Reviewing existing filter systems
We check where service life, flow, change interval or installation no longer match the process as it actually runs.
B2B process consulting
Industrial filtration consulting: process, filter media and custom builds
When filter service life drops, a process changes or an existing filter system no longer suits the application, a product recommendation is not the answer. We look at the plant, the medium, the filter element and the way the work is actually done, and we assess it from your data first. This is filtration consulting from a manufacturer rather than from a sales desk: if no catalogue part fits at the end of it, we build the replacement ourselves.
More than the filter element
What industrial filtration consulting covers
A filter can be technically correct and still cause trouble in the process. The cause is often not the medium but the installation, too little free filter area, a load peak in the cycle, or the way the filter gets changed. Industrial filter problems are rarely material problems, which is why those points belong on the table. Anyone looking at filter system optimization or at extending filter service life starts with the process rather than with the micron rating.
Placing industrial filter media
Material, grade, weave or web structure and available filter area are assessed technically and commercially. The grade on its own says little: two fabrics with the same micron figure can differ widely in area weight and permeability. Filter media consulting is about that comparison and not about a ranking of numbers.
Checking replacement and special versions
Where no standard version fits, we look at the sample, the drawing, the dimensions and what can be manufactured.
Looking at the plant and the workflow together
For complex or recurring problems, seeing the installation clears up more than a long email chain. Where distance makes that impractical, photos, video and a filled-in process sheet get us most of the way.
Typical reasons to get in touch
When a filtration process review is worth it
An enquiry rarely starts with a finished specification. Usually there is just a recurring problem: filters have to be changed sooner, solids are carrying further into the process, or a new liquid has changed the familiar behaviour.
Filter service life is changing
Filters blind off earlier or need changing more often than planned.
The medium or the process is changing
Temperature, chemistry, solids load or throughput are moving.
The plant is being modernised
An existing filter element has to work in a new installation situation.
The standard product is not enough
Dimensions, material, shape or load call for a custom version.
What we look at
What a filtration process consulting review examines
Installation and sealing
Filter seating, fixing, sealing faces, free filter area and possible bypass paths. A bypass of a few millimetres makes any discussion about grade pointless.
Medium and solids
Consistency, particles, temperature, chemistry, fluctuation, and the question of what result the process actually needs.
Flow and load
Volume flow, cycle timing, fill height, pressure conditions and load peaks.
Filter change and handling
How the filter is fitted, removed, cleaned or disposed of, and where unnecessary effort is created.
Service life and change intervals
We assess change and cleaning rhythms. The focus is the technical review rather than a blanket maintenance contract.
Commercial feasibility
A technically possible solution still has to suit the quantity, the changeover effort and the actual benefit in operation. Sometimes the answer is that it is not worth it. We say so.
Our focus is textile filters and industrial solid liquid filtration, among others in process liquids, coolants, electrolytes, waste water and sludge dewatering. As an industrial filter expert in that narrow field we will also review a case where no product of ours ends up being fitted.
From process to part
Custom filter bags and custom industrial filters from our own works
The difference from pure consulting is that we build the result afterwards. Sewing room, filter assembly, prototyping and technical textile laser cutting all sit in Werther, in the same building as standard production. Custom fabricated filter media therefore do not have to travel between three suppliers before anyone sees whether the idea works.
A custom textile filter needs one of three starting points, in this order of precision: a drawing, an existing sample part, or a description accurate enough with dimensions and photos. From an old part sent in we take the dimensions and derive the contour, even if it is damaged.
Bespoke filter bags and made to measure filter bags
For new processes with no catalogue part we work out shape, material and grade with you. That is how custom industrial filters come about that do not exist as catalogue goods: first a prototype, then a first article sample, then the series. What gets checked at which stage is agreed in advance.
Prototypes and first samples
Prototypes we make from one piece. With textile contour parts the contour runs through laser cutting, so a sample carries no tooling cost and the geometry can change between two samples.
Custom filtration products in series
If the prototype proves out, the same version goes into running production without a detour, with the same contacts and the same material. As a custom filter manufacturer we agree series capability and quantities before the first delivery rather than after it.
From problem to decision
How the consulting process runs
1. Record the starting situation
You describe the process, the filter solution in use and the actual problem. Photos, data sheets and samples help with the preparation.
2. Technical pre-assessment
We establish whether a remote assessment is enough or a visit to your site makes sense.
3. Assess plant and process
We look at the filter system, the medium, the installation and the workflow together, on site where that is practical and otherwise from your documentation.
4. Agree the next steps
You receive a recommendation you can follow, from an adapted standard product to a custom textile solution.
First technical assessment
Describe your industrial filtration task
The form is the entry point. The more we know in advance about the process, the filter element and its behaviour so far, the more precisely a call or a site visit can be prepared.
medium, solids and the filtration result you need
existing plant, filter element and installation situation
temperature, chemistry, flow and change interval
photos, drawings, data sheets or existing samples
If this is only about selecting a filter bag, a filter pouch or a micron rating, quick product advice is the shorter route.
If the form does not load, call us on +49 (0) 5203 8828-0.
FAQ
Frequently asked questions about industrial filtration consulting
Answers on remote assessment, site visits, existing filter systems, custom manufacture and the process itself.
Do I have to be in Germany for this?
No. The technical review, the filter media assessment and the custom build work from your documentation, and we deliver across Europe. Site visits are a different matter: they are arranged across Germany by appointment. Outside Germany we look at each case individually rather than promising a visit in advance.
When is a site visit worth it?
Above all when installation, plant operation and filter changing interact, or when several causes are possible. Before scheduling anything we check from your data which documents are needed and how far the question can already be narrowed down remotely.
Which industries is this suitable for?
The focus is industrial applications with textile filters and solid liquid filtration, for instance process liquids, coolants, electrolytes, waste water and sludge dewatering. The filtration task decides, not the industry. We work with businesses of any size, from a single case to a series project.
Can existing filters be copied or replaced?
We check that from a sample, a drawing, dimensions, material and process data. Not every version can be replaced in a way that makes technical or commercial sense, so the feasibility check is always part of it. A damaged old part is usually enough as a pattern.
Do you manufacture the custom filter yourselves?
Yes. Assembly, prototyping and laser cutting are our own production in Werther. With custom filter bags you are therefore talking to the people who build the part rather than to an intermediary.
Do you maintain filter systems?
The focus is technical advice on the filter element, the filter medium, the installation and the process. Change and cleaning intervals can be part of the assessment. We do not offer a blanket maintenance contract for complete filter plants.
Consulting and manufacturing together
From the reviewed process to the textile solution
If the review shows that a custom geometry or an adapted filter element is needed, we look at assembly, prototyping and, for suitable materials, technical textile laser cutting in our own works.
Typical next steps
adapt the existing filter element
reassess material or grade
make a prototype to drawing or sample
agree series capability and quantities
