Saxon Textile Research Institute e.V. (STFI)
On March 11 and 12, 2025, the 17th TEXTILE FILTER symposium took place in Chemnitz, which brings together experts from science and industry every two years to discuss the latest developments in the field of textile filter media. This year’s event focused in particular on sustainability, bio-based materials and digital simulations for optimizing filtration processes. The symposium was accompanied by a trade exhibition and an excursion to the host, the Saxon Textile Research Institute (STFI).
Sustainable and bio-based filter media
The reduction of the CO2 footprint through resource-saving filtration materials was one of the core topics of the symposium. One presentation introduced an automated method for the life cycle assessment of filter materials, which enables a systematic evaluation of their environmental impact. The method allows a precise analysis of material selection and production processes in order to optimize the sustainable use of filter media. In addition, hydroentangled nonwovens were presented, which can represent an environmentally friendly alternative to conventional filter materials. The innovative materials presented combine high filtration efficiency with improved environmental compatibility. In addition, sustainable concepts for the reuse and recycling of filter media were considered in order to reduce waste and extend the service life of the materials. Bio-based materials also played a central role. Meltblown nonwovens made from polylactic acid (PLA) and polyethylene furanoate (PEF) were offered as promising alternatives to conventional plastic filters. While PLA seems particularly interesting due to its biodegradability, PEF showed comparable filtration properties to PET and could replace fossil polymers in high-temperature applications in the long term. These developments underline the growing importance of bio-based materials in the filtration industry.
Digital simulation and filter optimization
Another key topic of the symposium was the use of digital twins to simulate filtration processes. Digital twins are symbolic virtual models of real filter processes that can be used to optimize material selection and process control. New software tools such as VISPI (Virtual Spinning) and FIDYST (Fiber Dynamics Simulation Tool) enable a de-tailed analysis of fibre deposition and material behavior, enabling more precise control of production processes. A particular highlight was a newly developed simulation model for predicting the aging behavior of electret filters. Electret filters use electrostatic charges to separate particles, whereby the efficiency can decrease over time due to environmental influences. Simulations allow these ageing processes to be predicted more accurately, so that manufacturers can optimize their filters specifically for a longer service life. A guideline for optimizing minipleat pleated filters was also presented. This is intended to provide small and medium-sized companies in particular with practical support in improving the pressure difference and energy efficiency. With the help of the GeoDict® simulation software, ideal pleat geometries can be developed to minimize pressure loss and increase the service life of the filter elements. Another important topic of filter optimization was material compression and its influence on the pressure loss and dust holding capacity of filter media. The test results presented showed that targeted material compression can have a significant impact on filter efficiency. With the help of computer-aided flow simulations (CFD), various degrees of compression were analyzed in order to find the optimum balance between filter performance and pressure difference. Another key point was the characterization of filter media using 3D image analysis and flow simulations. The DNSlab® software enables detailed analyses of pore structures, air permeability and separation efficiency. With the help of a new Python interface, simulation-based variation calculations can be carried out, which can supplement or even replace physical laboratory tests.
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