The perfection of the production
is the basis of product variety.

Extrusion

Extrusion
Fine-cell honeycomb moulds are produced by extruding a formula containing activated carbon and minerals. Cellularity, length and the selection of activated carbon produces customised filter elements are matched for the various applications.

 

 

Impregnation

Impregnation
The textile base materials can be impregnated in our impregnation plant with a multitude of formulas, adjusted to a certain surface weight, and dried. At the same time, particularly during the powder activated carbon and granular carbon impregnation of polyurethane foams and non-woven materials, a large range of surface weights and qualities can be presented.

 

 

Sprinkling

Sprinkling
By"Sprinkling"we mean finishing the carrier materials with adsorbers such as activated carbon in wet bonding or sprinkler bonding processes. At the same, there are various production methods at our disposal which ensure a suitable and homogenous order and thus high air permeability of the finished material. The efficiency of the filter material can be controlled by the type and quantity of the adsorber. If required, after the same process, these media can also be laminated or covered with materials for particle deposition or for purely mechanical stabilisation.

 

 

covering

Covering
By covering we mean here applying a non-woven material or another textile material to a filter media coated with a granular activated carbon. This prevents the fragmentation of activated carbon. The process is carried out immediately after coating the activated carbon or during the pleating process.

 

 

Flame bonding

Flame bonding
An adhesive coat is produced in this lamination plant by singeing/melting a foam medium, which is used as a smooth joint between two media layers.

 

 

Needling

Needling
With the existing non-woven technology it is possible to produce needled non-woven material out of viscose, polyester, polypropylene or other fibres in the surface weight range of approx. 50 to 500 g/m² and in the thickness range of approx. 1 to 5 mm. Special non-woven properties can be achieved by means of mixing binding fibres, antistatic fibres or other special fibres. Also, it is possible to produce functional non-woven compound materials by needling non-woven fibres to different types of base layers, such as fabric, foam agents or yarn layers.

 

 

Calendering

Calendering
Here non-woven material can be thermally reinforced with part binding fibre content and reinforced with non-woven material or other surface fabric or the surface be smoothed.

 

 

Flame bonding

Laminating
By"laminating"we mean the joining of at least two surface components to become one functional composite material. Depending on the properties of the starting position and the demand on the composite material, the different layers can be bonded with the right pressure, temperature and staying time in adapted plants.

 

 

Pleating

Pleating
The production process is performed using a measuring folding machine. The aim of the folding set up is to achieve the largest possible filter surface for adsorption and to create optimal through-flow conditions.

 

 

Covering edges

Covering edges
During this pasting over process, the pleated filter elements are further processed. To confection the final product a textile frame material is fixed over the entire edges by means of hot melt adhesive. The length and the width of the filter can be selected according to the customer’s requirements.

 

 

Cutting

Cutting
The flat media produced by helsa® can be virtually customised to almost any cutting sizes. To this end, there are cutting machines available for narrow rollers, water jet cutting technology or different die-cutting technologies.

 

 

Die-cutting

Die-cutting
Die-cutting describes a production step which leads to the exact surface moulding of filters, diaphragms or other moulds. The required geometry is cut out using the moulding tools designed for this, the so-called punches, from the respective material, which by all means may already be three dimensional.

 

 

Filter Encaseing

Filter Encaseing
The three-dimensional granular filter media may be cut if required into discs of various sizes, stacked and enclosed or framed with textile material (e.g. fine knit or non-woven material) into filter units/packages.

 

 

Assembling

Assembling
Not only can individual elements be produced but also special filter arrangements can be customised such as compact filter cells (V-cells Sorbexx), bonding of several individual elements or integration into metal or synthetic frames with and without handle protection bars.

 

 

Mould embossing

Moulding
By mould embossing we understand a production step which leads to the production of a 3-dimensional mould from a flat 2-dimensional material layer using patented processes with mould stamping or air deformation under the effects of temperature and time. Moulds produced in this way are irreversible. Properties such as adsorption capacity, flexibility or gas-tightness are preserved.

 

 

Elastomer coating

Coating
Coating with activated carbon. For very thin materials, an activated carbon coating method is used, during which the individual activated carbon particles are fixed on one or both side(s) on a surface in a mono coating to a textile carrier material. In doing so, the distance between the individual particles can be controlled.

 

 

Sintering

Sintering

Here, the mechanical but also unique chemical and physical filtration properties of the monolith are defined. This thermal treatment facilitates the use of helsa Sorbexx CS in both the gas and liquid phase.