Filters are at the heart of many manufacturing systems, and to keep your production up and running at maximum efficiency, replacing filters regularly is a must. But how do you know where to find filters and how can you make sure you’ve replaced them all?
Industrial filters tend to be hidden in equipment and machinery, and it’s not always obvious where they might be. By following the five steps below, you’ll be able to efficiently locate and manage filters, easily replacing them at the right time to ensure your plant remains efficient, safe and compliant.
Let’s take a closer look.
Step 1 – Understand the types of filter you’re looking for
Before you start your search to find filters, it’s important to know what type of filter you might be looking for, as this will help you to identify where to look. Here are some common types of filters:
- Air filters: These filters remove airborne contaminants and are found in heating, ventilation and air conditioning (HVAC) systems, air compressors, and cleanrooms.
- Oil and lubrication filters: These filters help to keep fluids clean so equipment can function effectively, and they are used in machines such as hydraulic systems, compressors, and engines.
- Water and liquid filters: These filters remove contaminants and particulates found in processes involving cooling, washing, or liquid transportation.
- Dust and particle filters: These filters capture fine particles from processes such as griding, sanding or machining and are usually located in dust collection systems.
- Process filters: These filters help to purify materials such as gases or liquids that are directly involved in manufacturing.
Step 2: Consult the facility and system blueprints and engage with maintenance
Manufacturing facilities typically have a system layout and standard operating procedures (SOPs) for the different systems. Check whether these ‘blueprints’ exist and whether there are maintenance manuals that can help you find filters. These documents should provide details about the equipment installed, the placement of filtration systems and the frequency of filter maintenance.
Engaging with the plant’s maintenance team can also help, as they may know the location of trickier-to-find filters, known problem areas that may require extra attention, or recommendations for hard-to-reach filters.
Step 3: Check key areas with high filter usage
Filters are often located in areas where raw materials or products needs to be moved between two points, or where air is being used to drive a process. For example, where air, fluids, or materials flow in high volumes or require treatment, such as in mixing powders or pellets in the manufacturing processes, or in pneumatic tools.
There are a few systems to check including HVAC and air systems, production lines and inline process filters in material transport systems, machine rooms and waste management systems.
One area in a plant which uses filtration is the compressor system, so this is a good place to start.
Step 4: Carry out a physical inspection
Once you’ve identified key areas, walkthrough the facility in an orderly way. Follow these tips during your inspection:
- Follow airflow and fluid lines: Since filters capture contaminants and ensure clean air circulation, filters are often located along airflow paths. Follow these paths within equipment to identify the filters’ potential positions. Filters are often installed at points where air or liquids enter, exit, or change direction within a system.
- Look for filter housings: Equipment typically includes access panels and doors to give users entry to internal components such as filters. Look out for identifiable cabinets, housing or casings, labels, access panels or inspection ports to check the filters.
- Look for hoods and panel filters: These can be found under hoods and housings, also known as “dog houses”.
- Inspect dust-prone areas: Filters in dust collection systems are often located near high-dust operations, such as grinding or cutting stations.
Step 5: Use technology
Modern manufacturing facilities may use technology to track equipment and maintenance. Check whether the site has any of the following tools that could help you to locate all the filters.
- Is there a computerised maintenance management system (CMMS) in place? These systems often log filter maintenance tasks, including location and service history, so accessing this data will help you to check if you’ve found all the filters.
- Is the site equipped with smart technology and IoT Sensors? In some cases the condition of filters may be monitored by sensors, which then alert staff when they need replacement.
- Does the facility have a digital twin that pinpoints filter locations? Advanced facilities may use a virtual model of the physical plant, which identifies all filter locations and maintenance requirements.
Additional questions
Once you have found the filters there are a few questions to ask yourself:
1. Does the filter need replacing?
Assess the condition of the filter to double check if it needs replacing. If it’s dirty or there are signs of wear, it’s time to change it as a clean filter keeps equipment running smoothly and prevents equipment failure.
2. Is the right type of filter being used?
Consider whether the current filter is appropriate, and is the right fit. Different types of filter to the one presently installed can often be used to provide a better performance.
3. Is the compressor or machine working harder than needed?
Take a look at what state is the compressor in, for example, is it running hot? If so, then maybe a filter that provides a better flow would be more appropriate.
4. Is there evidence of bypass around the ends?
Check what the seal is like. If a filter has a moulded end, rather than a metal one, it can often provide a better seal.
Finding filters might seem like a small task, but it’s an important stage in maintaining the overall productivity and sustainability of your manufacturing operation. By following these five simple steps and asking yourself the right questions, you’ll be able to find the filters without fail.