mini pleat medium and HEPA filters for industrial purification or laminar flow projects.
- Determine if the required filter size and interface size match.
- Determine the filter frame material: plastic frame, aluminum, galvanized and stainless steel frame, etc.
- The required filtration efficiency F6-H14 is selected and can be customized according to the actual efficiency requirements.
- Determine if flanges are required for the desired air filter (single and double flanges)
Custom mini pleat HEPA filters in industrial purification or laminar flow projects.
- Determine the filter frame material. The standard material is anodized aluminum.
- Determine the filter protection fence material. The standard is sprayed protection fence.
- Determine the size of the required filter.
- Determine if the filter has unique requirements, such as a gel seal.
- Determine the required air volume for the filter.
- Select the filter filtration efficiency from H13-U16, which can be customized according to efficiency needs.
When the air volume of the whole purification system is known, the number of filters required can be determined according to the rated air volume of the selected filter.
Custom air filters and air purification in cleanrooms
Air purification technology is a comprehensive technology that creates a clean air environment and ensures and improves product quality.
It mainly applies the primary, intermediate, and HEPA filters to filter out the particles in the air and get clean air, which is mixed with the original indoor air to take away the air with particles around it to achieve the purpose of clean air.
After the clean room is built and put into operation, the primary source of dust production is the personnel and equipment inside the plant.
In order to maintain the cleanliness of a clean room, it is necessary to filter out the dust generated through continuous filtration.
For a room of the same volume, the larger the air supply, the higher the number of air changes and the higher the cleanliness.
At the same time, the filter choice will also affect the cleanliness. The higher the filtration efficiency, the higher the cleanliness.
Custom air purifier and vacuum cleaner HEPA filters
Air purifiers and vacuum cleaners’ shape and air volume are much smaller than industrial filtration systems’ equipment and air volume.
Thus, their HEPA filters’ air volume and size are much smaller than industrial HEPA filters.
How to custom the air purifier hepa filter?
Selection of filter materials
Compared with industrial filtration, the filtration requirements are lower in commercial and residential HEPA filters.
More filter materials are available for processing convenience, including PET, PP, PP/PET melt-blown composite, and glass fiber.
The shape, width, length, and thickness of the HEPA filter
From the perspective of craft aesthetics, most air purifiers are square or round.
In order to fit the shape of the air purifier, the HEPA filters are designed as a panel or cylindrical type.
Material of filter frame or upper and lower end caps
In many cases, users install or replace the high-efficiency filters by themselves, and most of the high-efficiency filters have PET frames for easy replacement or disassembly.
In the first few years, the HEPA filters in the air purifiers in the market were all made of cardboard frames. Later, it was found that the paper would become soft and produce mold after contact with water vapor, which seriously affected the operation and filtration effect of the whole air purifier, so they were all changed to PET material frame.
PET material is stable, non-toxic, non-polluting, water resistant, and not affected by water vapor.
Filter efficiency
The HEPA filters on air purifiers are all H13-H14 rated, 99.97%-99.995%@0.3um.
Air volume and resistance
The air volume setting and resistance of the HEPA filter directly determine the energy consumption and noise of the air purifier.
It also has an important influence on air output and purification times.
Multi-stage filter
In order to remove small particles, dander, hair, viruses, bacteria, and odors from the air, air purifiers use multi-stage filtration, i.e., primary filter + activated carbon filter + high-efficiency filter configuration.
Sometimes ultraviolet light, photocatalysts, etc., are added to enhance filtration’s scope and effectiveness.
Hepa filter colors
To highlight the differences, different air purifiers will choose distinctive colors when customizing their HEPA filters, which can highlight various filtration technologies, capabilities, and brand differences.
How to custom the vacuum cleaner HEPA filter?
The vacuum cleaner is another essential household appliance used in almost every home.
It works by picking up a lot of dust, hair, and dander from the floor.
In order to prevent these pollutants from releasing into the air again, every vacuum cleaner is equipped with a HEPA filter to block these pollutants.
Size and shape of HEPA filters
Compared to industrial HEPA filters and air purifier HEPA filters, the HEPA filters used in vacuum cleaners are relatively small but very varied, numerous in shape, and rather complex in the production process.
The filter material has to be assembled in different-shaped housings, so the equipment of the air filter manufacturer and the industrial technical capability are required.
Housing and filter media colors
The color of the HEPA filters on different brands of vacuum cleaners is diverse, from the filter media to the housing.
The colors are very varied, which is an important aspect that requires customization.
Selection of filter materials
Vacuum cleaner filters are generally made of PET, PP, or melt-blown composite materials.
Filter efficiency
Hepa filters are usually selected for vacuum cleaners with an efficiency of H13 99.95%@0.3um.
Vacuum cleaner Hepa filters should be washable.
Compared to other industries or equipment with HEPA filters, most filters on vacuum cleaners are required to be washable and need the filtration efficiency remain the same after washing.
This washable filter facilitates the maintenance of vacuum cleaners and reduces costs.
Such requirements for filter material and manufacturing process are higher.
Summary of custom HEPA filters
For industrial filtration, there is a wide variety of air contaminants in different manufacturing industries. Such pollutants can affect production equipment and product quality, so industrial filtration is a relatively complex system with more factors to consider when customizing industrial HEPA filters.
In contrast, air filtration is mainly for improving indoor air quality in commercial or home environments, and the pollutants to be removed are relatively fixed.
The filtration requirements in commercial or home are lower than industrial filtration and only need to be considered in terms of filter material, shape, efficiency, etc.
Work with a professional air filter manufacturer.
Working with professional air filter manufacturers is essential to customize HEPA filters safely and quickly.
Professional manufacturers can give quick judgment and price and provide professional advice for air filters in various industries, use scenarios, and some special applications.
As a leading air filter manufacturer in China, we can help you realize any HEPA filter customization.
