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FILTRATION

Filtration
the facts
A survey of systems and methods
In my early When I first started in the brewing industry, filtration
Whitbread days, it was something carried out down in the cellars or
was always Process across in the packaging store. Even in France where I
and Packaging but worked in my first brewery, it was dans les caves.
when the bigger
Today, with take-home beer beginning to outstrip on-
breweries were built
sales, beer with a 12 month shelf life required closer
it became part of the
brewing area, mainly attention to filtration and stabilisation. With
because filtration consolidation of breweries and focus on capacity
problems were often utilisation and efficiency of packaging lines, beer
pushed back up- quality and filter problems are no longer acceptable.
stream in the Right first time is the requirement.
brewery. We were
brewing lager and
had to deal with beta see how filter design affects beer
By Paul Buttrick
filtration.
glucans which Beer Dimensions
gummed up the
Maximum pressure drop allowed
works and yeast that
refused to settle to
the bottom of tall
I have been an examiner for the
IBD Master Brewer examinations
for many years, and questions on
across a filter
On early 60cm plate and frame
filters, the maximum allowable inlet
flow on vessel filters tend now to be
nearer the lower rate. On vessel
cylindroconical filtration were often poorly pressure was 3 bar, for later versions filters, the filtration area is dictated
tanks. answered and showed a lack of and 100cm frames, this went up to 7 by the number of candles or screens.
experience and understanding, bar, so the newer filters gave a large Flowrates on kieselguhr-free
compared to other areas such as potential increase in filter run crossflow filters are slower at 0.5
brewhouse and fermentation. This lengths. It is easy to see how one of 1.0 hl/m2/h
may have been due to where the easiest and most cost effective
responsibilities lie for filtration and ways to increase filtration capacity Filter cake thickness:
there were debates about whether it in a small brewery was to replace an This is dependent on the solids
was a brewing or packaging old 60cm filter with a more modern content of the beer and dosing rate
The diverse nature of responsibility. In my early 100cm version. of body-feed powder. Breweries
kieselguhr as seen under Whitbread days, it was always which install centrifuges reduce the
a microscope. Process and Packaging but when Filter area: solids presented to the filter, are able
the bigger breweries were built it The 100 cm plate and frame filter to make large increases in filtration
became part of the brewing area gave the possibility of large filtration performance and capacity. The
mainly because filtration problems areas, so pressure drops were low sludge capacity, that is the amount
were often pushed back up-stream in and filter runs long. However with a of powder that can be put into a filter
the brewery. We were brewing lager flow-rates of 2.53.5 hl/m2/h, the will dictate the filter run length and
and had to deal with beta glucans area needed to be large to get a fast reducing the body-feed dosing rate
which gummed up the works and flow-rate compared to vessel filters enables more beer to be filtered. The
yeast that refused to settle to the designed for 510 hl/m2/h, although frames of the larger plate and frame
bottom of tall cylindroconical tanks.

The basics Flow rate = Permeability factor Pressure drop Area of filtration surface
Like all things, the laws of science
Filter bed thickness Liquid viscosity
dictate performance and Darcy from
way back in 1856 still shows the Pressure Drop = Flow rate Filter bed thickness Liquid viscosity
way. The table below develops his
Permeability factor Area of filtration surface
law and applies it to filtration :
Applying this equation, it is easy to

The BREWER & DISTILLER INTERNATIONAL Volume 3 Issue 12 December 2007 www.ibd.org.uk
12
(Photo: Puresep.)
frame filters. At Magor, now part of MAIN PICTURE: Four
InBev, long runs of very high quality fully automated 600 hl/h
filtered beer are achieved using high Filtrox kieselguhr and
area filters run at slow flow rates PVPP candle filter lines
with quite low porosity powders. installed in Becks
With these regimes it is possible to brewery Germany in
achieve yeast-free filtrate on a 2002.
100ml aerobic plating of beer from
the outlet of the filter. ABOVE: A 100 cm plate
and frame filter, still
used in many UK
Choice of powders breweries.
The choice of filter powders has not
changed much over the years in that
kieselguhr (diatomaceous earth) is
still the preferred material. No other
material gives quite the same
filtration performance. Perlites made
filters have comparatively more build up than coarser powder. A from volcanic rock are increasingly
capacity than vessel filters. The compromise was needed because the used for a first precoat, but few use it
standard frame was 40mm deep, and finer the powder used, the better and for second precoat and bodyfeed.
some companies increased this to brighter the filtered beer. It is also The main driver for brewers moving
50mm to increase filtration run important to remember that vessel away from kieselguhrs is health and
lengths filters which are run at faster flow safety, where particularly flux
rates generally use coarser filter calcined-white powders (heated in
Beer viscosity: powders to keep the pressure the presence of caustic soda) contain
I can remember, over 25 years ago, differential down. high levels of crystalline quartz
spending many hours in the When all is considered, it is easy (crystoballite) which is known to
Samlesbury Brewery brewhouse to see why some companies cause serious lung diseases.
doing starch tests on wort with my continue to use 100cm plate and The white flux calcined powders
fellow brewer the late Bill Barker
we were known as Starchy and
(Schematic: Krones.)

Schematic of the
Husk after a well know pair of
Steinecker TFS filter.
American detectives. Better This filter is specifically
brewhouse procedures and a malt designed to give an even
specification to reduce beta glucans powder coating over the
in the wort, sometimes with the aid whole candle.
of added beta glucanase, made sure
we were able to filter plenty of lager
in the hot summers of the late
seventies.

Permeability:
The pressure differential across a
filter bed is determined by the
permeability of the filter bed, which
is dictated by the size and porosity
of the filter powder. Very fine
powder produces a quicker pressure

The BREWER & DISTILLER INTERNATIONAL Volume 3 Issue 12 December 2007 www.ibd.org.uk
13
FILTRATION

The Pall Big Bagbulk best not to make them too big (say a
handling system, using maximum of a days supply)
0.5 tonne bags of filter because continual stirring can
powder at Reissdorf in degrade particles which will block
Kln. the filter rather than keep the bed
open. Also because it is very
abrasive, slurry pump design and
maintenance is key to operations. It
is also important to make sure that
the stirrer in the tank is either backed
up with a spare or alarmed because
powders settle and set like concrete
if they are not kept in suspension
digging them out is not fun.

Big Bags
Any reasonable size brewery should
be thinking of using bulk powder
supply rather than paper sacks.
Health and safety issues are greatly
reduced and man power in big plants
have larger particles and are With filter powders, being classed can be redeployed. With approx 10hl
The Pall ZHF - generally used for the first precoat. as hazardous materials, companies filtered per kg of filter aid, a brewery
Primus is equipped Perlites are now used for this purpose have sought to protect their people of 500,000 hl will be using 50 tonnes
with Durafil in many UK breweries. Perlites are from the dust. There have been many of powder per year; about 100 half-
screens of 30- difficult to manufacture in fine designs for handling 20kg paper tonne big bags a year. I dont know
micron size that grades and do not have the absorptive sacks in a special cabinet with bag of any brewery currently using
only requires the properties of kieselguhrs which give splitters and vacuum dust removers. tanker delivery and bulk silo storage
equivalent of a brilliant beers. There are very few Some have been more successful of filter powders, the main problem
working precoat. breweries who use a complete perlite than others and some have been here is the availability and cost of
Other filters regime and these use sheet filtration more dust dispersers than offering bulk powder tankers and the capital
including some afterwards to give their beer its final personal protection. The level of cost of a silo system.
candle filters also brilliance. Many filters using protection tends to go with the Even for big bag handling, the
have 30-micron kieselguhr do not use polishing amount of powder used, with number of powders used should be
gaps, although filters, but go straight to packaging smaller users still putting powder kept to a minimum, in most cases a
which includes either flash or tunnel directly into the dosing tanks, the first precoat, second precoat and
Filtrox have
pasteurisation. operator being protected with a face body feed should be enough, and
remained with a 70
Some filter manufacturers have mask specific for kieselguhr dust. very often the second precoat and
micron gap which
designed their filters to work without Filter powders are only hazardous body feed is the same powder. Some
is said to be less filter aid suppliers recommend
prone to blocking a first precoat. in powder form, so it is quite
The Pall ZHF Primus is common to see powder slurries mixing powders, not something I am
and has better too keen on to me it is a bit too
equipped with Durafil screens of mixed with water in a separate area
cleanability. much of a black art or a three of
30- micron size that only requires the from the filter room and then
equivalent of a working precoat. transferred to the dosing tank when sand plus one of cement approach.
Other filters including some candle needed. Another method is to have a The cost of supplying kieselguhr
filters also have 30-micron gaps, separate area above the filter room in big bags is similar to that of
although Filtrox have remained with with powders sent directly into the paper sacks. Some quite cost
a 70- micron gap which is said to be dosing tanks below. effective powder fluidising and
less prone to blocking and has better A little advice from experience transfer systems have been installed
cleanability. when designing slurry tanks, it is and can be justified on health and
safety as well as manpower savings
The KHS Kometronic for sack handling, although civil
system costs can be high. A large brewery
RIGHT: Diagram of a
(Diagramand photo: KHS.)

KHS Kometronic
precoat filter using
regenerable cellulose
fibres instead of
kieselguhr

FAR RIGHT: A KHS


Kometronic precoat
filter using regenerable
cellulose fibres on trial
with only one chamber
in the stack.

The BREWER & DISTILLER INTERNATIONAL Volume 3 Issue 12 December 2007 www.ibd.org.uk
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(Diagram and photo: Norit.)
using 200 tonnes of filter aid per Norit BMS.
year, would be handling 10,000 ABOVE: Schematic of a
20kg paper sacks so it must make 600 hl/h Norit BMF,
sense to reduce this to 400 half- showing from left to
tonne big bags. The big bags are right: cold store tank,
made from woven poly- stabilisation dosing,
propylene. They are not re-used in recirc/retentate tank,
the food industry, but may be filter, buffer tank,
collected free of charge or for a carbonator, bright beer
small fee for use in non-food tank.
applications. Robinsons of
LEFT: A 600 hl/hr (72
Stockport use big bag supplied by
module) Norit BMF
Flexibulk, and Thwaites are about to
installed in a brewery in
install a big bag powder handling Belgium.
system to be supplied by Mass
Measuring Ltd.
of regenerating and cleaning the automated vessel filters were
Disposal spent kieselguhr from a filter with introduced.
Disposal costs for spent kieselguhr caustic, acid and an enzyme Candle filters and other screen
is an increasing part of the total preparation. This material is used as filters were already in use on the
filtration costs. With landfill being the body feed for subsequent continent. In the 1980s, candle filters
carefully controlled, costs will only filtrations. A fresh, new precoat is and horizontal screen filters were Disposal costs for
increase. Soil injection is used by needed on each filter run. Overall most popular. Candle filters had spent kieselguhr is
many companies in the UK. In parts kieselguhr savings of 70-80% are comparatively small sludge volumes an increasing part of
of Germany spent kieselguhr is possible. which restricted filter run lengths, the total filtration
already considered as a chemical they were the answer for breweries costs. With landfill
waste which is extremely expensive Which filter is best for me? who wanted large volumes filtered in being carefully
to dispose of and more countries will In the UK, plate and frame filters a short time. Also, because the vessel
controlled, costs will
follow suit. were used extensively until the volume was large, losses were high
only increase. Soil
KHS are in final stages of 1970s. The plates and frames were because of the water-beer interfaces
injection is used by
developing a filter system called mostly 60 cm with flow rates limited at the start and end of the run. A
to 100hl/hr. This gave a typical run problem also associated with the many companies in
Kometronic incorporating a precoat
filter replacing kieselguhr with length of 1000 hl in ten hours. The large plate and frame filters. the UK. In parts of
regenerable cellulose fibres. introduction of the Seitz Orion 100 The introduction of large Germany spent
I know that a number of cm2 filters enabled a step change in horizontal screen filters was a major kieselguhr is already
companies are looking at throughputs where flow rates over step forward. This enabled long filter considered as a
manufacturing a replacement 320 hl/hr were possible. A maximum runs at fast flow rate and because the chemical waste
powder but they are not at the 67 bar inlet pressure allowed a filter cake sat on a horizontal screen which is extremely
commercial stage yet. I am sure differential pressure of 5 Bar (75 psi) the filters could be emptied using expensive to
there will be long queues of and gave run lengths of over 4000 hl carbon dioxide gas through low level dispose of and more
interested brewers when they and with centrifuges and rest elements which were not used countries will follow
eventually come on the market as optimisation runs over 24 hours are during the main filtration. The suit.
long as the economics are sound and achieved. The large sludge volume beginning and end of filter runs could
the material can be used on existing enabled much longer runs and even be free of beer-water interfaces, so
filters. some 200 cm2 frame filters were losses were greatly reduced.
introduced. The problem was that the Because of the horizontal screens,
Regeneration downtime to wash off, clean and the filtration could be halted the
Pall Food and Beverage has sterilise the filters was 46 hours and bed was stable, whereas the bed on a
developed a kieselguhr regeneration required a lot of manual input. candle would slip off. The same was
system called Befis which is used in Although attempts were made to true during a power interruption. The
conjunction with their Primus filter. automate cleaning of plate and frame main manufacturers with the
This system works on the principle filters, they were not successful, so exception of Filtrox concentrated on

The BREWER & DISTILLER INTERNATIONAL Volume 3 Issue 12 December 2007 www.ibd.org.uk
15
FILTRATION

(Photo: Pall Corporation 2007.)


Membrane modules brand name of various powder
(each of 12m2) on a Pall filters.
Profi filter installed at
Carlsberg in Fredericia Kieselguhr-free filtration
which processes up to The issues associated with powder
480hl per hour. handling and disposal of spent filter
powder have led to companies
developing kieselguhr-free systems
based on cross flow technology. This
technology is extensively used for
cider and wine, so what is the
situation with beer? Early attempts
by APV in the 1980s to filter beer
using ceramic membranes were
unsuccessful, but at least three major
players currently have systems in
use in breweries. The 0.7- 1.0 hl/m2
flow rates on cross flow filters are
slow compared with powder filters.
The principal of cross flow filtration
horizontal-screen filters. It seemed running in a precalculated volume of is straight forward with the
that the candle filter was becoming high gravity beer, thereby unfiltered beer circulating across a
outclassed. Horizontal-screen filters eliminating losses at start up. polymeric 0.450.6 micron
had many advantages, but changes to Similarly, at the end of the run, the membrane. A cross-flow rate of
brewing practice and a need for blending water can be shut down approx 1.2 m/s has a pressure which
simplicity has seen a come back by early to compensate for weaker beer is above the pressure on the filtered
the candle filter, with many of the being run at the end of the run beer side of the membrane (this is
concerns being answered. although care should be taken to called the trans-membrane
ensure proper mixing. The same differential pressure).
The introduction Candle filters make a system could also be applied to a The pressure difference between
of large horizontal comeback large plate and frame filter and some the rough and bright side of the
screen filters was a The complexity of moving parts and brewers who installed horizontal membrane provides the force to
major step seals on the screen filters produced screen filters never use the blow push the beer through the membrane
forward. This engineering headaches for some, so down facility. It must also be and take out any particles. Because
enabled long filter the simplicity and lack of moving remembered that when a filter is there is a fast flow across the
runs at fast flow parts in the candle filter again blown down with CO2, the filter membrane perpendicular to the flow
rate and because became attractive. Filtrox (Synox), cake contains full gravity (often high through the membrane, there is little
KHS (Getra Eco) and Steinecker gravity) beer, so the losses are not build up of solids. There is no dead
the filter cake sat
(TFS) all looked at the more zero as some have claimed. end filter bed to go through as in a
on a horizontal
negative aspects of candle filters and Another development by conventional filter, so there is no
screen the filters
came out with innovations, to Steinecker (Krones) is the TFS-Twin static filter bed build up and hence
could be emptied little pressure build up. There will
improve the efficiency and running Flow System candle filter introduced
using carbon cost. New wedgewire designs in 2000. This filter is different in that be some build up of solid material
dioxide gas replaced the scalloped ring candle there is no filtered beer section of the on the membrane which will cause a
through low level which are easier to keep clean and filter vessel. The rough beer comes rise in the trans-membrane pressure,
rest elements give a more even powder coating. into the vessel, filtered beer comes and the process will continue until a
which were not For example, in the Filtrox Synox out through the candles into a pressure difference of about 1.5 bar
used during the PF candle filter launched at Brau manifold within the body of the filter is reached. The manufacturers of
main filtration. 2004, an optimised version of the which feeds directly into the filter cross-flow filters all use an interim
successful Filtrojet filter, the filter outlet pipe. Ten percent of the flow pulsing or backwashing
area was increased by introducing a through the filter is recirculated from technique to disturb any solid build
25 mm instead of a 33mm diameter the bright back to the rough side in up and reduce the trans membrane
candle. The smaller diameter candle order to give an improved pressure. A stage is reached when
enabled more units to be put into the distribution of filter aid particularly the trans membrane pressure will
housing. The overall effect was to at the top of the candle. The TFS is not reduce, in which case a chemical
allow more filtration area and sludge also designed to be used without a clean is carried out.
space and less relative void volume first precoat. If we are looking at the physics of
which contributed to losses in the So which powder filters are filtration, the same principles apply
form of water-beer interfaces at the available and who makes them? The crossflow filtration is enhanced by
beginning and end of a filter run. The main filter suppliers have a large surface area, thin filter bed,
increased use of high gravity consolidated over the years, with and slow flow rate/m2, so there is
brewing meant that beer at the only Filtrox remaining independent slower pressure build up compared
beginning of a filter run could be run and having the same ownership. Pall with conventional filtration.
into a tank at very low gravity bought Seitz-Schenk in 2002, while The three systems presented by Pall,
(assuming deaerated water is used to Steinecker became part of Krones Norit and Alfa Laval, all use
charge and pre-coat the filter) which and SEN became part of KHS. Table polyethersulphone membranes put
could be compensated for by 1 shows the main manufacturers and together in a series of modules.

The BREWER & DISTILLER INTERNATIONAL Volume 3 Issue 12 December 2007 www.ibd.org.uk
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FILTRATION

(Photos: Alfa Laval.)


Alfa Laval systems.

RIGHT: A 300 hl/h


Alfafine membrane filter
in operation in a
brewery in Western
Europe since 2005

FAR RIGHT: A 0.7m2


Sartoconmembrane
cartridge used on a
Alfabright membrane
filter.

Norit and Pall use hollow fibre at Drinktec 2001, and extensive
modules and Alfa Laval use a series work has been carried out with
of cassettes to make up the filter. A Heineken. A filter with the
large recirculation pump is used to capability of up to 200 hl/h has 24
provide the fluid flow across the filtration modules of 9.8m2 filtration brewing industry, which specialises
membrane. Table 2 compares the area each. The membranes are 0.5 in filtration technology. The Profi
systems features (previous page). micron PTS (polyethersulphone), system was developed in
Cross-flow membrane filters each consisting of 2800 1.5 mm conjunction with GEA Westfalia
produce a yeast free filtrate (due to diameter fibres. In process terms, Separators and a great deal of
0.4-0.65 micron pore size) Suppliers the filtration flow rate is 0.8hl/m2/h development work has been carried
Another have also reported improved hazes and the cross flow rate is 1.2 m/s. A out with Carlsberg. A filter with the
development by in bright beer as well as better system pressure of 3 bar gives a capability of up to 240 hl/h has 20
Steinecker (Krones) flavour and haze stability due to maximum trans membrane pressure filtration modules of 12 m2
is the TFS-Twin Flow reduced oxygen and iron pick up of 1.2 bar. The filters have a typical filtration area each.
System candle filter from filter powders. This is a good average run length of 20 hours The membranes are 0.65 micron
introduced in 2000. start, but only with longer term use which includes a small number of PTS (polyethersulphone). In
This filter is different and experience will these backflushes, to reduce the trans process terms, the filtration flow
in that there is no improvements be substantiated. membrane pressure and allow CIP. rate is up to 1.0 hl/m2/h. The
filtered beer section The chemical based clean using an system is designed in blocks of
of the filter vessel. The cross-flow players oxidising agent and membrane modules, which are taken out in
The rough beer Norit is a Dutch company which cleaner takes 2.5 hrs and is carried sequence for cleaning, thus
comes into the specialises in purification out when the membranes become allowing a continuous operation.
vessel, filtered beer technology, including water and partially blinded. Because the beer solids are mostly
comes out through other beverages. The BMF-200 beer Pall Food and Beverage is a removed by the centrifuge, no
filter was introduced to the market global company, well known to the retentate buffer tank is required,
the candles into a
and the volume of beer involved in
manifold within the
Table 1: Main manufactures and beer changes is low. Beer changes
body of the filter
brand name of their powder filters and the end of batch operations are
which feeds directly
carried out by blowing out the
into the filter outlet system with CO2.
Company Plate and frame Horizontal screen Candle
pipe. Like the Profi system, Alfabright
Filtrox Novox Filter-o-mat Synox PF is based on a combination of a
KHS Orion Cosmos Getra Eco centrifuge from Alfa Laval and a
Pall/Schenk Niro Primus Ecoflux membrane system supplied by
Krones/Steinecker - Steineker FS 130K Steineker TFS German filtration specialist
Sartorious. A typical system
Table 2 Comparing available kieselguhr-free filtration systems

Norit Pall Alfa Laval


Configuration Batch or continuous Continuous Continuous
Module size 9.8 m2 12 m2 0.7 m2 cassette
Size/modules etc Blocks of 24 modules up to max Blocks of 20 modules (up to Up to 432 cassettes
of 72 (600 hl/h) 240 hl/h per block) (up to 300 hl/h)
Membrane Polyethersulphone Polyethersulphone Polyethersulphone
Pore size 0.5 micron 0.65 micron 0.6 micron
Flow rates 0.8 hl/m2/h 0.5 1hl/m2/h 0.7 hl/m2/h
Number in use 19 11 2

The BREWER & DISTILLER INTERNATIONAL Volume 3 Issue 12 December 2007 www.ibd.org.uk
18
designed for 225 hl/hr based on recommend using a centrifuge to guarantees and replacement costs Another unknown
302m2 of filtration area (0.75 reduce yeast load on the are substantiated, many brewers will is the robustness
hl/m2/hr). The membrane filter is membranes. Norit argue against the not take the kieselguhr-free route. and reliability of the
made up of a number of 0.7 m2 need for a centrifuge because they However there have been huge membranes and
Sartocon cassettes with a 0.6 believe a separator does not remove strides in membrane technology and until better
micron PES membrane. This design the small particles (< 0.5 micron) it is widely used in other industries, guarantees and
is different from Norit and Pall in which are responsible for blocking so the time will come when brewers replacement costs
that the membrane cassettes have a pores on the filter. The Norit system feel more confident to embrace the are substantiated,
very narrow distance between includes a retentate/recirculation powder-free route. For companies many brewers will
membranes 120 microns, which tank where the solids removed from with a longer term view of capital
not take the
according to Alfa Laval enables the the beer are collected. In the investment on strategic items,
kieselguhr-free
filter to be run using lower Alfabright and Profi systems, the overall project lifetime costs may
route.
powered, smaller recirculation solids are mostly removed by the well be better on cross-flow than
pumps. The compact design of the upstream centrifuge. current powder systems, when
cassette is also said to give a more Centrifuges are very costly to buy everything including energy and
stable membrane and optimium and operate and not having to environmental cost is considered. In
cleaning characteristics which have include one in a new filtration the mean time, only continued
a positive impact on membrane life. scheme gives a big financial development and experience will
The filter system works advantage to the Norit system. Like confirm whether crossflow is the
continuously, with sections taken all new technologies, the debate will future for beer filtration.
out for cleaning every 2-5 hours. continue and only plant
performance and experience will
Do you need a centrifuge? dictate whether centrifugation is Acknowledgements
There continues to be a debate about necessary.
The author would like to thank those
whether a centrifuge is required to Another unknown is the companies who supplied information
clean beer before it is filtered on a robustness and reliability of the and images in the preparation of this
crossflow filter. Pall and Alfa Laval membranes and until better article

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