Media and Materials Brochure

World Class Filtration SolutionsMedia and Materials Sinterfl o®, Vyon® and BioVyonTM Sintered Porous MaterialsPorvair Filtration Group is an international leader in the development and supply of materials and products for applications in fi ltration and separation. Porvair manufacture in both the UK and USA and have an extensive network of sales offi ces and distribution channels throughout the world. Our expertise is wide and varied and its products are used in markets such as: • Aerospace and Defence • Nuclear and Energy • Chemical Process • Industrial Process • Water Treatment • Printing • Sciences and LaboratoryOur ongoing success is based on a dedication to technical excellence and superior customer service. Our future will be built on our investment in research and development to provide innovative new products that exceed the expectations of our customers in solving the challenges that they face.Media and Materials Sinterfl o®, Vyon® and BioVyonTM Sintered Porous Materials2Porvair Filtration Group3Porvair Filtration Group is a major manufacturer and developer of sintered porous materials, offering optimum solutions in a wide range of applications.Whether used in finished products or supplied for OEM manufacture, our materials span industries as diverse as pharmaceuticals, healthcare, chemical processing and engineering. Applications are also varied and include filtration, aeration of liquids, fluidisation of powders, vacuum table covers, support media in chromatography columns, sound attenuation and fragrance emanation.Our extensive range of polymeric and metallic materials allows us to select the fit-for-purpose option gained through understanding the customers’ requirements and our in-depth knowledge of the material’s properties.Our core materials are:• Sinterflo® sintered porous metal materialsMainly sintered porous stainless steel and bronze materials, sintered metal fibre and multilayer stainless steel meshes.• Vyon® sintered porous plastic materialsMainly sintered porous polyethylene and polypropylene materials.• BioVyonTM sintered porous plastic materialsSpecialised Vyon® materials manufactured for applications in the life science markets.Sinterflo® sintered porous metal materials are ideal for applications that involve aggressive chemical environments, high temperatures and high pressures. Available for OEM producers or as fabricated products designed to meet your needs, our advanced welding and assembly capability, supported by a high quality ethos, ensures total satisfaction.Both mechanically and chemically robust, these materials allow for effective cleaning for reuse thereby delivering cost-effective solutions for difficult applications.The range of Sinterflo® sintered porous metal materials includes:• Sinterflo® P Sintered Metal Powder Mainly sintered porous stainless steel and bronze materials.• Sinterflo® PM Sintered Powder Membrane Mainly sintered porous stainless steel.• Sinterflo® F Sintered Metal FibreMainly sintered porous stainless steel.• Sinterflo® MC Sintered Metal Mesh Multilayer stainless steel mesh materials.ApplicationsThe scope of applications for sintered porous metal materials is diverse and includes:• General chemical processing• Catalyst recovery• Corrosive liquid and gas filtration• Solvent filtration• Nuclear processing and waste treatment• Process steam filtration• Polymer melt filtration• Flame arresting• Sensor protection• Sparging and aeration• Silencers for pneumatic tools• Chromatography column supports• Powder handling fluidisation4Sinterflo® Sintered Porous Metal Materials Sinterfl o® PM Sintered Powder MembraneSinterfl o® F Sintered Metal FibreSinterfl o® MC Sintered Metal MeshSinterfl o® P Sintered Metal PowderA robust material manufactured from sinter-bonded metal powders. Primarily produced in 316L grade for use in temperatures up to 540ºC (1004ºF), depending on process conditions, and offering resistance to most chemicals, Sinterflo® P media can also be produced in other grades of stainless steel and alloys such as Inconel®, Hastelloy® and Monel®.Sinterflo® powder media can be manufactured in both disc format or in cylinder format. For cylinders, our isostatic pressing ensures greater media uniformity with no welds, leading to increased corrosion resistance.Features and Benefits• Resistant to high temperatures and corrosive environments Suitable for aggressive air and liquid filtration applications. • Strength and RobustnessEnsures reliability and longer on-stream service life.• Excellent media uniformityAllows consistent filtration and effective loading.• Seamless structureNo welds provide increased corrosion resistance.5Sinterflo® P Sintered Metal PowderA flexible, strong and aesthetically appealing material manufactured from pre-alloyed bronze. Sinterflo® P, available in any mouldable shape and offering resistance to temperatures of up to 300ºC (572ºF) with good chemical resistance, makes it the preferred medium for many filtration applications. Features and Benefits• Inherent strength For long service life in arduous applications. • Resistant to high temperatures and corrosive environmentsSuitable for aggressive air and liquid filtration.• Controlled pore distributionEnsures optimum repeat performance.Sinterfl o® P Sintered Porous BronzeOther grades available on requestSinterflo® P Standard Bronze Grades Table 2Grade MeanPore Size(µm)ViscousPermeabilityX1012M2RemovalRating (µm)(Liquid)Sinterflo® P B05 4 1.0 2Sinterflo® P B10 7 2.5 6Sinterflo® P B15 15 10 15Sinterflo® P B20 20 15 20Sinterflo® P B30 35 30 35Sinterflo® P B40 60 180 85Sinterflo® P B50 74 230 100Other grades available on requestSinterflo® P Standard Stainless Grades Table 1Grade MeanPore Size(µm)ViscousPermeabilityX1012M2Minimum Thickness(mm)RemovalRating (µm)(Liquid)Sinterflo® P S10 6 1.0 1.5 6Sinterflo® P S20 10 2.0 2.0 10Sinterflo® P S30 15 7.5 2.5 15Sinterflo® P S40 30 25 3.0 30Sinterflo® P S50 60 70 4.0 60Manufactured from randomly laid metal fibres, sinter-bonded to form a uniform high porosity filter medium, Sinterflo® F demonstrates a significantly low pressure drop, high permeability and excellent dirt holding capacity. Moreover, sintered metal fibre may be pleated to increase the available filtration area of a filter element, thereby further increasing dirt holding capacity and so minimising maintenance and maximising on-stream processing.With the feasibility to formulate metal fibres to meet specific application requirements combined with inherent durability, sintered metal fibre filters can be cleaned in-situ without interrupting process flow thereby providing the ultimate in process economics by reducing downtime to a minimum.Available alloys include 316L stainless steel, Inconel®, Hastelloy® and Monel®.A list of grades and specifications are available on request.Features and Benefits• Resistant to high temperatures and corrosive environmentsSuitable for aggressive air and liquid filtration applications.• Can be cleaned in-situ Reduces downtime to a minimum providing excellent process economics.• Pleatable structure Offers higher surface area with excellent dirt holding capacity for longer on-stream life.• High void volume Provides high permeability combined with low pressure drop.Sinterflo® F Sintered Metal Fibre6Sinterflo® PM Sintered Powder MembraneAn advanced patented metallic fi lter media that combines the strength of the sinter bonded metal powder with the levels of fi ltration effi ciency associated with membranes.Features and Benefi ts• Inherent strengthSuitable for long service life in aggressive environments.• High fi lter effi ciencyUltra-thin layer of fi ne, narrow distribution metallic, carbide and/or ceramic powder provides high levels of fi lter effi ciency. • Controlled pore size distributionMicronic and sub-micronic pore structures ensure optimum repeat performance.• Uninterrupted operationIdeal when combined with pulse jet blowdown cleaning operations.7Sinterflo® MC Sintered Metal MeshThese multi layer precision fi lter meshes are produced using a novel sintering process resulting in superior mechanically strong structures. Primarily made from 316L stainless steel, they are also available in Inconel®, Hastelloy® and Monel® materials for use in the most aggressive environments. Depending on atmospheric conditions, our stainless steel option can be used in temperatures up to 540ºC (1004ºF), with intermittent operating peaks up to 650ºC (1202ºF), and are resistant to most chemicals.Formats available include fl at sheet, custom shapes, welded cones and welded cylinders, and the materials can be manufactured in a variety of layer combinations depending on your specifi c application. Standard material combinations can include perforated plates for additional support.Sinterflo® MC is available in a range of fi ltration grades from 2 micron and up. Features and Benefts• Fabricated shapes without expensive support structures or joining stripsOffers robust and self-supporting structures.• Can be cleaned repeatedly Suitable for reuse; providing an economical choice.• Non-shedding mediaProvides resistance to mechanical abrasion.• Easily custom-engineered To meet required specifi cations of materials, strength, fl ow requirements, thickness, micron rating and environment.Our Vyon® sintered porous plastic materials offer excellent chemical compatibility, exceptional strength and are resistant to most acids, bases, many organic chemicals and temperatures up to 110ºC (230ºF). Produced in both sintered porous polyethylene and polypropylene, materials are available in roll, sheet, cut shapes and moulded formats. The materials can also be fabricated into cylinders, cones and other three dimensional shapes.Features and Benefi ts• Strong lightweight and self supportingA versatile material that can be manufactured in a variety of shapes and sizes.• Narrow Controlled Pore Size DistributionA very effi cient and effective fi ltration material.• High and Even porosityLow pressure drop and even fl ow.• Chemically inertResistant to many chemicals making it suitable for many applications.Applications• Domestic water filters• Activated carbon filters• Chemical filters• Air and dust filters• Fluidisation and aeration of bulk solids• Battery vents• Pneumatic silencers• Water and effluent aeration• Fragrance emanators• Vacuum platens and cones8Vyon® Sintered Porous Plastic Vyon® media grades Table 4Name Material Filtration GradesLiquids GasesVyon® D HDPE 10µm 6µmVyon® PPD Polypropylene 5µm 1µmVyon® F HDPE 40µm 25µmVyon® PPF Polypropylene 20µm 10µmVyon® HP Polypropylene 70µm 50µmVyon® PPHP Polypropylene 60µm 40µmVyon® Porvent HDPE 15µm 5µmVyon® Porvent PP Polypropylene 15µm 5µmVyon® T UHMWPE 10µm 2µm9BioVyonTM Sintered Porous PlasticPorvair Filtration Group has developed a revolutionary new range of porous BioVyonTM materials, designed specifi cally to meet the demands of the life science and analytical markets.BioVyonTM standard sintered porous plastic materials are manufactured in ISO cleanroom areas in accordance with cGMP practices and achieve a variety of quality approvals including USP Class VI. These highly regulated materials are continuously developed for use in diverse applications within industries such as pharmaceuticals, medical and healthcare. In addition to the benefi ts of the Vyon® materials, such as excellent chemical compatibility and strength, our BioVyonTM materials benefi t from lower bio-burden, ultra-low extractables and minimal particle shedding.Applications• Solid phase extraction and chromatography column fritsOur vast range of frit options, using BioVyonTM ultraclean, nanoclean, hydrophilic and oliophobic materials, provide optimum solutions for SPE sample preparation devices and process chromatography columns.• Solid extraction and chromatography resinsBioVyonTM composites incorporate the resins within the sintered porous polymer to eliminate the use of frit supports.• Medical device fi ltrationUsing BioVyonTM manufactured to cGMP processes.• Personal Healthcare and pharmaceutical ventsBioVyonTM is used in pharmaceutical liquid dispensers and aspirators such as nasal sprays.• DiagnosticsBioVyonTM hydrophilic and laminates are used as a fi lter and a wick.• Catheter VentsUsing a BioVyonTM composite, incorporating a cellulosic material within the sintered porous material, that expands and shuts off the air fl ow if in contact with liquid such as blood.• Antibody Purifi cationThe BioVyonTM functionalised grade for antibody purifi cation, offers the stability and robustness of our BioVyonTM materials and additional benefi ts compared to the traditional sepharose technology.Features and Benefi tsContinuous material development has resulted in an unique range of BioVyonTM materials each exhibiting different properties critical to these progressive markets.• BioVyonTM UltracleanOur standard materials exhibit very low extractables.• BioVyonTM NanocleanProprietary techniques deliver high purity materials with trace extractables.• BioVyonTM Hydrophobic and OliophobicA permanently oliophobic treatment preventing BioVyonTM from wetting-out in many organic solvents.• BioVyonTM HydrophilicA permanently hydrophilic treatment for instant water wettability.• BioVyonTM LaminatesUsed as a support for membranes, extending the fi ltration range to 0.1 micron for the retention of microorganisms.• BioVyonTM CompositesIncorporating active substances within the sintered porous material such as chromatography resins, carbon and cellulosics.• BioVyonTM FunctionalisedChemically or biologically active sintered porous material functionalised with amines, carbonyls, carboxylic acids, linker chains or ligands.10Product Innovation, Manufacturing, Testing and QualityPorvair Filtration Group has a policy of continuous improvement in all areas of its business. Listening to the customers’ present and future requirements is a vital part of our operations and a key part of driving change.We understand that product development involves building multidiscipline teams, not only within the company, but often in partnership with our customers, improving project effi ciency and ensuring complete customer satisfaction. This continuous development of products and materials is vital, to enable us to offer new and better solutions to applications. Porvair has implemented various methodologies to drive out waste and process variance across the company to achieve the ultimate goal of zero defects.We have a dedicated team of scientists, engineers, production and quality professionals working towards the best possible fi ltration solutions for our customers. We have a fully equipped test house and laboratory, and our experienced design engineers use the latest AutoCAD® technology, with 3D solid modelling, integrated with a fi nite element analysis system to give full structural assurance capability.Quality is at the heart of every stage of our operation and a fundamental part of our culture. We are ISO9001 approved at a number of our manufacturing facilities and hold many other accreditations for the various industries we serve.Research and DevelopmentContinuous development of products and materials are vital to enable Porvair to offer new and better solutions to applications. Development plays a fundamental part in our operations and, as a result, we have developed a number of new bespoke products based on our established porous polymeric materials (Vyon®) and sintered metal media (Sinterfl o®).Although we operate across many fi ltration and separation markets there is signifi cant interaction between each division in terms of product research and development. The new product development team is drawn from scientists and engineers from across all divisions encouraging new ideas and new solutions. The success of this approach has been in the interaction of chemists and engineers working together to fi nd practical solutions to some extremely complex scientifi c challenges identifi ed in the chosen market areas. EngineeringFrom initial concept design through manufacture and validation to in service support, our highly experienced team of dedicated engineers work to develop the optimal fi ltration solution. Our team utilises the latest engineering tools of 3D AutoCAD®, Finite Element Stress Analysis, Computational Fluid Dynamics (CFD) and bespoke pressure vessel design software (PD5500, ASME VIII, EN13445). This is combined with over 30 years of proven experience and a knowledge and strong ethos of working closely with our customers, ensuring fi ltration solutions that meet customers requirements.ManufacturingPorvair Filtration Group produce fi lters and fi ltration systems, as well as a range of porous materials based on sintered polymers and metals, at production sites within the UK and the USA. We manufacture for a wide variety of industrial, pharmaceutical and biomedical applications, as well as suppling fi ltration solutions for extreme conditions of temperature, pressure and corrosion for the aerospace and nuclear markets.Our production capabilities include the complete element or cartridge construction, along with the build of entire tubeplate and vessel assemblies. We boast specialist fabrication skills and techniques in all of our manufacturing sites around the world as well as extensive ISO certifi ed cleanroom facilities. Testing and LaboratoryOur dedicated test, development and laboratory services underpin our design and development activity, from fi ltration media and material characterisation, product verifi cation testing to customer systems simulation trials and in service performance evaluation. Our capabilities include fi ltration characterisation, environmental testing and analysis.QualityOur policy is to provide products and services that consistently satisfy the commitments made to our customers by complying with their requirements, working together as a team and by achieving continual improvement in our skills, systems, processes and performance.We have a dedicated team of quality professionals with many years experience in defi nition, implementation and maintenance of quality management systems meeting multiple industry requirements. This extends across the workforce through a strong quality culture and a philosophy of ‘getting it right fi rst time’ driven from the top of the organisation.Our quality management systems are regularly audited internally and by customers and regulatory bodies. We hold ISO9001 at a selection of our manufacturing sites along with, EN 9100 and EASA Part 21 Subpart G at our Segensworth facility. We are NQA1 capable subject to specifi c project requirements.11Porvair Filtration Group Ltd.1 Concorde CloseSegensworthFarehamHampshirePO15 5RTUKTel: +44 (0)1489 864330Fax: +44 (0)1489 864399Email: info@porvairfi ltration.comPorvair Filtration Group Inc.10190 Maple Leaf CourtAshlandVirginia 23005USATel: +1 804 550 1600Fax: +1 804 550 3262Email: infoUS@porvairfi ltration.comwww.porvairfi ltration.comPFG600Porvair, Sinterfl o and Vyon are registered trademarks of Porvair plc.BioVyon is a trademark of Porvair plc.AutoCAD is a registered trademark of Autodesk Inc.Inconel and Monel are registered trademarks of Special Metals Corporation.Hastelloy is a registered trademark of Haynes International Inc.© Copyright 2011. Porvair Filtration Group Ltd. All rights reserved.Whilst every effort has been made to ensure the accuracy of this document, due to continuous product development, the data contained is subject to constant revision and Porvair Filtration Group Ltd. reserves the right to change, alter or modify its contents.