Turning Air Flow into Cash Flow!

Custom Oversize Frame & Pad Method Overview

Let’s begin by examining how our custom oversize frame & pad filtration method works. First, we construct heavy duty oversized galvanized steel frames, which would be a one time investment for you! This oversize construction eliminates any possibility of bypass through the spaces between standard size pleated filters. While we do currently tape your pleated filters together, there is always a possibility of bypass.

The oversize frame & pad method also increases the filtration surface area because there are no cardboard supports on the front side. We calculated that the filtration surface area is reduced by as much as 29% when cardboard supports and frame edges are present, as they are in pleated filters. We eliminate that problem by utilizing steel braces and welded wire grid to support the filter and hold it in place. For example, a typical track in a rooftop HVAC unit takes 3-16 x 25 x 2 pleated filters. We could construct a frame that would encompass the entire length of the track; i.e. 1-16 x 75 x 2 (See Figure 1.1).

In addition to eliminating any possibility of bypass and increasing the surface area of filtration; our oversize frame & pad method also allows for a more uniform distribution of dust particles. With pleated filters, the cardboard supports often lead to the unequal distribution of dust. This causes dust to accumulate more heavily in certain areas which can cause the filter to become more restrictive. When a filter is more restrictive, it uses more electricity to force air through the filter, thus increasing utility costs. This is eliminated with oversize frame & pad.

The filtration media that we use is also depth loading, rather than pleated filters, which are face loading filters. A pleated filter exhibits face loading because the media used is very thin and tightly woven. The dust can only build up on the face of the filter, once again, causing the filter to become more restrictive. Our filtration media exhibits depth loading because of its design. It is a one or two inch thick filtration pad that is loosely woven on the air-entering side, and becomes more tightly woven toward the air-leaving side.

This allows the coarser particles of dust to become suspended on the face of the filter, and the finer particles of dust to become suspended throughout the depth of the filter. In addition, there is a wet tack on the air-leaving side of our media, which adds an extra barrier to stop the finest of dust particles.

Now that you understand our unique method of air filtration, we would like to show you how it compares to the pleated filters you currently use, how it can save you money, and how it will help you greatly reduce your waste consumption.

Performance Comparison: Pleated Filters vs. Our Filtration Media

In comparing typical pleated filters to our filtration media, you will see that our media specifications are just as good, if not better. Our media was recently tested by LMS Technologies, Inc. using ASHRAE 52.2 testing standards. It was rated as a high MERV 7 with a minimum average efficiency of 39.8% on a 1.0 to 3.0 micron scale (See LMS Test Data, Under Media Products).

With very comparable performance data, and the added benefits discussed above, we are confident that our custom frame & pad method will provide the same or better filtration quality as using pleated filters, while not compromising efficiency.

Cost Savings

In addition to being a better quality product, our custom frame & pad method is significantly less costly than using typical pleated filters. In staying consistent with our example above, let’s examine the cost difference between pleated filters and our custom filtration media. The cost of 3-16 x 25 x 2 typical pleated filters is anywhere from $7.00 to $15.00, where as our oversize KU1C filtration media (1-16 x 75 x 2) would only cost around $6.00. So the cost savings are even evident on a small scale. While pleated filters are still good quality filters, there are other benefits to using our frame & pad method.

Waste Reduction

% of Composition

*16%

28%

20%

*18%

*18%

* Indicates % factored into recycled or regenerated

Fiber Source

Regenerated

295

Low Melt

Regenerated

Recycled

Fiber Denier

6 x 2

15 x 2

6 x 2

15 x 2

Same as above

Source: Bonded Filters Midwest

Our custom frame & pad filtration method will help you become a more environmental friendly company. Our custom filtration media is manufactured using between 45 and 52 percent recycled and regenerated material (See Table 1.1). This helps reduce the consumption of raw materials. Typical pleated filters are manufactured using virgin fibers, requiring a greater use of raw materials.

In addition to helping you consume fewer raw materials, we can also help you reduce waste. As described above, our custom filtration media uses no cardboard supports, glue, or tape, as typical pleated filters do. Each time the pleated filters are changed, all that cardboard is wasted. Because of the permanent metal frame used in our custom oversize frame & pad method, that waste can be eliminated. Figure 1.3 shows a graphical representation of the waste difference between pleated filters and our media. Figure 1.4 is an actual visual representation of the difference in waste.

Figure 1.3
Graphical Representations

Figure 1.4
Visual Representation of Waste Difference

As you can see, using the example of converting 3-16 x 25 x 2 pleats into 1-16 x 75 filtration pad, we can eliminate all cardboard waste. In examining this same principle based on the filters that ABC Corporation uses, you can visibly see how much waste can be eliminated by using our frame & pad method (See Figure 1.5).

Figure 1.5
Actual Waste Comparison for ABC Corporation

By using our custom oversize frame & pad method, we can help you consume fewer raw materials, reduce waste consumption, and make a smaller ecological footprint on the world.

Summary

We have outlined our custom frame & pad method of filtration. This method is very adaptable to changing environmental conditions, and has helped many retailers such as Meijer, Marsh, and Kroger, save a lot of money on filter and utility costs.

Based on test data, our custom filtration media has a higher efficiency and performs better than typical pleated filters. Both have a MERV rating of 7, but our filtration media allows for increased filtration area, less restriction, and less bypass of dust particles.

Our custom filtration method is also significantly less costly than using typical pleated filters. After making an initial one-time frame investment, you can save as much as 45% on your filtration service costs.

Finally our frame & pad filtration method greatly reduces the waste associated with using pre-manufactured pleated filters. With our method, all cardboard waste is eliminated, which reduces the amount of total waste consumed by your company. Give it a try, you’ll be happy that you did!