Disc Pack Melt Filter – High-Precision Polymer Melt Filtration Solution

1. Product Overview

The disc pack melt filter (also known as a disc‑type filter element or melt filtration disc) is a high‑precision filtration component specifically designed for viscous polymer melts. It consists of multiple discs made of sintered stainless steel fiber felt or multi‑layer sintered stainless steel mesh, stacked onto a central core tube. This design efficiently removes contaminants such as impurities, gel particles, unmelted materials, and fish eyes from the melt stream.

Core Value: Compared with traditional candle‑type filters, the disc‑type filter offers significant advantages in both capital investment and operating costs, while delivering superior filtration precision. The disc stack design provides an extremely large effective filtration area per unit volume, enabling compact system layouts and space‑saving installation.

2. Working Principle

The disc pack melt filter operates on the pressure‑driven surface filtration principle:

1. Melt inlet – Polymer melt enters the filter housing under controlled pressure through the inlet port.

2. Radial flow – Melt flows from the outer circumference of the disc stack toward the inner core, passing radially through the filtration media on each disc surface.

3. Contaminant capture – As the melt flows through the multi‑layer sintered stainless steel felt, impurities, gels, and unmelted particles are retained on the disc surfaces.

4. Clean melt outlet – The purified melt collects into the central core tube and exits through the filter outlet.

Multiple discs are stacked onto the central core tube with sealing gaskets between them, and the entire assembly is housed tightly inside the filter chamber. The outside‑in flow path ensures a large filtration area, low pressure drop, and high efficiency.

3. Key Advantages

🎯 Extremely Large Effective Filtration Area

The disc‑stack design maximises filtration area per unit volume, significantly increasing throughput without enlarging the filter footprint.

🔧 High Filtration Precision

Available in filtration ratings from 3 to 200 μm – from coarse straining to fine polishing. Premium variants achieve absolute 1 μm precision.

💪 High Temperature & Pressure Resistance

Manufactured from stainless steel (316L, 310S, etc.), operating temperature ranges from 200 to 600°C, with maximum working pressure up to 30 MPa.

♻️ Reusable & Cleanable

The discs can be cleaned and reused multiple times, offering high porosity and long service life – dramatically reducing consumable replacement costs.

📉 Low Pressure Drop

Optimised disc geometry minimises flow resistance, resulting in lower pressure loss compared with conventional screen packs.

⏱️ Minimal Melt Residence Time

The internal void volume is kept to a minimum with no dead zones, ensuring the shortest possible melt residence time and effectively reducing the risk of thermal degradation.

4. Technical Specifications

Above are standard specifications; customised solutions are available upon request.

5. Applications

The disc pack melt filter is widely used in the following industries and processes:

📍 Film Manufacturing

• Biaxially oriented films: BOPP, BOPET, BOPA

• High‑performance films: optical films, paint protection films, protective films, reflective films

• Capacitor films, solar backsheet films

📍 New Energy Materials

• Lithium‑battery separator melt filtration

• Carbon fibre melt filtration

📍 Chemical Fibre Industry

• Polyester fibre and recycled polyester polymer melts

• High‑speed spinning and fine‑denier fibre production

📍 Plastic Recycling

• Bottle‑to‑bottle (B2B) PET recycling

• rPET fibre production

📍 Other Sectors

• Engineering plastics, packaging materials, petrochemicals

• Pharmaceuticals, dust removal, and wastewater treatment

6. Why Choose Disc Pack Melt Filters?

Source: “Selection and Application of High‑Polymer Melt Filters”

7. Selection Guide

To choose the right disc pack melt filter for your process, consider the following factors:

1. Required filtration rating – Select from 3–200 μm based on your final product quality demands.

2. Melt temperature and pressure – Verify that your operating conditions (200–600°C, up to 30 MPa) fall within the product’s capability.

3. Equipment interface dimensions – Ensure the disc outer diameter matches your existing filter housing.

4. Core tube type – Choose rigid, semi‑rigid, or flexible based on installation and maintenance preferences.

5. Filter media type – Sintered fibre felt (higher dirt‑holding capacity) vs. multi‑layer sintered mesh (higher mechanical strength).

6. Number of discs – Determine the stack height (typically 4–40 discs) according to flow rate and required filtration area.

8. Quality Assurance

• ✅ Made from 316L / 310S premium stainless steel – corrosion‑resistant and heat‑tolerant.

• ✅ Precision‑engineered sintered stainless steel fibre felt – high porosity and excellent permeability.

• ✅ Proven stacked sealing structure – ensures no bypass or short‑circuiting.

• ✅ OEM / ODM services available to meet custom requirements.

• ✅ Widely used on world‑renowned film lines such as Brückner, Dornier, and DMT.

9. Request a Quote

📧 Contact us today – let us provide a tailored disc pack melt filter solution for your process.

To help us match the right product for you, please provide:

• Application industry / process

• Required filtration rating

• Operating temperature and pressure

• Equipment model and interface dimensions

• Estimated order quantity

We will respond to your enquiry within 24 hours with professional selection advice and a quotation

 

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