Cleaner Air Longer Filter Life Greater Cost Savings For All Collectors
Transcript of Cleaner Air Longer Filter Life Greater Cost Savings For All Collectors
UltraWebisAlwaysBetter.com
Cleaner Air • Captures submicron particles with patented nanofiber technology
and pre-HEPA MERV 13 efficiency
Longer Filter Life• Lasts up to 2 times longer than cellulose or blended media,
depending on the application
Greater Cost Savings• Provides the best value and long-term savings
For All Collectors• Ultra-Web filters are standard on all
Donaldson® Torit ® cartridge collectors
• Ultra-Web filters are also available as replacement for all brands of cartridge collectors
Ultra-Web nanofibers are the smallest synthetic fibersused in filtration today. To put it into perspective,compare Ultra-Web nanofibers to the eye of a fly.
Fly Head (25X) Fly Eye (100X) Fly Eye (2000X)
Proven Performance
The Ultra-Web advantage is cleaner air. Nanofibers are scientifically proven to have anadvantage in efficiency and pressure drop. Ultra-Web nanofibers are patented and made with an electrospinningprocess that produces a very fine, continuous fiber of 0.2-0.3 micron in diameter to form a permanent web-likenet with very fine interfiber spaces. This nanofiber “web” is constructed on a variety of media, resulting in:
1 micron = 1/25,400 of an inch
Ultra-Web (2000X)Nanofibers areSmaller than a FlyEye!
10 MicronCellulose / SyntheticMedia Blend
600X
10 MicronCellulose Media
600X
10 MicronNanofiber Technology
600X
• Advanced media that captures submicron and
larger dust particles
• A media that traps dust on the surface and
promotes self-cleaning
• Better pulse cleaning and lower stabilized
pressure drop
• Cleaner air, longer filter life, and greater
cost savings
Lasts Longer
Ultra-Web filters last up to 2 times longer. Pressure drop starts high and rises quickly withdepth-loading commodity filters such as plain cellulose or cellulose/synthetic (80/20) media blends. Ultra-Webnanofiber technology provides phenomenal surface loading ability and superior dust release capabilities due to itsnano-fine interfiber spaces. Filtration scientists have long attributed surface loading with lower operating pressuredrop over a much longer period of time. As a result, the web-like nanofiber technology allows Ultra-Web filters tolast up to 2 times longer than commodity filters.
Results were derived testing Atomite test dust in an 8-cartridge collector @1.0 gr./cu.ft, Goyen Millenniumvalves, 90 psi cleaning pressure, 100ms on time 10 secondoff time. Airflow goal = 4064 scfm.
Lower Pressure Drop= Longer Filter Life
Clean Ultra-Web Filter Surface-Loaded Ultra-Web Filter(The substrate is still clean)
Surface Loading Promotes Self Cleaning
“Ultra-Web just works. Once you get Ultra-Web, the value speaks for itself.”John Peterson, Co-President, Atlas Manufacturing
Ultra-Web nanofibermedia is loaded withISO fine dust. Dustparticles collect on thesurface of the mediaand clean off easilywhile the substratestays clean. A depth-loading filter wouldallow dust particles topenetrate deeply intothe substrate wherethey build up andchoke off the airflow.
Filters with Ultra-Web nanofibers
lasts up to
2X Longer
See the savings add up with Ultra-Web. Cellulose or 80/20 commodityfilters cost less than Ultra-Web, but Ultra-Web nanofiber filters save you more money inthe long run, particularly with energy savings that can’t be beat. No other filtrationtechnology provides the powerful combination of higher efficiency and cleaner air,lowest pressure drop and longer life, plus high energy savings.
Saves Money
Ultra-Web improves the bottom line. Count on significant savings with themost powerful filtration media available. Cartridge filters made with Ultra-Web nanofibertechnology last longer, resulting in fewer filter changes, lower replacement and labor costs, andless production downtime. Extraordinary surface loading performance provides lowest pressuredrop and significant annual energy savings.
Lower Pressure Drop Saves Energy
Fewer Changeouts Save Energy, Maintenance & Filter Costs
This is one example of energy savings due to lower pressure drop. Energy savings can furtherincrease with larger collectors. These energy savings are calculated based on the followingassumptions: Cartridge collector running 4000 hours per year and energy costs are 5 centsper kilowatt hour.
Maintenance and filter replacement calculations are based on a comparison of 80/20 media blend cartridges and Ultra-Web nanofiber cartridges. 80/20 media filters are replaced after six months. Ultra-Web filters provide twice the lifeof 80/20 media filters. 80/20 media filters are priced at $55 each, Ultra-Web filters are $110 each. Labor rate equals $50per hour, filters are replaced at a rate of 16 filters/hour and disposal costs are $50/drum.
Number of Annual Maintenance & Annual Energy Total AnnualUltra-Web Cartridges Filter Cost Savings Savings Savings
8 $458 $386 $845
12 $688 $579 $1,267
24 $1,375 $1,159 $2,534
36 $2,063 $1,738 $3,801
48 $2,750 $2,318 $5,068
72 $4,125 $3,412 $7,537
96 $5,500 $4,571 $10,071
128 $7,333 $6,116 $13,450
80/20 Media Ultra-Web Nanofiber Blend Media
Cartridge Filter 24 24
Airflow ACFM 18,000 18,000
Operating Delta P 4" 2"
Motor HP 50 40
Break HP 42.1 35.2
Annual Energy Use $2,318 $1,159
Reduces energy costs
By 1⁄2
Annual total savings up to
$13,450
Ultra-Web captures what the eye can’t see. The smaller the dustparticles, the lower the emissions. A filter must be rated at least a MERV 13 on the ASHRAE20-point scale to effectively filter submicron dust particles. Ultra-Web is the only standardcartridge filter media rated to capture submicron dust particles.
Your Air Is Cleaner
Ultra-Web raises the bar. Manufacturing processes generate submicron dust—fromwelding and cutting fumes, smoke and toner to paint pigments, insecticides and pharmaceuticalcompounds. As pressure mounts to maintain a cleaner plant environment, manufacturers have a provenhigher efficiency solution with pre-HEPA MERV 13 rated Ultra-Web filters.
Ultra-Web MERV 13 efficiency has been certified by independent lab testsand tested per the ASHRAE Standard 52.2-1999, the most current industryaccepted test method used to evaluate filter performance.
Higher Efficiency = Cleaner Air
“[Our] air quality is so much better.”
Lennie Helms, Maintenance Manager, Ready Machine Tool & Die Corp.
Only Ultra-Web efficiently captures submicron dust particulate. Cellulose and80/20 blend media are not efficient enough to rate on submicron dustparticulate. Typical cellulose and 80/20 blend media are rated to capture 1-3micron dust particles and some competitive 80/20 blend media is only rated tocapture larger 3-10 micron particulate.
Ultra-Webcleans the air better
MERV 13Efficiency
Cartridge Filter MERV 3-10 µm 1-3 µm 0.3-1 µm
Ultra-Web® 13 ✔ ✔ ✔
Typical Cellulose 10 ✔ ✔ Not Efficient Enough to Rate
Typical 80/20 Blend 10 ✔ ✔ Not Efficient Enough to Rate
Other 80/20 Blend 9 ✔ Not Efficient Enough to Rate Not Efficient Enough to Rate
Other 80/20 Blend 8 ✔ Not Efficient Enough to Rate Not Efficient Enough to Rate
Ultra-Web provides
40% LowerEmissions
on 1µm dust particles
Ultra-Web provides
58% LowerEmissionson 0.5µm dust
particles
Donaldson Company, Inc.Industrial Air FiltrationP.O. Box 1299Minneapolis, MN55440-1299 U.S.A.
Tel 800.365.1331 (USA)Tel 800.343.3639 (within Mexico)www.donaldsontorit.com
The value of Ultra-Web keeps going and going…Sheet metal fabricator Atlas Manufacturing, Minneapolis, Minn.,counts on Ultra-Web to keep their custom-configuredEnvironmental Control Booth (ECB) dust collectors runningwithout much upkeep. Installed in six 6-cartridge Donaldson ToritECB modules used in grinding and powder paint applications, the36 first-fit Ultra-Web filters have been cleaning the air at Atlaswithout changeout for four years. And they’re still going.
“Ultra-Web just works. It keeps dust on the surface of the media,with low pressure drop, and dust is easier to pulse off,” said JohnPeterson, Co-President of Atlas. “Our air is more efficiently cleanedwith Ultra-Web.”
For Atlas, Ultra-Web’s long-term savings in maintenance and filter costs faroutweigh any initial price difference compared with lower-pricedcommodity filters. “Once you get Ultra-Web, the value speaks for itself,”said Peterson.
John Peterson, Co-PresidentAtlas Manufacturing, Minneapolis, Minnesota
Significantly improve the performance of your collectorwith genuine Donaldson Torit replacement filters and parts.
Information in this documentis subject to change without notice.
© 2006 Donaldson Company, Inc.Printed in U.S.A. on recycled paper
Ultra-Web (1/06)
Over$2,300
in energy savingsper year
UltraWebisAlwaysBetter.com
Cleaner air comes to Ready MachineIn October 2004, Ready Machine Tool & Die Corp., Connersville,Ind., decided it was time for cleaner air.
“Our other collector just wasn’t doing its job and the filters didn’tclean well. It had 16 filters that I kept having to change out everythree months because they would plug up,” said Lennie Helms,Maintenance Manager.
Ready Machine replaced their collector with a Donaldson ToritDownflo® Oval™ (DFO 3-12) cartridge dust collector with higher
efficiency, longer lasting Ultra-Web® nanofiber filters. The DFO collector has been operating almost around-the-clock for a year without having to replace the first-fit Ultra-Web filters.
“The DFO collector has only 12 Ultra-Web filters and it’s doing twice the job,” said Helms. “The air qualityis so much better. You can visibly tell that there is no smoke in our plant now.”
Lennie Helms, Maintenance ManagerReady Machine Tool & Die Corp., Connersville, Indiana
Up To $3,200
in filter, labor and energy savings
U.S. patents: 6955775, 6924028, 6716274, 6743273. Other U.S. and foreign patents pending.