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BSK Global

Alaaddinbey Mh. 628. Sk. Kaan Plaza No: 2/K 16120 Nilüfer, BURSA

T: +90 224 441 99 62 F: +90224 443 63 28

sales@bsk-global.com

Providing environmental solutions to industry since 1928, in Einbeck - Germany

� Needlefelt production

� Treatments

� ePTFE Membrane lamination

� Filter bag stitching

� Filter cage production

� Project Management, Selectionof Filter Media

� Maintenance, Exchange ofFilter Bags

� Laboratory Tests,Investigations

� Filterbag Testing2

KAY-TEX® is an expanded microporous PTFE-membrane that is bonded to the surface of conventional filtermedia, including felts and woven fabrics.

This membrane provides high filtration efficiencies (99.99+ %), superior dustcake release and improved airflow at lower energy consumption levels.

KAY-TEX® ePTFE-Membrane provides:

� Higher airflow

� Near Zero emissions

� Superior clean-down

� Longer bag life

� Lower differential pressure

KAY-TEX® – MEMBRANE PRODUCTS

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▪ Mikroporous Membrane is made out of expanded Polytetrafluorethylene (ePTFE)

▪ stable to chemical attacks

▪ water-repellent

▪ fibre distance is that big to allow air passage, but not that big for particles

▪ extremely fine pored and smooth filtration surface

▪ helps to have a better dedusting during the filtration process

▪ Free of PFOA (Perfluorooctanoic acid)

▪ Pore size ≤ 1µm

Mikroporous ePTFE-Membrane & characteristics

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1.PTFE powder blended with extrusion aid (lubricant)

2.Powder and lubricant pre-formed into cylinder shape

3.Preform extruded through a die into tape

4.Tape calendared to desired thickness

5.Lubricant removed through drying

6.Tape stretched to desired width to create

membrane

Production of ePTFE-Membrane

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Dedicated for these substrates:

▪ Needlefelts

▪Woven fiberglass

ePTFE Membrane thermal laminated at

▪ Polypropylen (PP)

▪ Polyester (PES)

▪ Meta Aramid (MAR)

▪ Polyacrynitril (PAN)

▪ Polyphenylensulfid (PPS)

▪ Polyimid P84 (PI)

▪ Polytetrafluorethylene (PTFE)

▪ Fiberglass (GL)

KAY-TEX® – INNOVATIVE MEMBRANE LAMINATES

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Dr. Roy J. Plunkett & team at his laboratory at DuPont, where he discovered Teflon in

1938

� Polytetraflurethylene (PTFE) is a fluoroplastic

� PTFE is used nowadays at different products, due to its unique characteristics:• Medical technology (e.g. Stents / Bypass / Implants)• Sealing material for the aerospace as well as for the chemical and pharmaceutical industry• Textile industry (breathable – water and draftproof clothes / shoes etc.)• expanded PTFE-film (ePTFE) – used at filtration

� PTFE discovered by DuPont in 1938

� Development of ePTFE Membrane by Gore in 1969

� Expanded PTFE (ePTFE) is a special processed type ofPolytetrafluoroethylene by the guidance of the molecule fibres

� The ePTFE membrane consists of very thin expanded layers. Thismembrane has such fine pores that are still big enough to let water steampenetrate, but not water in liquid form

� Tetratec starts production of ePTFE Membrane in 1981. Donaldson aquiredTetratec in 1994

� BHA Technologies starts producing its own ePTFE Membrane in 1994

� KAYSER aquired the technology of BHA in 2010

PTFE characteristic& diversity

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2,54 cm: 25.400 µm

Human hair: 40-120 µm

Ballpoint pen tip:500-1.200 µm

KAY-TEX® – ePTFE Membrane Size comparison

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Magnification: 2000x

KAY-TEX® – qualitydetermining criterias

Established & proven ePTFE Membrane Types

Firstclass Substrates� Needlefelts� Woven Fiberglass

controlled Laminationprocess� Cleanliness� Temperature� Pressure� Speed 9

Conventional filtermedia vs. membrane laminates

Conventional filtration:Dust particles penetrating thru the filtermedia

Staubpartikel…

Membrane filtration:Dust particles are collected on the membrane surface

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� KAYSER offers with its own production line the full portfolio ofmembrane products.

� The Kayser ePTFE-Membrane can be laminated to followingsubstrates:

• Polypropylen (PP)• Polyester (PES)• Meta Aramid (MAR)• Polyacrynitril (PAN)• Polyphenylensulfid (PPS)• Polyimid P84 (PI)• Polytretrafluorethylen (PTFE)• Fiberglass (GL)

� KAYSER offers ePTFE-Laminates, which are well-establishedand proven technology at high quality standards (BHA).

KAY-TEX® Product series

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Traditional Industries

Cement

Asphalt

Steel

Foundry

Minerals

Mining

Aluminium

Incineration

Energy

Gypsum

Glass

Waste combustion

Lime

Carbon black

ferro-silicon

Indust. Boiler

Battery/Lead

Sec. Smelting

Process Industries

Chemistry

Plastics

Food

Pharmacy

Tire / Rubber

TiO2

Fiberglass

Paint

Wood / Paper

Grain

KAY-TEX® - area ofapplications

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KAY-TEX® - ReferenceWoven fiberglass with ePTFE

Membrane

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KAY-TEX® - ReferencePTFE Needlefelt with ePTFE Membrane

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KAY-TEX® OFFERS:

� Increased airflow at lower energy consumptionKAY-TEX® prevents penetration of fine particulate without restricting airflow

� Lower pressure dropThe non-stick properties of KAY-TEX® make filters easier to clean, allowing a lower pressure drop to be consistently maintained

� Lower outlet emissionswith KAY-TEX® emissions are reduced to nearly ZERO

� Longer filter bag lifeKAY-TEX® filters can extend the life of your filters dramatically.

KAY-TEX® - Advantages

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� Homogeneous and consistent fabricstructure

� PTFE-Finish takes place in a specialmethod under high temperature and untilthe deep of the fabric after an efficientdesizing of the woven fibre glass (ovenprocess used to clean the fabric prior to thefinishing step).

� PTFE-Impregnation is predominant on thesurface

• only little limitation for the laminating process

� Removal of textile size / facing from theproduction of the glass yarns does not oronly insufficient take place

• Impregnation more or less on the surface• PTFE-Finish realized under lower

temperatures

Asian Substrate KAY-TEX® Substrate

KAY-TEX® Substrate vs. Asian Substrate

High Magnification

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KAY-TEX® Substrate vs. Asian Substrate

Asian Substrate KAY-TEX® Substrate

High Magnification

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KAY-TEX® Substrate vs. Asian Substrate

Asian Substrate KAY-TEX® Substrate

� KAYSER woven fibre glass produced withtexturised weft yarns / homogeneous

� Caramelization process and PTFE-Finish ensure:

• Maximum mechanical durability• Very good lamination results

KAY-TEX® Substrate vs. Asian SubstrateMIT Flex-Test results

MIT Flex Test – ResultsFor

Fiberglass - Substrate (750 g/m²)

Specification KAY-TEX Asian

Weight g/m² 770 g/m² 780 g/m²Thickness mm 1,0 mm 1,0 mm

LOI % > 10% >10%

MIT Flex Test results(Cycles to failure) Warp 100.000 70.000(Cycles to failure) Weft 20.000 15.000

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Membrane damages at bonding points

Membrane damages and delamination

SEM-images of an asian PTFE-Membrane Fiberglass material

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Membrane damages Membrane damages, broken fibers

High Air Perm Test Results

• Fiber diameter is 10 microns ���� Fiber grade is G-Glass (lower cost, less flex resistance)

• Industry standard is the high quality DE-filament ( 6 microns, higher flex resistance)

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SEM-images of an asian PTFE-Membrane Fiberglass material

Example of a less homogeneous PTFE-finish with possible future consequences

PTFE Finish non-homogeneous PTFE Membrane will be damaged thru Glass fibres after wear (Flextest)

Influencing factors at theWoven Glass-Laminate

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Example of an homogeneous and perfectPTFE-Finish of a woven fiberglass

PTFE Finish homogeneousPTFE Membrane with a good bonding and an homogeneous structure

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Influencing factors at theWoven Glass-Laminate

Pore structure (Asian) Pore structure (KAY-TEX®)

KAY-TEX laminateAsian laminate

SEM-comparison ofMembrane structures

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Asian PTFE Needlefeltwith Membrane

The physical characteristics of the laminate comply with the specification, but the membrane structure and the lamination

indicate „Overbonding“

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KAY-TEX® PTFE Needlefeltwith an ePTFE Membrane

Excellent controlled and homogeneous bonding of the membrane, Well-preserved Membrane structure for high filterperformance

Standard 26

The correct manufacturing of Membrane filter bags

Consider some characteristics during construction and man ufacturingof membrane filter bags:� Tight bag-to-cage fit

Pinch at needlefelt: 6-10mmPinch at woven glass: 0-5mm

� Adjustment of cutting preferablywith a sample filter cage

� Longitudinal wire distance max. 30mm at needlefelt and 25mm at woven glass

� Increased care at seams needed� Welded longitudinal seam preferred (if possible)

if applicable additional seam sealing� GMP-special designs are possible,

to prohibit product contact with fibresrespectively to minimize bonds

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Turned filter bag Reinforcement with bottom seam

protection

Seam sealing with PTFE-tape at top

area

Seam sealing with PTFE-tape and Siliconinlay at

bottom area

GMP-seam at Needlefelt28

The correct construction of Membrane filter bags

Installation of membrane filter bags without installation sleeves causes membrane damages

Improper installation of the snapring � leakage consequences

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The correct installation of Membrane filter bags

KAYSER belongs to the 5 leading producers of textil e filtermedia in Europe

KAYSER has appropriate experiences and is the only producer worldwide, who � produces needlefelts� Laminates with an ePTFE-Membrane � stitches filter bags � manufactures filter cages � provides engineering services

YOUR FILTRATION PARTNER, SINCE 1928