SUPRAdisc™ II Depth Filter Modules product photo Primary L

SUPRAdisc™ II Depth Filter Modules

Introduction

Stacked disc modules have a long history in Food and Beverage applications. They arose out of the need to package sheet-based depth filter technology in more user-friendly, modular closed systems, especially for small batch production or medium flow rate applications. Due to the relative high dirt holding capacity and filtration performance of filter sheet-based products, they provided an optimal and cost-effective solution for handling food and beverage fluids.

The filtration effect of these sheet-based products is based on a combination of surface, depth, and adsorptive filtration. Selected combinations of cellulose, different types of filter aids, or other ingredients in the filter matrix result in a highly porous structure, which achieves effective filtration, including coarse to fine particle removal, colloidal removal, and final filtration.

Classic stacked disc modules represent first generation module design, but they have performance disadvantages.

SUPRAdisc II modules eliminate the disadvantages of classic stacked disc modules. They offer increased capacity, reliability, handling advantages, and robustness, which satisfies customer needs and requirements for a higher performing product.

SUPRAdisc II modules are ideal for many food and beverage applications.


Basic construction of classic stacked disc modules

To better appreciate the design advancements of SUPRAdisc II filter modules, an understanding of the basic features and construction of stacked disc modules should be considered.

Since their inception, classic stacked disc modules have been manufactured leaving the cells of media fully exposed within the filter housing (Figures 1 and 2).

  • Individual cells are made from two sheets of depth filter media with a polypropylene separator in between them. This separator is sandwiched inside the cell, on the downstream side of the two sheets, as the flow path is from the outside surface of the sheets to the inside (Figure 3).
  • A polypropylene seal around the outside edge is used to bind the two sheets together, thus forming one complete cell.
  • The cells are stacked on top of each other until the desired height is achieved.
  • End caps are then affixed to the center core, thus locking each cell in place and forming a complete stacked disc module.

Design limitations of classic stacked disc modules

Classic stacked disc modules have inherent design limitations.

  • Depth media is exposed
    • The integrity of the media can be compromised during shipping, handling, installation and removal. Extra care must be taken to avoid damage.
    • Modules can fall apart when removed from the housing.
  • Individual cell proximity to one another is very close. During steaming, rinsing, or filtration, the cells may shift or warp causing individual cells to touch. This causes blinding of portions of each cell, which reduces the effective filtration area.
  • Classic stacked disc designs do not withstand any back pressure. With only the downstream support layer (the separator), even as little as 0.05 bar (0.7 psid) of back pressure can rupture the unsupported media in these modules. This is seen as a half moon tear on either the top sheet of the top module or the bottom sheet of the lowest module in the stack, creating fluid bypass areas and compromising filtrate quality.
  • Classic stacked disc modules are sensitive to high temperature operations such as hot water sanitization, steaming, or hot filtration. Deformation caused by high temperature exposure is a common problem (Figure 4).





Construction technology of SUPRAdisc II modules

SUPRAdisc II modules (Figure 5) incorporate a double separator concept.

  • Alternating outside separators, discs of depth media, and inside separators are affixed to a rigid polypropylene core until the desired height is achieved.
  • Two techniques are used to connect the separators:
    • For 287 mm (12 inch) diameter modules, the unique Clip-Seal Interlock is created by using a hydraulic ram to apply pressure and snap and lock the outside to the inside separators. Each disc of filter media is thus sealed in between the separators.
    • For 410 mm (16 inch) diameter modules, the inside/outside separators are connected by ultrasonic welding.
  • Locking end caps are then applied to the center core, creating a complete module.

Design features of SUPRAdisc II modules

The unique separator design provides both upstream and downstream support of the filter media. The media is sealed inside a polypropylene cage assembly and is no longer exposed. The unique Clip-Seal Interlock and the welded design connects the outside to the inside separators resulting in an extremely robust design (Figures 6,7).

Each sheet of filtration media is individually sealed and separated. Depth sheets cannot come into contact with each other, eliminating blinding of the media.

Due to the separator channels, SUPRAdisc II modules have close to 100 % effective filtration area that is dimensionally stable during shipment and handling, filtration and removal.

Deformation or cell collapse is no longer an issue and sheet damage during use is minimized. Backflushing to regenerate the modules is now possible.

Backflushing SUPRAdisc II modules

With the use of a backflush set consisting of supporting discs and intermediate distance discs (Figure 8), modules can be backflushed either with water or product in order to remove contaminants and prolong their life.

For more detailed information on backflushing and availability of backflush sets, please contact Pall.






Benefits of SUPRAdisc II modules

SUPRAdisc II modules offer a multitude of benefits that overcome the disadvantages of the classical stacked disc design (Figures 9, 10, 11). These benefits result in important cost savings.

  • Longer onstream life, due to highest utilization of the filter sheet area, no blinding of filter surfaces, open design of the separators, optimized drainage, and distribution of incoming fluid to each filter sheet via the outside separator
  • Repeated use is possible due to regenerability of the modules with backflushing
  • Higher operational security, due to resilience against vacuum or back pressure shocks, and no cell or module deformation from hot operation or sanitization and steaming
  • Better handling before and after operation, due to robust design and protection of filter media from exposure and damage
  • Higher yields, as rest filtration in reverse flow mode is possible
  • High filtrate quality, without chance of bypass, due to module design and use of proven and reliable filter media recipes

SUPRAdisc housings

SUPRAdisc II modules are used in SUPRAdisc housings. Up to 4 modules can be stacked in a housing without concern of deformation or loss of module integrity. This is due to the solid design of the inner tubular core. This center core is capable of carrying the load of the saturated wet weight of the modules, minimizing the compressive forces on individual filter cells, and subsequently the filter sheets.

For further technical and ordering information on Pall SUPRAdisc housings, please consult Pall.




SUPRAdisc II Module Types

Standard Range

Available in 287 mm (12 inch) and 410 mm (16 inch) diameters, SUPRAdisc II Standard Range modules contain single layer Pall filter sheet media, in K, T, and IR grades (Figure 12).

HP Range

Available only in 410 mm (16 inch) diameter, the SUPRAdisc II HP Range combines 2 different grades of Pall filter sheet media into a single module. A coarse layer on the upstream side and a fine layer on the downstream side allows pre-clarification and clarification in one assembly. Each of the sheet layers is separated by a separator (Figures 13, 14).

A wide range of upstream and downstream sheet combinations is available.

SUPRAdisc II HP modules are not designed for backflushing.

Benefits of SUPRAdisc II HP modules

  • Enhanced clarification abilities for fluids with wide particle size distribution, due to graded particle removal. Larger particles are retained by the top sheet layer, thus avoiding plugging of the finer sheet material below. In turn, the downstream layer enables increased efficiency of the upstream layer.
  • Up to 30 % higher filtration efficiency than in single layer formats
  • Reduced capital expenditure for small batch processing, due to two-step filtration in one housing
  • Reduced rinsing water and cleaning chemical consumption





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Description

Introduction

Stacked disc modules have a long history in Food and Beverage applications. They arose out of the need to package sheet-based depth filter technology in more user-friendly, modular closed systems, especially for small batch production or medium flow rate applications. Due to the relative high dirt holding capacity and filtration performance of filter sheet-based products, they provided an optimal and cost-effective solution for handling food and beverage fluids.

The filtration effect of these sheet-based products is based on a combination of surface, depth, and adsorptive filtration. Selected combinations of cellulose, different types of filter aids, or other ingredients in the filter matrix result in a highly porous structure, which achieves effective filtration, including coarse to fine particle removal, colloidal removal, and final filtration.

Classic stacked disc modules represent first generation module design, but they have performance disadvantages.

SUPRAdisc II modules eliminate the disadvantages of classic stacked disc modules. They offer increased capacity, reliability, handling advantages, and robustness, which satisfies customer needs and requirements for a higher performing product.

SUPRAdisc II modules are ideal for many food and beverage applications.


Basic construction of classic stacked disc modules

To better appreciate the design advancements of SUPRAdisc II filter modules, an understanding of the basic features and construction of stacked disc modules should be considered.

Since their inception, classic stacked disc modules have been manufactured leaving the cells of media fully exposed within the filter housing (Figures 1 and 2).

  • Individual cells are made from two sheets of depth filter media with a polypropylene separator in between them. This separator is sandwiched inside the cell, on the downstream side of the two sheets, as the flow path is from the outside surface of the sheets to the inside (Figure 3).
  • A polypropylene seal around the outside edge is used to bind the two sheets together, thus forming one complete cell.
  • The cells are stacked on top of each other until the desired height is achieved.
  • End caps are then affixed to the center core, thus locking each cell in place and forming a complete stacked disc module.

Design limitations of classic stacked disc modules

Classic stacked disc modules have inherent design limitations.

  • Depth media is exposed
    • The integrity of the media can be compromised during shipping, handling, installation and removal. Extra care must be taken to avoid damage.
    • Modules can fall apart when removed from the housing.
  • Individual cell proximity to one another is very close. During steaming, rinsing, or filtration, the cells may shift or warp causing individual cells to touch. This causes blinding of portions of each cell, which reduces the effective filtration area.
  • Classic stacked disc designs do not withstand any back pressure. With only the downstream support layer (the separator), even as little as 0.05 bar (0.7 psid) of back pressure can rupture the unsupported media in these modules. This is seen as a half moon tear on either the top sheet of the top module or the bottom sheet of the lowest module in the stack, creating fluid bypass areas and compromising filtrate quality.
  • Classic stacked disc modules are sensitive to high temperature operations such as hot water sanitization, steaming, or hot filtration. Deformation caused by high temperature exposure is a common problem (Figure 4).





Construction technology of SUPRAdisc II modules

SUPRAdisc II modules (Figure 5) incorporate a double separator concept.

  • Alternating outside separators, discs of depth media, and inside separators are affixed to a rigid polypropylene core until the desired height is achieved.
  • Two techniques are used to connect the separators:
    • For 287 mm (12 inch) diameter modules, the unique Clip-Seal Interlock is created by using a hydraulic ram to apply pressure and snap and lock the outside to the inside separators. Each disc of filter media is thus sealed in between the separators.
    • For 410 mm (16 inch) diameter modules, the inside/outside separators are connected by ultrasonic welding.
  • Locking end caps are then applied to the center core, creating a complete module.

Design features of SUPRAdisc II modules

The unique separator design provides both upstream and downstream support of the filter media. The media is sealed inside a polypropylene cage assembly and is no longer exposed. The unique Clip-Seal Interlock and the welded design connects the outside to the inside separators resulting in an extremely robust design (Figures 6,7).

Each sheet of filtration media is individually sealed and separated. Depth sheets cannot come into contact with each other, eliminating blinding of the media.

Due to the separator channels, SUPRAdisc II modules have close to 100 % effective filtration area that is dimensionally stable during shipment and handling, filtration and removal.

Deformation or cell collapse is no longer an issue and sheet damage during use is minimized. Backflushing to regenerate the modules is now possible.

Backflushing SUPRAdisc II modules

With the use of a backflush set consisting of supporting discs and intermediate distance discs (Figure 8), modules can be backflushed either with water or product in order to remove contaminants and prolong their life.

For more detailed information on backflushing and availability of backflush sets, please contact Pall.






Benefits of SUPRAdisc II modules

SUPRAdisc II modules offer a multitude of benefits that overcome the disadvantages of the classical stacked disc design (Figures 9, 10, 11). These benefits result in important cost savings.

  • Longer onstream life, due to highest utilization of the filter sheet area, no blinding of filter surfaces, open design of the separators, optimized drainage, and distribution of incoming fluid to each filter sheet via the outside separator
  • Repeated use is possible due to regenerability of the modules with backflushing
  • Higher operational security, due to resilience against vacuum or back pressure shocks, and no cell or module deformation from hot operation or sanitization and steaming
  • Better handling before and after operation, due to robust design and protection of filter media from exposure and damage
  • Higher yields, as rest filtration in reverse flow mode is possible
  • High filtrate quality, without chance of bypass, due to module design and use of proven and reliable filter media recipes

SUPRAdisc housings

SUPRAdisc II modules are used in SUPRAdisc housings. Up to 4 modules can be stacked in a housing without concern of deformation or loss of module integrity. This is due to the solid design of the inner tubular core. This center core is capable of carrying the load of the saturated wet weight of the modules, minimizing the compressive forces on individual filter cells, and subsequently the filter sheets.

For further technical and ordering information on Pall SUPRAdisc housings, please consult Pall.




SUPRAdisc II Module Types

Standard Range

Available in 287 mm (12 inch) and 410 mm (16 inch) diameters, SUPRAdisc II Standard Range modules contain single layer Pall filter sheet media, in K, T, and IR grades (Figure 12).

HP Range

Available only in 410 mm (16 inch) diameter, the SUPRAdisc II HP Range combines 2 different grades of Pall filter sheet media into a single module. A coarse layer on the upstream side and a fine layer on the downstream side allows pre-clarification and clarification in one assembly. Each of the sheet layers is separated by a separator (Figures 13, 14).

A wide range of upstream and downstream sheet combinations is available.

SUPRAdisc II HP modules are not designed for backflushing.

Benefits of SUPRAdisc II HP modules

  • Enhanced clarification abilities for fluids with wide particle size distribution, due to graded particle removal. Larger particles are retained by the top sheet layer, thus avoiding plugging of the finer sheet material below. In turn, the downstream layer enables increased efficiency of the upstream layer.
  • Up to 30 % higher filtration efficiency than in single layer formats
  • Reduced capital expenditure for small batch processing, due to two-step filtration in one housing
  • Reduced rinsing water and cleaning chemical consumption



Applications
Beer
  • Particle Removal
  • Polishing Filtration
  • Final Filtration

Spirits
  • Particle Removal
  • Chill Haze Removal
  • Bottling Filtration

Wine
  • Particle Removal
  • Polishing Filtration
  • Filtration after Stabilization
  • Pre-filtration prior to Final Membrane Filters

Sparkling Wine
  • Particle Removal
  • Polishing Filtration
  • Filtration after Stabilization
  • Pre-filtration prior to Final Membrane Filters

Fruit Juice
  • Particle Removal
  • Polishing Filtration
  • Filtration after Stabilization
  • Pre-filtration prior to Final Membrane Filters
  • Reduction of Alicyclobacillus Acidoterrestris

Sweeteners and Gelatin
  • Particle Removal
  • Polishing Filtration
  • Final Filtration
Performance

SUPRAdisc II filter media options

K Series

With 13 different grades of permeability, the K Series modules represent Pall's standard depth filter series. These sheets consist of a cellulose matrix with very fine kieselguhr (diatomaceous earth or DE) mixtures and perlite, as filtration-active substances.

Table 1: Removal performance of K Series Modules
 
Sheet Media Type Application Examples of use
EKS, EK1, EK,
KS 50, KS 80
Fine Filtration Microorganism reduction and yeast removal in wine
Microorganism reduction in beer with moderate
to high microbial load
Final filtration of juice and juice concentrate prior to bottling
Microorganism reduction in sugar syrups
Microorganism reduction in enzyme solutions
K100, K150, K200,
K250, K300
Polishing
Filtration
Polishing filtration of wine
Microorganism reduction in beer with low microbial load
Fine filtration of beer and yeast removal
Fine filtration of beer following DE prefiltration
Polishing filtration of beer
Prefiltration of juice prior to final membrane filtration
Haze removal in apple juice before bottling
Polishing filtration of sugar syrups
Polishing filtration of enzyme solutions
Polishing filtration of thick liquor gelatine
Secondary sedimentation prevention in tea
K700, K800, K900 Coarse
Filtration
Clarification of wine
Particle removal in fruit juice
Particle removal in tea-based beverages
Prefiltration of juice concentrate
Polishing filtration of olive oil
Clarification of enzyme solutions
Clarification of thin liquor gelatine
 

These modules are used for a wide range of very fine to coarse filtration in many food and beverage applications.


SUPRAdisc II filter media options

T Series

The T Series modules include 7 different grades of permeability. Some types consist of a mixture of cellulose and the filtration-active substance perlite, while others consist of pure cellulose.

Table 2: Removal performance of T Series Modules
 
Sheet Media Type Application Examples of use
T950, T1000, T1500 Coarse Filtration Wine clarification Coarse filtration of natural extracts
T2100, T2600, T3500, T5500 Coarse Filtration Roughing filtration of spirits Clarification of enzyme solutions
 

These modules are designed for general purpose coarse filtration, as they are characterized by a loose structure with high particle load capacity.

They also prove to be very successful in filtering viscous fluids, and retaining gel particles or coarsely dispersed components.


IR Series

The IR Series modules include 4 grades of permeability. They are optimal for ion-sensitive applications. Due to a proprietary manufacturing process, they release minimum levels of calcium and magnesium, and negligible levels of iron and copper to the filtered product.


Table 3: Removal performance of IR Series Modules
 
Sheet Media Type Application Examples of use
KS50IR Fine Filtration Polishing filtration of white spirits
K100IR, K250IR Polishing Filtration Polishing filtration of white spirits Chill haze removal in brown spirits
K800IR Coarse Filtration Chill haze removal in brown spirits
 

IR modules are uniquely suited to filtering distilled spirits, providing a visually bright finished product. In spirits, calcium and magnesium precipitates in the form of sulphate or carbonate compounds often result in particulate turbidity. Pall IR modules reduce the danger of precipitate formation due to their extremely low content of extractables.

The particulate turbidity in spirits often contributes to chill haze caused by esters of the higher fatty acids (C12-C16 chains). In such cases, IR filter sheets distinguish themselves by their selective adsorption capacity that can be used for specific separation of medium to long chain fatty acid esters. The short chain fatty acid esters, which are important for creating the aroma in spirits, are not negatively affected by the removal performance of these modules.

Type
Sheet Filters and Modules
Use
Clarification, Polishing
Additional Information

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SUPRAdisc™ II Depth Filter Modules Installation - English


SUPRAdisc™ II Depth Filter Modules - English
Ordering Information

SUPRAdisc II Standard Range

This is a guide to the Part Numbering structure only. For specific options, please contact Pall

Part Number:
200 [Table 1] [Table 2] [Table 3] [Table 4] [Table 5] W

Example Part Number:
200 X100 C 232 S P W

See bold reference codes in tables

Table 1
 
Code Sheet Media Type
K Series
XEKS EKS
XEK1 EK1
XEKO EK
X050 KS50
X080 KS80
X100 K100
X150 K150
X200 K200
X250 K250
X300 K300
X700 K700
X800 K800
X900 K900
   
IR Series
C050 KS50IR
C100 K100IR
C250 K250IR
C800 K800IR
   
T Series
T950 T950
T100 T1000
T150 T1500
T210 T2100
T260 T2600
T350 T3500
T550 T5500
 

Table 2
 
Code Adapter Nominal Height
C Flat gasket 272 mm (10.7 in)
 

Table 3
 
Code Nominal Diameter Number of Sheets Area
232 287 mm (12 in) 32 1.8 m2 (19.4 ft2)
440 410 mm (16 in) 40 5 m2 (54 ft2)
 

Alternative module dimensions are available on request.


Table 4
 
Code O-ring Seal Options
S Silicone (standard)
E EPDM
 

Seal materials meet FDA requirements for food contact use detailed in 21 CFR Section 177.2600. Alternative materials are available on request.


Table 5
 
Code Cage Assembly
P Polypropylene
 


SUPRAdisc II HP Range

This is a guide to the Part Numbering structure only. For specific options, please contact Pall

Part Number:
200 [Table 1] D [Table 2] [Table 3] [Table 4] [Table 5] [Table 6] W

Example Part Number: 200 X D L6 C 420 S P W

See bold reference codes in tables


Table 1
 
Code O-ring Seal Options
X K Series
C IR Series
 

Table 2
 
Code Sheet Media Combination
Top Sheet
Prefilter
Bottom Sheet
Fine Filter
K Series    
O7 K900 K150
O8 K900 K200
N6 K800 K100
N7 K800 K150
M5 K700 KS80
M6 K700 K100
L4 K300 KS50
L5 K300 KS80
L6 K300 K100
L7 K300 K150
K3 K250 EK
K4 K250 KS50
H2 K200 EK1
H3 K200 EK
H5 K200 KS80
G1 K150 EKS
G2 K150 EK1
G5 K150 KS80
F1 K100 EKS
F3 K100 EK
IR Series    
N4 K800IR KS50IR
N6 K800IR K100IR
N9 K800IR K250IR
K4 K250IR KS50IR
K6 K250IR K100IR
F4 K100IR KS50IR
 

For alternative combinations, contact Pall.


Table 3
 
Code Adapter Nominal Height
C Flat gasket 272 mm (10.7 in)
 

Table 4
 
Code Nominal Diameter Number of Double Layers Area
420 410 mm (16 in) 20 2.5 m2 (27 ft2)
 

Alternative module dimensions are available on request.


Table 5
 
Code O-ring Seal Options
S Silicone (standard)
E EPDM
 

Seal materials meet FDA requirements for food contact use detailed in 21 CFR Section 177.2600. Alternative materials are available on request.


Table 6
 
Code Cage Assembly
P Polypropylene
 
Application
Preclarification, Clarification, Particle Filtration, Fine Filtration, Polish Filtration, Polishing Filtration, Chill Haze Removal/Stabilization, Polishing Filtration/Colloid Removal