Mirror Polished Multi-Bag Filter Boosts Resin Production Yield by 32% – A Southeast Asian Coating Manufacturer Case Study

2026-08-20

Mirror-faced stainless steel multi-bag filter | Overseas customer application case

Region: Southeast Asia

Industry: Industrial coatings and resin production

Operating conditions:

This customer is a medium-sized synthetic resin and automotive topcoat manufacturer in the local area, with products exported to Europe, America, and the Middle East. The original filter equipment on their production line was a common carbon steel core filter, which had long faced three major problems:

Filter element replacement was frequent, requiring 2-3 shutdowns per day, severely affecting the continuous production rhythm;
Internal rusting of the carbon steel material led to occasional secondary contamination of the paint material with particles, resulting in non-compliant product fineness and an increase in customer complaint rates;
Insufficient filtration area, with high-viscosity resins experiencing significant flow attenuation in cold seasons, necessitating a reduction in feeding speed to maintain production.

Solution implementation:

After communicating with our technical team, a 6-bag mirror-faced stainless steel filter was configured for this customer. The shell material is 316L stainless steel, with the inner surface mirror-polished to Ra ≤ 0.4 μm. At the same time, based on the characteristics of the medium, double-layer polyester fiber filter bags (filtration accuracy 25 μm) were provided, and a jacketed insulation interface was added to cope with the impact of local morning and evening temperature differences on viscosity.

The equipment installation and commissioning took only one working day. The original pipeline flanges were fully compatible with the new filter, and there was no need to modify the pipeline.

Usage effect and data comparison (after continuous operation for 3 months):

Filter element replacement cycle: Extended from 2-3 times per day to once every 72 hours, with a reduction in monthly filter material consumption by approximately 60%;

Product first-pass qualification rate: Increased from 89.7% to 97.2%, with zero customer complaint batches;

Single batch filtration time: Under the same 2000-liter batch, the filtration time was shortened from the original 4.5 hours to 2.8 hours, a reduction of 38%;

Cleaning and maintenance time: The mirror-faced inner wall only requires low-pressure water gun rinsing for 5 minutes to restore smoothness, while the old equipment requires manual rust removal and grinding for about 2 hours;

Annual comprehensive cost: Including filter materials, downtime for maintenance, waste disposal, and quality inspection rework costs, it is estimated to save approximately 32% of filtration-related expenses.

Customer feedback highlights:

The production supervisor stated that the equipment no longer frequently adjusted the outflow speed of the upstream reaction vessel due to filter blockage. The quality supervisor particularly recognized the improvement in cleanliness brought by the mirror-faced inner wall - even when switching between different color series of resin products, the metal residue in the samples after cleaning was below the detection limit, completely eliminating batch-to-batch color differences.

Future cooperation：

Based on the reliable performance of this equipment， the customer has planned to continue using the same series of larger-capacity 10-bag mirror-faced filters in their newly-built water-based coatings workshop， and simultaneously add a set of spare filter bags and sealing components to ensure the turnover of spare parts during peak production periods.