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Secondary BWRO deep desalination and boron removal
The primary produced water enters the secondary system and uses our high-throughput, high boron removal rate brackish water membrane to further reduce the total salt content and specifically remove boron elements that have significant impacts on agriculture and health, ensuring that the quality of the produced water fully meets standards.
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First level SWRO desalination core:
Using our specially designed high desalination rate (>99.8%) and high anti pollution seawater desalination membrane components. Its special membrane formula and flow channel design can effectively inhibit organic matter adsorption and microbial growth, reduce operating pressure, and thus save energy consumption.
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Precision security filtration (core protection link)
Before entering the high-pressure pump and SWRO membrane, we use large-sized, high capacity, and absolute precision melt blown or folded filter cartridges to ensure the removal of all particles ≥ 1-5 microns. This is the "last barrier" to protect expensive high-pressure pumps and RO membranes, and its performance directly determines the cleaning frequency and lifespan of the membrane.
customized engineering solutions based on a deep understanding of food material rheology, colloid chemistry, and microbiology.
Our core capability lies in the ability to accurately analyze the particle distribution, viscosity, pH value, and thermal sensitivity of specific materials for customers, in order to design a full process, multi-stage filtration system from coarse filtration pre clarification, fine filtration purification to terminal absolute sterilization. This depends on our selection of specialized membrane materials such as hydrophilic and stain resistant ultrafiltration membranes, high-temperature and acid alkali resistant microfiltration membranes, as well as the optimization and integration of system fluid dynamics and hygiene grade design.
F-SLPP Non Fiber Shedding Polypropylene Filter Cartridge Series
For example, we once solved the filtration problem of concentrated protein solution for a high-end dairy product enterprise in East China. When producing high value-added dairy protein products, the ceramic membrane system in the original process faced serious irreversible pollution due to the complex interaction between protein and minerals, with extremely short cleaning cycles and prominent production capacity bottlenecks. We have innovatively configured the 'F-SLPP Non Fiber Shedding Polypropylene Filter Cartridge Series' for it, which, through a unique surface charge balance design and progressive pore size distribution, preferentially intercepts specific colloidal components that are prone to clogging. After implementation, the cleaning frequency of the core separation membrane was reduced by more than 50%, and the overall operational stability of the system was improved by 40%. This not only ensured the purity and yield of the product protein, but also enabled the production line to achieve its designed capacity, meeting the rapidly growing market demand.
Value and results achieved:
The value brought by this precise process intervention ultimately manifests as measurable economic benefits and operational optimization. By applying our solution, customers can extend the effective operating cycle of critical filtration units by 30% to 60%, directly reducing the consumption of filter materials, cleaning agents, and disinfectants, while also lowering related waste disposal costs. The more significant value lies in ensuring production continuity and improving product quality: reducing unplanned downtime means higher overall equipment efficiency and capacity utilization; By ensuring the consistency of filtration in each batch, the first pass rate of the product can be significantly improved, almost eliminating batch rework or scrap losses caused by poor clarity or microbiological indicators. In some processes, efficient membrane filtration technology can also achieve the recovery and concentration of valuable components (such as specific proteins and flavor substances), turning waste into treasure. The savings and benefits of all these links - reduced operational consumables, improved production line efficiency, reduced product losses, and additional recycling benefits - ultimately work together on a core business indicator: systematic optimization of total operating costs. We are committed to using reliable engineering technology to safeguard the absolute safety and excellent quality of our customers' products, while building a more resilient and sustainable competitiveness for them.
Food & Beverage Industry Filtration Solutions: Technical Principles & Process FAQ
Q1: What is the fundamental difference between water treatment for the food & beverage industry and general industrial water treatment? What are the core requirements?
A: The fundamental difference lies in the dual, non-negotiable standards of "Safety" and "Sensory Quality." Process water in this industry is not just a utility; it is an ingredient. The core requirements go beyond simple demineralization or descaling:
- Absolute Safety: Complete removal of microorganisms (bacteria, viruses), endotoxins, and any chemical residues (e.g., chlorine, heavy metals) that could impact human health.
- Flavor Stability: Removal of dissolved organics, chlorine, and off-tastes that could alter the intended flavor and aroma of the final product.
- Regulatory Compliance & Reliability: All processes and materials must comply with stringent food safety regulations such as FDA, 3-A Sanitary Standards, and EC 1935/2004. Therefore, food-grade filtration systems—from filter media and sealants to flushing procedures—must meet Food Contact Material standards, ensuring zero risk of extractables.
Q2: Why is an "Absolute-Rated" Final Guard Filter essential before a Reverse Osmosis (RO) or Ultrafiltration (UF) system? How does it impact the final product?
A: The guard filter is the "last line of defense" for the core membrane system and is critically important:
- Principle: It uses absolute-rated (e.g., 1µm, 0.45µm) melt-blown or pleated cartridges for precise surface screening, guaranteeing 100% removal of particles larger than its rating (e.g., carbon fines, resin fragments, pretreatment slippage).
- Impact: Failure here allows abrasive particles to scratch or block the expensive RO/UF membranes, leading to reduced salt rejection, plummeting productivity, and frequent cleanings. More critically, damaged or soiled membrane surfaces can become breeding grounds for microbes, ultimately threatening product microbiological safety. A reliable guard filter directly determines the stability and output quality of the entire purification system.
Q3: What is "Cold Sterilization"? How does membrane sterilization compare to traditional methods like Pasteurization and UV treatment?
A: "Cold Sterilization" refers to the removal of microorganisms without heat, primarily through membrane filtration (using cartridges with absolute ratings of 0.22µm or 0.1µm).
- Principle: It relies on microporous sieve retention, trapping bacteria and yeast on the membrane surface while allowing flavor compounds and the product to pass through.
- Comparative Advantages:vs. Pasteurization: Entirely low-temperature, perfectly preserves the original flavor, color, and nutrients of heat-sensitive products (e.g., fresh juices, mineral water, wine) with no "cooked" taste.vs. UV Treatment: A physical removal method with absolute efficacy, unaffected by fluid clarity or flow rate. It produces no disinfection by-products and simultaneously removes particulates.
- Application: Widely used for final polishing filtration of beverages, beer, spirits, and sauces. It is a key technology for premium products requiring natural flavor preservation.
Q4: When filtering high-viscosity liquids like syrups and juices, how do you balance filtration precision, flow rate, and product (sugar) loss?
A: This is a core challenge in high-value liquid processing. The key lies in selecting the right filtration mechanism and media:
- Staged Filtration: Implement a multi-stage "coarse → fine" process. First, use high-flow, depth-type filter bags or large-pore cartridges to remove most pulp and colloids, protecting the final precision filter.
- Specialized Filter Media: For fine filtration, recommend hydrophilic, low-adsorption pleated cartridges. Their benefits include:Precision & Flow: Increased surface area maintains high flow rates while guaranteeing sterilization/clarity (e.g., 0.45µm), reducing batch processing time.Minimized Loss: Specially treated membrane materials exhibit very low adsorption of sugars, pigments, and flavor compounds, maximizing product yield.
- Process Optimization: Techniques like pre-coat or cross-flow filtration can further prevent excessive cake buildup, extending filter service life.
Q5: Why is filtration critical in a CIP (Clean-in-Place) system, and how do you select compatible filter cartridges?
A: The cleanliness of the CIP system directly determines if production equipment is truly clean, making it the core safeguard against cross-contamination and microbial growth.
- Importance: CIP return water contains soils, product residues, and scale particles removed from equipment surfaces. If not filtered before re-entering the cleaning tank, these contaminants become a pollution source for the next cycle, creating a vicious circle and leading to cleaning failure.
- Key Selection Criteria:Chemical Compatibility: Must withstand high temperatures, strong alkali (NaOH), and acid (HNO₃) cleaners. Polypropylene (PP), PTFE, and stainless steel cartridges are common choices.Temperature Resistance: Must match high CIP operating temperatures (often >80°C / 176°F).Rating: Typically 25-100µm for capturing particulate soil, ensuring the purity of the cleaning agent itself. The filter on the CIP return line is often called the "Kidneys of the CIP System."
Q6: How do I select and validate the right filtration scheme for my specific production line?
A: A scientific selection and validation process is fundamental to filtration success:
- Define Key Parameters: Clarify the goal (sterilization, clarification, decolorization), fluid characteristics (pH, viscosity, temperature, composition), required flow, and point of use (ingredient water, process stream, final product).
- Perform Compatibility Testing: Soak candidate cartridges in the actual fluid to test for integrity, extractables, and adsorption, ensuring no impact on product safety or flavor.
- Conduct Challenge Testing: Validate the system's removal efficiency and stability in a lab or pilot setting using standard microorganisms or particles.
- Establish Integrity Test Protocols: For sterilizing-grade filters, mandatory pre- and post-use integrity tests (Bubble Point, Diffusion Flow, or Pressure Hold) are a regulatory requirement for product release.
Q7: Can you provide a complete solution from design to operation?
A: Okay. We are not only a core membrane component supplier, but also able to provide:
>Early stage: process design, simulation calculation, technology selection.
>Mid term: System integration guidance, installation and debugging support.
>Post production: Operations training, remote monitoring, preventive maintenance plans, and timely on-site technical services to ensure the long-term success of your project.
Q8: How can I obtain a specific plan and quotation for my project?
A: Please submit your requirements through the "Contact Engineer" or "Get Solution" button on the website, including basic information such as project location, expected water production, type of raw water source, and water production purpose. We will assign professional engineers to liaise with you within 24 hours and provide preliminary technical solutions and business consulting.
Our Expertise:We offer a full range of certified food-grade filter cartridges and membrane products, supported by application labs to assist withcartridge selection, process design, compatibility testing, and validation.Contact our Food & Beverage specialiststo safeguard your product safety and quality.