MEMBRAFLOW - Solutions
Membrane technology, filtration technology
& plant engineering
- Improve quality
- Reduce costs
- Increase efficiency
- Promoting sustainability
Solid-liquid separation with ceramic membranes
Membrane filter technology is at the heart of modern process engineering and offers a number of advantages over traditional separation methods. It enables advanced and highly efficient separation of solids and liquids at the molecular level, resulting in improved product quality, increased efficiency and significant cost savings. Thanks to its versatility and environmental compatibility, membrane technology is a future-oriented solution for numerous industries.
Our conviction that ceramic membranes would break new ground in the world of filtration led to the founding of MEMBRAFLOW.
With countless systems installed worldwide at our satisfied customers, reality confirms that this thinking was right. Based on our vision, we are able to carry out filtration tests either at the customer's premises or in our filtration test center. The results of the tests carried out serve as the basis for the design and engineering of the filtration system. Our employees' extensive knowledge of chemistry and process engineering is used to offer our customers tailor-made solutions.
Advantages of MEMBRAFLOW membrane technology
MEMBRAFLOW systems that use ceramic filters offer a number of advantages.
They are particularly suitable for processes that require precise separation of dissolved and solid substances from liquids.
High efficiency & accuracy
Filtration with ceramic membranes enables very precise separation of molecules and particles down to nanometric sizes, which is essential for many industrial processes.
Energy efficiency
Compared to other separation processes, such as reverse osmosis, membrane filtration requires less energy, which leads to a significant reduction in operating costs.
Improving product quality
The precise separation of unwanted substances can significantly improve the quality of the end product (filtrate), which is particularly advantageous in the food and pharmaceutical industries.
Environmental friendliness
Filtration with ceramic membranes reduces the need for chemical separation processes, which has a positive impact on the environment.
Versatility
Systems with ceramic membranes can be used in a wide range of industries. From water and wastewater treatment to food and beverage production, pharmaceuticals and chemicals.
Cost reduction
The efficient separation and reduced energy consumption of filtration with ceramic membranes lead to lower operating costs. Materials separated in the process can also be recycled, which further increases the potential for cost reductions.
Scalability
Systems that use membrane technology can be easily scaled to cope with increasing production volumes or to respond to changing process requirements.
Longevity & lower maintenance costs
Ceramic elements are robust and durable, resulting in lower maintenance costs and longer replacement intervals.
Increasing security
By removing impurities and contaminants, membrane filtration contributes to a safer production environment and higher safety standards.
Promoting sustainability
The technology supports sustainable production processes by minimizing waste and making efficient use of resources.
Water & wastewater treatment
Solutions for municipalities & industry:
For municipal water management and industrial operations, we offer efficient water and wastewater treatment solutions that ensure drinking water quality and treat industrial wastewater so that it can be disposed of or reused in an environmentally friendly manner.
Food & Beverages
Quality & safety for your products:
In the food and beverage industry, our membrane filtration systems ensure the removal of unwanted microorganisms and particles, which extends the shelf life and increases the quality of products such as wine, beer and juices.
Pharmaceuticals
Purity & precision for medical applications:
We supply customized solutions for the pharmaceutical industry that meet the highest standards of purity and safety. Our technologies support the production of sterile and contamination-free solutions.
Chemistry
Efficient & safe processes:
We develop systems for the chemical industry that enable the safe and efficient separation of chemical components, recover catalysts and optimize production processes.
Cross-flow filtration
The MEMBRAFLOW filtration process
Membrane technology is a mechanical process for separating gaseous or liquid mixtures and solutions using multilayer membranes. Depending on the type of membrane used, separation results can be achieved for different requirements. The purely physical separation of mixtures of substances and solutions makes this type of filtration particularly interesting from an economic and ecological point of view.
MEMBRAFLOW systems work according to the principle of cross-flow filtration. In contrast to conventional filtration methods, the filtrate flows tangentially to the filter surface. This creates a turbulent flow on the membrane surface. The resulting shear forces prevent the formation of a coating (cake) on the filter surface and clean it during the process to ensure a constant flow rate.
Functionality
The structure of a membrane comprises a supporting body with a microporous structure to which a membrane layer is applied. This membrane layer determines the filtration properties due to its fineness. The liquid mixture to be cleaned flows along the membrane layer in a closed circuit. The membrane retains particles larger than the separating layer and the clarified medium penetrates the membrane layer and is drawn off.
Different geometries are used depending on the requirements. The membrane elements are divided into mono- and multi-channel elements. The diameters of the mono-channels primarily installed in test systems are generally between 6 and 16 millimetres. In multi-channel elements , several channels with diameters of 1.5 to 8 millimetres are arranged next to each other in a membrane element. Depending on the geometry and outer diameter of the ceramic element, this results in different membrane areas per membrane element.
Classification of membrane separation processes
Depending on the size of the particles to be separated, membrane technology distinguishes between the separation processes microfiltration, ultrafiltration, nanofiltration and reverse osmosis. Depending on the customer's requirements for the purity of the filtrate, these separation processes can be combined, as shown in the diagram below, or individually integrated into the design of the MEMBRAFLOW system.
Micro-filtration
Ultra-filtration
Nano-filtration
Membrane materials
Both polymeric plastics and ceramic materials are used as diaphragm materials. Ceramic materials in particular are often preferred to polymeric plastic diaphragms due to their durability and excellent mechanical and chemical properties. This is why MEMBRAFLOW relies exclusively on ceramic diaphragms.
Test trials & analytics
For products whose filtration properties are not yet known, there are various options for carrying out tests. Laboratory systems are available for testing the filterability of a product. After successful test trials, further filtration cycles can be carried out on a pilot plant. The results obtained are then incorporated into the corresponding design of an industrial plant.
Test trials can be carried out directly at our customers' premises or in our test center. Our test center has various systems for this purpose, which can be made available to our customers on a rental basis if required.
In the case of test runs directly at our customers' premises, there is first a training phase during which the first filtration cycles can run simultaneously. Once training has been completed, the system is operated by the customer for an agreed period of time.
"The results of pilot tests form the basis for the planning of industrial filtration systems"
Planning
Construction
Engineering
The planning and design of process engineering systems is one of our particular strengths. Thanks to our employees' many years of experience in a wide range of applications, we have comprehensive knowledge of the entire field of process engineering.
We offer our customers planning and engineering services, whether as a pure service or as part of the delivery of a turnkey process plant.
The basic procedure for providing these services follows a standardized process. Once the initial concept has been developed and approved by the customer, the detailed planning phase begins. This involves specifying the equipment parts and defining the delivery limits. This also includes the clarification of interfaces in order to be able to integrate any of the customer's existing systems. To ensure successful implementation, all communication takes place in close cooperation with the customer.
By outsourcing these services to us, our customers benefit above all from our many years of experience in the areas of planning, design and engineering.
Planning
Rough concept planning is carried out, taking into account the general conditions. Both a process flow chart and an initial rough layout are created and submitted to the customer for approval. After approval, the process switches to the detailed planning phase.
Construction
In the first step of the detailed planning phase, a 3D model of the process plant is created. This step goes hand in hand with the creation of a detailed floor plan in which the delivery limits are specified. After detailed discussion, coordination and approval by the customer, we move on to the next phase.
Engineering
In the next step, a detailed flow diagram is created and the plant equipment is specified. The design drawings, including the parts lists, are created on the basis of the 3D model. Based on these drawings, the manufacturing process of the system can begin.
Plant production & design
In order to guarantee our customers the highest quality standards, we work together with leading local companies in the field of system production. This gives us access to state-of-the-art warehouses and production halls as well as highly qualified personnel.
We manufacture both systems we have planned ourselves and those designed by the customer. One of our special features is the complete pre-assembly and comprehensive functional testing of all systems at our partners' premises. After successful functional testing, the system is dismantled and delivered to our customer. This means that the time required for assembly and commissioning can be reduced to a minimum, which minimizes production downtimes and thus saves costs and resources for the customer.
Once the equipment and systems have been delivered, they are commissioned, instructed and handed over to the end customer on the basis of a certificate.
Design procedure
For products with unknown filtration properties, we offer various test options.
A laboratory system is available for basic testing of filterability. After successful test runs, further filtration cycles can be carried out on a pilot plant. The results obtained are then integrated into the design of a corresponding industrial plant.
Our customers can use both laboratory and pilot systems on a rental basis.
Laboratory facility
Pilot plant
Industrial plant
After Sales & Service
Regular and recurring inspections can prevent unplanned downtime of equipment and systems. Proactive maintenance identifies potential weak points so that they can be eliminated before problems occur. This in turn reduces machine downtimes to a minimum or largely prevents them.
Unforeseen damage that can cause production downtime often inevitably leads to high downtime costs. Not only do sales and earnings losses have to be considered, but dissatisfied customers are also often an undesirable effect.
We therefore support you by carrying out proactive maintenance measures. Our customers can choose between various support concepts, ranging from one-off inspections to periodic recurring maintenance measures at regular intervals. Our service technicians are available either on site or via remote maintenance connections.
Our employees are trained to recognize potential weak points at an early stage. Our customers are informed directly in this regard and presented with proposed solutions. The best option is identified together and implemented by us. On completion of our inspections, our customers receive a detailed report with the results of the maintenance and information on the condition of the system.
Increased efficiency, cost reduction & sustainability
Choosing MEMBRAFLOW brings with it a number of benefits that directly impact the performance, profitability and sustainability of your business. Here are the key benefits you can expect when you choose our membrane filter technology and plant engineering solutions:
Increased efficiency
Our advanced solutions are specifically designed to optimize your production processes. By implementing our membrane filter technology and automated plant systems, you can achieve a significant increase in operational efficiency. This leads to faster throughput times and increased production capacity without compromising the quality of your products.
Cost savings
Optimizing your processes with our technologies not only leads to an increase in efficiency, but also to significant cost savings. Reduced energy consumption, minimized use of resources and lower maintenance costs are just some of the financial benefits you can realize by working with Membraflow.
Sustainability gains
In today's world, it is more important than ever to act in an environmentally conscious manner and implement sustainable production methods. Membraflow helps you to follow this path. Our technologies reduce the ecological footprint of your production through more efficient use of resources and lower emissions. This not only helps you to protect the environment, but also improves your corporate image.
Adaptability & future-proofing
The world is constantly changing, and with it the demands on production processes. MEMBRAFLOW ensures that your systems not only meet current challenges, but also those of the future. Our solutions are flexible and scalable so that they can grow with your company and adapt to new situations.
Competent support & service
As a MEMBRAFLOW customer, you benefit not only from our technical solutions, but also from our comprehensive range of services. From consulting, planning and implementation to ongoing maintenance and support, we are at your side with our expertise. Our aim is to build a long-term partnership with you in which your success is our driving force.
By choosing MEMBRAFLOW, you are choosing a partner that focuses on quality, efficiency, sustainability and customer satisfaction. Let's work together to shape the future of your company.
Technologies & Solutions
Ceramic filters & more: Our technologies explained
- Our range of filtration technology solutions enables precise separation by size and molecular weight.
- We also offer filtration technology for fully integrated solutions.
Individual solutions: Adapted to your needs
- Each system is specially designed to meet the requirements of our customers.
- From the initial consultation to the final implementation, we work closely with you to develop a solution that meets your specific process requirements.
FAQ - Frequently asked questions
In cross-flow filtration, the fluid to be filtered is passed tangentially over the filter surface, enabling continuous cleaning of the filter membrane. Part of the fluid flow is directed through the membrane, while the rest flows tangentially along the membrane and carries separated particles or substances with it.
Cross-flow filtration enables continuous filtration without clogging the filter membrane, resulting in a longer service life and higher yields. In addition, particles of different sizes and shapes can be separated efficiently without any loss of product quality.
Cross-flow filtration is suitable for a wide range of liquids, including suspensions, cell cultures, food and beverage products, wastewater and industrial waste.
The selection of the right system depends on various factors, including the type of material to be filtered, the desired filtration performance, the operating conditions and the product quality requirements. A thorough analysis of the application requirements and advice from MEMBRAFLOW is therefore advisable.
Membranes are the central element in a cross-flow filtration system and can be made of different materials such as polymers, ceramics or metals. The selection of the right membrane material depends on the type of material to be filtered and the operating conditions.
These parameters influence the filtration performance, yield and product quality. A higher pressure can increase the filtration rate, while an optimum flow rate and temperature are crucial for efficient filtration.
Common cleaning methods include backwashing, chemical cleaning and automatic cleaning cycles, which help to remove deposits on the membrane surface and maintain filter performance.
Membrane life depends on several factors, including the type of material being filtered, operating conditions and proper maintenance. As a rule, membranes can last several months to years before they need to be serviced or replaced.
Cross-flow filtration is used in a wide range of industries, including the food and beverage industry, the pharmaceutical industry, biotechnology, the chemical industry, the oil and gas industry and waste water and environmental technology.
Ceramic membranes offer several advantages over conventional polymer membranes. They are chemically and thermally more stable, which enables a wider range of applications. They are also more robust and less prone to clogging, resulting in longer service life and lower maintenance costs. Ceramic membranes also offer greater separation efficiency and can separate particles of different sizes more efficiently. Their long service life and high retention efficiency make them a preferred choice for demanding filtration applications.