Pre-Paint Dirt Removal - Case Study 3

Company August 2009
Application Automotive Body Paint � North America
Project description Existing paint pre-finish filter was not functioning. Filter deemed "self-cleaning" was clogging. High turbidity and conductivity rates indicated high levels of after-filter particulate. Needed to reduce the costs of operating the filter while improving the results.
Filter K-600 [600 gpm]
Micron requirement 25 microns nominal
Location Pre-rinse
Flow 500 gpm
Units/hour 48.9
Units 440/9 hour shift
Media advance in one hour 9 Inches
Specifications, Drawings & Photos Click to View

One sq. ft. of 25 micron clean media weighs 2.5 grams

One Sq. ft. of 25 micron dirty media weighs 20.5 grams

Weight of Dirt per sq. ft. 18.0 grams

K-600 filter media width: 6 Sq. Ft.

Total weight of 6 Sq. Ft. of dirty media: 108 grams

Less 25% to account for 9" media advancement 27 grams Less

Total dirt removed in one hour 81 grams

48.8 units per hour divided by 81 grams 1.7 grams per unit

Deluge proposal:

  • More dirt at the deluge
  • Smaller tank at the deluge
  • More tank turn over for the deluge
  • The proposal was to install a 150 gpm unit in Deluge to replace the abandoned Red Filter.
  • The calculations for the existing filter show a removal rate of 1.7 grams
  • The new K factor Filter will remove at least .6 grams per unit.
  • Due to the higher volume of dirt the expectation will be 1.0 grams per unit or greater.
  • Get the dirt to the filter and it will remove more.

Budget costs

Cost for the filter $20,000

Cost for the installation $5,000

Total cost $25,000


  • The K Factor Filter will remove all the dirt above 25 micron and lower.
  • The K Factor Filter will remove:
    • Kevlar
    • Sealer
    • Metal
    • Sand
    • Grit
    • All the dirt regardless of weight

The K Factor Filter is a cost effective way to reduce Dirt Per Unit (DPU)

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