Continuous Filter Belts
Continuous Filter Belts | Auto Screen Belts | Screen Changer Belts
Continuous Filter Belts, also known as automatic belt filters or continuous screen changer belts, are innovative woven wire mesh rolls used in extrusion machinery to maintain a constant flow of clean molten polymer. Unlike traditional static screens that require frequent manual replacements, these belts automatically advance through a screen changer mechanism, introducing fresh filtration media as contaminants accumulate. This design ensures non-stop production, minimizing interruptions and maximizing throughput.
Introduction to Continuous Filter Belts
Primarily constructed from premium stainless steel wires, our continuous filter belts feature a Reverse Dutch Weave (RDW) pattern, which offers exceptional tensile strength and precise filtration. They are resistant to acids, alkalis, corrosion, and extreme temperatures (up to 500°C), making them suitable for demanding applications in the plastics industry. By filtering out impurities like gels, unmelted particles, and foreign matter, these belts prevent defects in extruded products such as films, sheets, and profiles, while protecting downstream equipment like dies and gear pumps.
In the context of polymer extrusion, continuous filter belts are integrated into screen changers that operate under pressures of 40-100 psi or higher. As the belt moves, dirty sections are expelled, and clean ones take their place, often triggered by pressure sensors for optimal performance. This automation is particularly beneficial for processing recycled plastics, where contaminant levels are high, allowing for extended run times and reduced labor costs.
Our manufacturing process adheres to strict quality standards, ensuring uniform mesh openings and durable construction. With a focus on customization, we tailor belts to fit specific extruder models, enhancing compatibility and efficiency.
Advantages of Continuous Filter Belts
Incorporating continuous filter belts into your extrusion line offers numerous benefits, transforming your production process for better efficiency and profitability. Here are the key advantages:
- Uninterrupted Production: Automatic advancement eliminates manual screen changes, reducing downtime to near zero and enabling 24/7 operations—potentially quadrupling throughput in high-volume settings.
- Superior Durability and Resistance: Corrosion, acid, alkali, and high-temperature resistant, ensuring long service life even in aggressive environments.
- Enhanced Filtration Efficiency: RDW weave provides precise contaminant removal while maintaining low pressure drop, improving melt quality and reducing defects like streaks or holes.
- Cost Savings: Minimizes labor, scrap rates, and energy consumption; ideal for recycling lines where frequent changes would otherwise be costly.
- Easy Maintenance: Simple roll replacements and compatibility with automated changers reduce operational complexity.
- Versatility: Suitable for various polymers (PP, PE, PET, PVC) and high-contaminant feeds, offering flexibility across industries.
- Environmental Benefits: Supports sustainable practices by enabling efficient recycling without production halts.
Compared to semi-continuous or manual systems, our belts provide a competitive edge by optimizing flow and extending equipment life.
Specifications of Our Continuous Filter Belts
We offer a wide range of specifications to meet diverse extrusion needs. Below is a detailed overview of key parameters, based on industry-standard designs for optimal performance in continuous screen changers.
Material and Construction
- Materials: High-grade stainless steel (201 304, 304L, 316, 316L) for corrosion resistance and longevity. Optional nickel alloys for highly corrosive environments.
- Weave Type: Reverse Dutch Weave (RDW) for superior strength and filtration precision; also available in Plain Dutch Weave (PDW) or Twill Dutch Weave.
- Tensile Strength: High tensile (standard) or normal tensile options, ensuring durability under mechanical stress.
Dimensions and Mesh Details
- Belt Widths: 50 mm to 300 mm (common sizes: 97 mm, 120 mm, 150 mm, 200 mm).
- Roll Lengths: Up to 100 meters per roll, customizable for extended use.
- Mesh Ratings: 60 to 1000 microns filtration rating; common mesh counts include 48×10, 72×15, 132×17, 152×24, 260×40, and 400×120 for balanced flow and particle capture.
- Wire Diameter: Varies by mesh (e.g., 0.15 mm to 0.50 mm warp/weft), optimized for minimal pressure drop.
Performance Ratings
- Temperature Resistance: Up to 500°C, suitable for most polymer melts.
- Pressure Tolerance: Handles 40-100+ psi, with low initial pressure drop for energy efficiency.
- Filtration Layers: Single-layer standard; multi-layer options available for enhanced dirt-holding capacity.
| Popular Sizes of Continuous Belts Filter (Reverse Dutch Weave) | |||||
| Mesh Size (warp/inch × weft/inch) | Wire diameter (mm) (warp × weft) | Fineness of filtering (micron) | Weight (kg/m2) | Width (mm) | Length (m) |
| 48 × 10 | 0.5 × 0.5 | 400 | 3.63 | 50-300 | Up to 100 |
| 63 × 18 | 0.4 × 0.6 | 220 | 4.14 | 50-300 | Up to 100 |
| 72 × 15 | 0.45 × 0.55 | 250 | 4.78 | 50-300 | Up to 100 |
| 100 × 16 | 0.35 × 0.45 | 190 | 3.87 | 50-300 | Up to 100 |
| 107 × 20 | 0.24 × 0.60 | 210 | 3.34 | 50-300 | Up to 100 |
| 120 × 16 | 0.35 × 0.45 | 180 | 4.49 | 50-300 | Up to 100 |
| 132 × 17 | 0.32 × 0.45 | 170 | 4.24 | 50-300 | Up to 100 |
| 152 × 24 | 0.27 × 0.4 | 160 | 3.73 | 50-300 | Up to 100 |
| 160 × 17 | 0.27 × 0.45 | 160 | 2.02 | 50-300 | Up to 100 |
| 170 × 18 | 0.27 ×0.45 | 160 | 4.01 | 50-300 | Up to 100 |
| 171 × 46 | 0.15 × 0.30 | 130 | 2 | 50-300 | Up to 100 |
| 180 × 20 | 0.27 × 0.45 | 170 | 4.29 | 50-300 | Up to 100 |
| 200 × 40 | 0.17 × 0.27 | 120 | 2.17 | 50-300 | Up to 100 |
| 240 × 40 | 0.15 × 0.25 | 70 | 1.98 | 50-300 | Up to 100 |
| 260 × 40 | 0.15 × 0.27 | 55 | 2.19 | 50-300 | Up to 100 |
| 290 × 76 | 0.09 × 0.19 | 40 | 1.27 | 50-300 | Up to 100 |
| 300 × 40 | 0.15 × 0.25 | 50 | 2.31 | 50-300 | Up to 100 |
| 300 × 80 | 0.15 × 0.2 | 35 | 2.49 | 50-300 | Up to 100 |
| Special specifications can be customized upon your requirements | |||||
Applications of Continuous Filter Belts
Our continuous filter belts are versatile and trusted across multiple industries for their reliability in demanding extrusion processes. Key applications include:
- Plastic Film and Sheet Extrusion: Ensures clean melts for high-quality films, reducing defects in packaging and industrial films.
- Rubber Processing and Compounding: Filters contaminants in rubber extrusion for tires, seals, and profiles, handling high-viscosity materials effectively.
- Polymer Recycling Lines: Ideal for processing recycled plastics with heavy impurities, improving output quality and profitability.
- Petroleum and Petrochemical Refining: Used in extrusion for oils and chemicals, providing robust filtration under extreme conditions.
- Fiber and Non-Woven Production: Maintains purity in melt-blown or spunbond processes for textiles and medical fabrics.
- Food and Pharmaceutical Extrusion: Compliant options for edible polymers or high-purity applications, ensuring contaminant-free outputs.
In each case, our belts integrate seamlessly with continuous screen changers, supporting high-speed production while meeting stringent quality standards.
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