There are several common products that are created using the custom injection molding process, and a great example here is that realm of filter plates. What are filter plates, what are some of their types and uses, and why does injection molding often serve as an ideal manufacturing method for filter plates?
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At EnviroTech Custom Injection Molders, we’re proud to provide a huge range of filter plates from the best injection molders in the business, including chamber plates, membrane plates and numerous other options. Here’s a primer on what filter plates are and how they work, some of the types you may be considering, and why injection molding is often the ideal process for creating these components.
What Are Filter Plates?
For those just learning about them, filter plates – also known as filter press plates – are common components of filter press machines and other filtration systems. As the name suggests, these plates play a key role in filtering and separating solids from liquids in industrial applications.
Filter plates are meant to provide a stable, flat surface for the filter cloth or membrane to be held in place during the filtration process. They also help to evenly distribute pressure and prevent leaks or breaks in the filter press.
They have uses across numerous industries, including chemical, pharmaceutical, food and beverage, and wastewater treatment. Some of the common applications for filter plates include removing impurities from liquids, separating solids from liquids, and dewatering sludge or other materials.
Types of Filter Plates
There are several types of filter plates available on the market today, each with its own unique design and purpose. Some common types include:
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- Chamber Plates: These are solid plates that have a single channel for liquid to flow through. They can be used for any type of filtration process that requires pressure to force liquid through the filter cloth.
- Membrane Plates: These feature a flexible membrane attached to the plate surface which expands when pressure is applied, allowing for higher levels of filtration efficiency.
- Mineral Plates: These plates are molded with high impact-resistant PP-copolymer, giving them high wear resistance and especially efficient high-flow drainage surfaces.
- Flush Plates and Frames: These filter plates can be opened and separated from the frame, making it easier to clean and maintain.
Filter Plate Accessories
While the filter plate itself tends to be the most important component, there are also a number of accessories that are often used in conjunction with them:
- Gaskets: These are placed between each filter plate to help create a tight seal and prevent leaks during the filtration process.
- Filter Cloths: These are used to cover the surface of the filter plates and trap solids while allowing liquid to pass through. Different types of cloths may be used depending on the specific application.
- Handles: Handles are often attached to the filter plates for easier handling and maneuverability during setup and maintenance.
- Shifter pins: These pins are used to hold the filter plates in place within the filter press frame.
- Sealing plugs: These are used to seal any unused filter plate holes, ensuring efficient filtration and preventing leaks.
- Feed and discharge assemblies: These are used to connect the filter press plates and provide a path for the liquid to enter and exit the filtration system.
- Filtrate valves: These valves control the flow of liquid through the filter plates, allowing for customization of the filtration process.
Why Use Injection Molding?
Out of all the manufacturing methods available, injection molding is often considered one of the best options for creating high-quality filter plates. This is due to a few key reasons:
- Cost-effective: Injection molding allows for mass production of identical parts at a lower cost compared to other methods, making it an ideal choice for large-scale production.
- High accuracy and precision: The injection molding process allows for tight tolerances and accurate replication of intricate designs, ensuring consistent and reliable filter plate performance.
- Versatile material options: With injection molding, various plastic materials can be used to create filter plates with different properties, such as high chemical resistance or strength.
- Efficiency and speed: Injection molding is a highly efficient process that can produce large quantities of filter plates in a short amount of time, making it ideal for meeting tight production deadlines.
Micronics offers you a comprehensive range of filter plate types – both standard, stock plates and special, custom designs – and the expertise to help you choose what is right for your system. Some plate options include:
- Recessed Chamber – CGR – Caulked and gasketed. Read our recent blog post here to learn about some of the many benefits of CGR plates.
- Recessed – Non-Gasketed
- Center feed, corner feed, top center feed, bottom center feed, and even external feed designs.
- Plates accepting “Clip-neck” Filter Cloth. Filter plates designed to accept Micronics-designed “clip-neck” filter cloth have become an industry standard, when cake washing and easy filter cloth change-out are particularly important.
- Membrane squeeze (Diaphragm) Filter Plates, including both fixed and replaceable membrane. Learn more about membrane filter plate advantages here.
- Companion recessed, non-membrane Plates (which “mate” with membrane plates for mixed-packs)
- Vacuum Membrane Filter Plates for achieving drier cakes.
- “Plate and Frame” filter plates. This older-style plate design is still used in various polishing applications where filtration area is more important than volume. While they are non-gasketed and prone to wicking, an advantage of this older design is that different frame thicknesses can be used for different cake thicknesses.
- Steel, Steam-jacketed Plates for temperature-controlled filtration for applications including high-viscosity oils, waxes, etc.
Polypropylene, Kynar® (PVDF), and Nylon filter plates - Cast Iron, Stainless Steel, and Aluminum filter plates
Micronics offers both standard and special, custom machined and manufactured filter plate designs, tailored to your market/application. Polypropylene recessed, CGR, membrane, replaceable membrane, and “Plate & Frame” designs are the most common types of filter plates. Plates constructed from PVC, Kynar® (PVDF) and nylon are typically custom designs as are aluminum and steel, steam-jacketed plates. We don’t shy away from “complicated” plate requirements.
Details matter. Our sales and applications engineering expertise to ensure the right filter cloth/filter plate combination is paramount. We take into consideration a host of factors including whether you are combatting abrasive conditions, need chemical/corrosion-resistant plates, require plates robust enough to handle high-volume slurries, or are trying to improve cake dryness and washing efficiency.
Even if your filter press is quite old or it is not made in the U.S., there is no need for concern. Micronics has a wide selection of OEM replacement plates for any brand, style, or “make” of filter press equipment.
For more Chamber/Recessed Filter Plateinformation, please contact us. We will provide professional answers.