Industrial & Process Air Filtration

In industrial manufacturing, air filtration differs fundamentally from conventional building HVAC applications. Process air often has to be treated under demanding conditions: high dust concentrations, aggressive media, oil mist, solvent vapors, or temperatures far beyond the normal operating limits of conventional filters. At the same time, occupational safety regulations and emission limits place high demands on exhaust air filtration. Anyone using standard filters in such environments risks short service life, frequent replacements, and, in the worst case, production downtime.

HS-Luftfilterbau has been developing and manufacturing filtration solutions for a wide variety of industrial requirements at its Kiel site for more than 50 years – from robust coarse dust prefilters and self-supporting process pocket filters to high-performance compact filters, high-temperature HEPA filters, and cleanable HEPA filters for ATEX zones. Combined with modular housing systems and mobile filter units, this makes it possible to implement filtration systems that are precisely tailored to the respective production environment.

Process Air vs. Room Air – Different Requirements

In building ventilation, the primary concern is the filtration of outdoor air with moderate dust concentrations in accordance with ISO 16890 and VDI 6022. In industrial process air filtration, the conditions are different: the supply air for paint booths, surface treatment systems, or test benches often has to achieve high purity levels, while at the same time the exhaust air from welding, soldering, or grinding processes contains concentrations of particles, aerosols, or gases that are many times higher than those found in building ventilation systems.

The result: industrial filters must not only provide high filtration efficiency, but also be mechanically robust, temperature-resistant, and chemically resistant. In potentially explosive areas, ATEX requirements for electrostatic dissipation must also be met. HS-Luftfilterbau offers suitable solutions for each of these requirements from its own development and production.

Standards and Regulations

ISO 16890 and EN 1822

The classification of prefilters and fine dust filters is based on ISO 16890 (classes ePM10, ePM2.5, ePM1), while high-efficiency particulate filters are classified according to EN 1822 / ISO 29463 (classes E10 to U17). In practice, a two-stage concept is often used in industrial supply air systems: prefilters of class ePM10 or ePM2.5, followed by fine dust or particulate air filters depending on the purity requirements of the process.

Occupational Safety and Emission Control

The Technical Rules for Hazardous Substances (TRGS 900) define workplace exposure limits for dusts and aerosols that must be complied with by means of appropriate exhaust air filtration. TA Luft regulates emission limits for industrial plants. Both sets of regulations largely determine the requirements for exhaust air filtration in production halls, paint systems, and metalworking operations.

ATEX and Explosion Protection

In areas where flammable dusts or gases may occur, the ATEX Directive 2014/34/EU and the German Ordinance on Industrial Safety and Health apply. Filters in these zones must be able to safely dissipate electrostatic charges. HS-Luftfilterbau’s HS-Strongshield filter technology provides a dedicated solution for this: the filter medium is electrically conductive on the dust-laden air side, preventing the formation of ignitable potentials on the filter surface.

Filtration Concepts for Industrial Applications

Supply Air Filtration for Sensitive Production Processes

Paint booths, surface treatment systems, and coating processes require particle-free supply air in order to avoid inclusions, defects, and rejects. Depending on the requirements, pocket filters of classes ePM2.5 or ePM1, compact filters such as the HS-Makro F, or, for the highest requirements, EPA/HEPA filters are used. For turbomachinery and surface technology, HS-Luftfilterbau offers the HS-Pak 55 Extreme and HS-Pak 65 Extreme, self-supporting welded process pocket filters that ensure minimal operating pressure and maximum product safety even with varying air volumes.

Exhaust Air Filtration and Emission Control

Welding and soldering fumes, grinding dust, paint mist residues, and other production emissions must be filtered before being released into the environment. HS-Luftfilterbau offers multi-stage concepts that combine particulate filters with activated carbon filters to remove both particulate and gaseous contaminants. Special HS combination filter cells are available for capturing and filtering welding and soldering fumes, combining particulate filtration and gas adsorption in a single element.

High-Temperature Filtration

In drying processes, furnace exhaust air, hardening shops, and thermal treatment processes, operating temperatures extend far beyond the limits of conventional filters. HS-Luftfilterbau manufactures high-temperature particulate air filters based on the HS-Mikro S series with aluminum separator technology, which, depending on the design, can be operated up to 120 °C or up to 250 °C – even at full humidity up to 100% RH. These filters are individually tested according to EN 1822 and are available in classes E11 to U15.

ATEX-Compliant Safety Filtration

The HS-Strongshield filter technology was developed specifically for demanding processes with particular risks and hazard potential. The filter medium is reinforced on both sides with robust protective polyester layers and achieves a media tear strength up to 400% higher than that of conventional filters. HS-Strongshield filters are designed for compressed-air cleaning up to 6 bar, allow up to 10,000 cleaning cycles, and offer maximum safety in filter classes up to EN 1822 H14, even in ATEX areas.

Oil Mist and Emulsion Mist Separation

CNC machining, grinding, hardening, and pressing generate oil mist and emulsion mist that affect machines, workpieces, and the air in the production hall. The HS-Fogdrain is a self-draining oil mist filter that fits as a replacement filter in Absolent-compatible systems (ODF 1000/2000) and offers high holding capacity with low pressure drop.

Typical Applications

• Automotive and supplier industry: Supply air filtration for paint systems, body construction, and final assembly. Exhaust air filtration for welding and bonding processes.
• Surface technology and coating: High-purity supply air for electroplating, powder coating, anodizing, and wet painting. Process pocket filters for spray booths.
• Metalworking: Oil mist and emulsion mist separation on CNC machines, grinding systems, and hardening plants. Welding fume filtration in production halls.
• Chemical and process industry: Filtration of aggressive media, acid vapors, and solvent mist. Activated carbon filters for the removal of VOC, H₂S, SO₂, and formaldehyde.
• Electronics and optics: Cleanroom-adjacent supply air filtration for assembly, soldering, and mounting areas. HEPA filters for test benches and measuring laboratories.
• Textile and wood processing: Coarse dust and fiber filtration in production halls. Exhaust air filtration to comply with emission limits according to TA Luft.

Housings, Mobile Systems, and Custom Solutions

The modular HS-Vario CAT duct housing system made of aluminum profiles and galvanized sheet steel is the versatile basis for industrial filtration solutions. Thanks to its modular concept, HS-Vario CAT can be configured from a single-stage workplace extraction system to a multi-stage complete solution – typical applications range from odor and grease post-filtration in the food service industry to oil mist extraction, exhaust air filtration in VOC-contaminated processes, and supply air filtration for production tasks. HS-Vario CAT is designed for particulate filters up to class ePM1 95%. Both housing systems – HS-Vario CAT and HS-Solid CAT – can be equipped with activated carbon filters such as HS-AKP 26 or HS-Carbo Pak and, if required, supplied as ready-to-operate units with pre-installed controllable fans.

For higher filter classes – especially EPA and HEPA filters from EN 1822 E10 upward – the HS-Solid CAT housing range made of welded stainless steel is available. HS-Solid CAT housings provide the necessary stability and leak-tightness for high-efficiency particulate filter stages and are also suitable for corrosive environments, safety applications, and processes with increased hygiene requirements.

For temporary applications – such as refurbishment work, emergency extraction, or during conversion phases – HS-Luftfilterbau offers mobile filter units supplied ready to plug in with all accessories and enabling particulate, gas, or combined filtration depending on the configuration.

Maintenance and Condition Monitoring

In industrial systems with high dust loads, filter service lives are shorter than in building ventilation systems. This makes systematic differential pressure monitoring across all filter stages all the more important. HS-Luftfilterbau offers suitable differential pressure gauges and pressure sensors as accessories, which can be integrated into all housing systems. Cleanable HS-Strongshield filters with up to 10,000 cleaning cycles significantly reduce filter consumption in suitable applications and lower operating costs.

Your Advantages with HS-Luftfilterbau

• Broad product range for every requirement: From coarse dust mats and self-supporting process pocket filters to high-performance compact filters, high-temperature HEPA filters, and ATEX-compliant safety filters – all from our own development and manufacturing in Kiel.
• HS-Strongshield safety technology: Media tear strength up to 400% above standard, electrostatically dissipative, cleanable up to 6 bar – for processes with particular risks and hazard potential.
• High-temperature particulate air filters up to 250 °C: HS-Mikro S-HT separator design with individual EN 1822 testing, suitable for dryers, furnace exhaust air, and thermal processes at full humidity.
• Modular housings and mobile filter units: HS-Vario CAT for filter stages up to ePM1 95%, HS-Solid CAT for HEPA classes and corrosive environments – both optionally with pre-installed fans as ready-to-operate units. Mobile filter units for temporary applications.
• More than 50 years of industrial experience: In-house testing facilities according to ISO 16890 & EN 1822, special dimensions, and customer-specific solutions from our own manufacturing – from individual filters to turnkey systems.

Are you looking for a filtration solution for your production process, a paint system, or an ATEX area? Our engineers support you with the design process – from the concept phase and sampling through to series supply. Contact us for individual consultation and a project-specific quotation.