Water Filter

Profits flow to a water-filtration system manufacturer as a result of a new filter design by Porex. Using proprietary manufacturing processes, Porex’s filter dramatically improves the performance and aesthetics of the finished product – enabling the manufacturer to command higher prices, extend its product line and gain market share.

Click here to view the sq-easy prefilter animation.

Design Challenge:
Home water filtration systems have grown in popularity in recent years. Typically, household water filters have four primary components: end caps (located on either end of the filter), an inner tube, an outer tube and an active ingredient, such as activated carbon, which is located between the inner and outer tubes and serves to purify the water. Both the inner and outer tubes are constructed of a porous material to contain the active ingredient and permit water flow through the filter. Porex was asked to participate in a filter design that would improve the aesthetic and functional performance of the filter's outer tube. Functionally, the new design would be required to provide efficient pre-filtration, minimize back pressure, maximize fluid flow, prevent migration of the carbon from the internal region of the filter, extended the useful life of the carbon, and comply with NSF standards.

Solution:
Porex engineers first selected a material from Porex's NSF compatible materials that would meet the water flow and backpressure requirements of the design goal. Next, the engineers developed a manufacturing process to produce this porous plastic material in a sheet format. The sheet, measuring approximately twelve inches in length, was rolled onto master rolls measuring several hundred feet in length. From the roll stock, Porex's engineers developed a secondary manufacturing process that converted the rolled sheet stock into a welded tube using Porex's proprietary welding technologies.

Result:
Porex's water filter solution made it possible for the manufacturer to extend its product line and gain market share. The manufacturer also gained a profitability advantage. The pure white color of the finished product, combined with Porex's porous plastic natural surface texturing, provided an aesthetically and functionally improved design that supported a higher price point at the retail level.

Click here to download a pdf version of this case study