Local Air Filter Case Studies
Because having proof is better than just saying so
Because having proof is better than just saying so
By switching from a traditional 2-Stage MERV-8 Prefilter and MERV-13 Final filter one of the largest shopping centers in the world was able to save 68% of the labor hours for unloading, changing, and disposing their air filters in their 32 air handlers that provide over 3,000,000 cfm of air. This was accomplished with the Hi-FloES from Camfil, the only high efficiency air filter specifically designed to be operated without a prefilter and not sacrafice filter life, even the boxes are designed with multiple handles to make trasporting the filters to the air handler easier. The previous 2-stage systems final filters averaged 12 months between changes and the Hi-FloES was able to go 14 months before reaching final pressure and there were no more prefilters to change.
A large International Airport in the Twin-Cities was on a strict low-bid selection for air filters, which lead them to change high-capacity pre-filters weekly and their MERV-14 Bag style final filters monthly in their baggage claim area. After hearing about other succes of the Hi-FloES they purchased enough for one change in their airhandler, with us happy to refund the purchase if they didn’t last as long or longer without using the prefilter. Even we were surprised when the Hi-FloES filters were able to last over two years before reaching final pressure. Even if their incumbent filters cost $1 each, the Hi-FloES still cost less annually.
A School District in West-Central Wisconsin had been putting out annual bids for their air filter needs. An outside engineering firm that designed their HVAC systems was used to help write the spec, which was viewed as an asset as they were an “objective third party” that didn’t sell filters. After allowing us to asses their needs and perform an HVAC Filter Audit it was found that our proposed plan of implementing FARR 30/30 and Hi-FloES filters from Camfil would reduce the district’s filter consumption in half – resulting in significant disposal, time, and energy savings. The competitive filters required the district to change-out between 5,400 and 5,500 filters every year, our plan reduced that to less than 2,200 filters annually.
A large Food Processing facility in the South-West Twin Cities Metro Area has multiple make up air units situated close to the exhaust stacks of one of their processing lines. This exhaust stack introduced a high concentration of water into the air which is immediatly sucked into the make up air units. By using high capacity beverage board pleated filters the facility managers still had to have the filters on a 1-month PM schedule and still faced multiple filter blow-outs due to frame failure caused by this excess moisture. Farr 30/30 filters were installed and now they have added 50% more time to the PM schedule and no longer face the problematic and time consuming blow-out issues.
A corrugated box manufacturer was required to buy everything from an integrated supply house, which lead to using a high capacity wire backed pleat. These filters were blowing out every 4-6 weeks because of the excess dust created by their manufacturing process, causing massive maintenance issues. A sample set of Farr 30/30 pleated filters were sent for trial and they lasted their entire 16 week PM schedule without suffering any blow-outs or air-flow restrictions. This is a 260% increase in filter life
A large Community College in the Metropolitan area had been purchasing filters off the State Contract. They operated on a 3-4 month PM schedule for their air filters, but once they switched to the Farr 30/30 they were able to extend that PM schedule to an entire year. This is a 3-4 time longer service life.
The largest school district in NorthWest Wisconsin were using a ring-panel or polyester link air filter and were experiancing a lifespan of 3-6 months depending on which building and airhandler they were being used in. There was also significant pressure drop across the filter banks, which is an attribute of that style of filter. After switching to the Farr 30/30 the static pressure went down across the filter bank and the filters are lasting minimum of a year in nearly all of their airhandlers. The switch increased airflow, maintained efficiency, and doubled filter life.
A large industrial coating facility was experiancing short filter life and low airflow in their NESHAP 3-stage filter system. The low airflow lead to imperfections in the coating and the short life was troublesome as the 3rd stage filters were very expensive. We partnered with Columbus Industies and were able to creat a 2-stage filtration system that met the control efficiency requirements set by their air permits which helped solve the airflow issue in the booths. This aolution also increased the final stage filter life from 1 week to 2 1/2 weeks. This was all possible becuase of an extensive on-site evaluation of their coating process that their current supplier didn’t do.
15/40 denier ring panel and link filters were being used at a church and school in the southern metro area and was happy with the 6 month air filter life. After reviewing the operating time and seeing how restrictive the filters were becoming they installed Farr 30/30 pleats and now have less airflow restriction and change filters only once a year.
A large outdoor rectreation store added several indoor shooting ranges to their offering at locations throughout the United States. In en effort to help control the costs associated with this expansion the engineer specified AHUs that were as small as possible to deliver the required CFM. They then set a PM schedule based on run-time instead of static pressure. Because the units had to run at full speed to supply the required CFM the filters were becoming oveloaded with debris prior to the set PM schedule; the self-supported prefilters were collapsing and required changing every week. The secondary filters were only lasting maximum of one month, and the HEPA filters lasted two months. This was increadibly expensive and time consuming, as these filters were considered hazerdous waste due to the lead dust the disposal was also a concern. After utilizing Cafmil’s 5-star products the Farr 30/30 prefilters last an entire month, the DurafilES intermediaries last 6 months, and the Absolute V-G HEPA last an entire year. In addition the Durafil weighs 28% less than the traditional ASHRAE-Cell style Box Filter and the Absolute-VG HEPA weighs 40%C less substantially reducing the disposal cost of the filters.
A large North metro school district was using a combination of links-panel and commodity V-Bed final filters. The prefilters were changed 3 times a year and the finals were changed every other year. With the Hi-FloES being comparable in cost to their current final filters and having the no prefilter guarantee they decided to install them in all of their airhandlers that used high efficiency. The result was the Hi-FloES filters lasted 2 years and no prefilters were used, meaning there were $0 in filter expenses for the second year of service.
A large manufacturing company in Central Minnesota located adjacent to I-94 was under a directive to order everything they could from a Large Industrial Supply-House. Thier airhandlers contained 330 pleated filters. The High-Capacity wire backed pleat they were using needed to be changed every two months, and they still occasionally had blow-out failures. In need of a higher quality product they decided to try the guaranteed to last longer Farr 30/30 in their systems. They now go 8 months – 4 times longer – between changes with no blow-out failures. This reduced thier annual filter consumption from 1,980 units to only 495 units.
A large industrial coatings company was using a 2-stage Custome Formed polyester Media paint arrestor and 2-pocket high efficiency cube filter combination. The prefilters were lasting only 1/2 to 2 shifts and the finals were lasting only 2 shifts. After an on-site review of their coating process and reviewing their air permit to be able to provide the proper documentation to prove compliance we were given some of their paint, and specifications of their spray rate, nozzle, and transfer efficiecny and sent that to the test facility at Columbus Industries. After testing multiple options Columbus Industries was able to design a custom first stage paint arrestor to give the longest life possible. Then the appropriate final filter was selected that would work best with the custom arrestor and exceed the permit requirements. Now the first stage lasts 3-6 shifts, that’s 3-4 times longer, and the final filters last 10 shifts or more – 5 TIMES LONGER
A Northern Wisconsin school district was using a low-bid process to select air filters. The cheapest ones they could find were supplied by a local distributor selling 3-ply links and the Sonically welded bag filter made with synthetic media. The bags struggled to last one year even with the 3-ply prefilters being changed three times a year. When the cost of the filters were totaled for the entire year, and taking into account the Hi-FloES no prefilter guarantee the less expensive option was to use the higher initial cost Hi-FloES and forgo the use of prefilters. Now filters are changed only once a year.
With financial pressure put on the maintenance department of a Central Wisconsin School District they were purchasing filters via low-bid, and the cheapest thing they could find was a “SElf-Supported” style pleat supplied through a local distributor. Interested in the Farr 30/30 lasts longer guarantee and needing complete objective data to get approval for spending significantly more on a per filter basis the District Facility Director decided to have us conduct our HVAC Air Filter Audit program. The Audit showed AAF Perfect Pleats would last a maximum of 4 months, with some blow-out failures occurring, and the Farr 30/30 lasted an entire year. Annually it was cheaper to use the Farr 30/30.
A large public University in Central Minnesota was using high capacity pleated air filters then supplied through State Contract for air filters. In the first trial air handler they were changing twice per year, but were getting structural failures that allowed enough by-pass that black flies were getting stuck in the coils. Looking to put an end to this issue they tried the tougher built Farr 30/30. After an entire year of service the Farr 30/30 filters maintained their structural integrity and allowed no by-pass prompting the rest of the campus to adopt use of the Farr 30/30.