Learn how Pall’s filtration technology supports high-performance recycling. Contact us to discuss your application needs.
Industry Challenge: Clean Recycling for Optical-Grade Polymers
As the demand for specialty films with high transparency and optical performance increases across industries like electronics, automotive, healthcare, and aerospace, manufacturers face mounting pressure to deliver high-quality materials while reducing environmental impact.
To meet these rigorous standards, virgin polymer production requires ultra-clean processing, achieved through advanced filtration technologies at every stage: monomer handling, polymerization, and downstream manufacturing.
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Challenge
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Solution
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Results
Recycling Without Compromising Clarity
An Asian specialty polymer producer sought to recycle in-house scrap materials which include edge trims and off-spec films, without sacrificing the optical clarity and cleanliness of virgin resin. Their goals were ambitious:
- Maintain high transparency and optical performance in final film products
- Significantly reduce CO₂ emissions through closed-loop recycling
Pall’s Multi-Stage Filtration System
To enable sustainable, high-performance recycling, Pall deployed a customized multi-stage filtration solution designed specifically for specialty polymer processing:
| Filtration Stage | Technology Used |
|---|---|
| Bulk Contaminant Removal | Polymeric and cellulosic depth filter modules (5–20 micron retention ratings) |
| Fine Particle Filtration | Polymeric pleated filter cartridges (2–10 micron ratings) |
These filtration stages were adapted from Pall’s proven systems used in virgin resin polymerization to ensure consistent quality, reliability and scalability.
Virgin-Like Resin from Recycled Feedstock
The integrated filtration system effectively removed:
- Additives
- Undissolved polymers
- Impurities that compromise optical clarity
Post-filtration, the polymer solution was concentrated, dehydrated, and granulated into high-quality resin. This recycled resin was then used to produce optical films that matched the performance of virgin materials.
Impact: Sustainability Meets Performance
The customer now operates a full-scale commercial recycling plant powered by Pall’s filtration technology. Key achievements include:
- Closed-loop recycling of specialty polymers
- Production of high-performance optical films from recycled resin
- Significant reduction in CO₂ emissions, supporting corporate sustainability goals
Conclusion: Driving Circular Innovation in High-Tech Manufacturing
Pall’s advanced filtration solutions enabled the customer to meet rising market demands while aligning with environmental targets. This case study highlights how precision filtration can unlock circular economy benefits—without compromising product performance—in the most demanding industries.
Learn more about the solution that can support your applications or contact an expert today.