Recently, we partnered with a customer specializing in the production of small filter cartridges, providing them with customized filter testing equipment that successfully helped them address quality issues in mass production.
Background and Challenges
This customer primarily produces various types of filter cartridges for robotic vacuum cleaners and vacuum cleaners. While their manufacturing process had improved over time and their initial product deliveries were well-received, problems arose as order volumes increased and mass production began. The customer noticed a significant drop in product yield, especially with rectangular filter cartridges, where the pass rate was far below expectations. This resulted in numerous returns, severely impacting their production efficiency and reputation.
Their end customers had clearly stipulated that the filtration efficiency of the products must meet a minimum standard of 90%, with factory test reports provided as quality assurance. Faced with this strict requirement, the customer found themselves in a difficult position, as their traditional testing methods could no longer meet the high-quality standards. They urgently sought reliable testing equipment to ensure the stability of every batch of products.
Customized Solution
After evaluating several suppliers, the customer found our company, **SCINCE**, through an online platform. Our filter testing equipment is capable of accurately measuring filtration efficiency and resistance, and it can be customized with special fixtures to test various filter shapes. Understanding the customer’s production needs, we quickly developed a tailored solution that included multiple fixtures for their diverse product range, effectively addressing the challenges of testing different filter types.
Identifying and Resolving Issues
Once the equipment was delivered, our technical team assisted with installation and calibration, followed by on-site testing of the customer’s products. The test results showed that while the round filter cartridges met the expected standards, the rectangular cartridges did not perform well. Their filtration efficiency ranged from 60% to 70%, with a resistance of about 40 Pa, which was far below the required 90% efficiency standard.
In collaboration with the customer’s production team, our engineers conducted a thorough analysis using precise data from the testing equipment. We quickly identified the root of the problem: issues such as poor sealing, uneven gasket placement, and filter deformation during production were causing leakage in the rectangular filters, drastically reducing their filtration efficiency.
This testing process made the customer realize that relying solely on high-quality raw materials and basic production procedures was not enough. Effective quality control required more advanced testing methods and improvements in the production process, especially in the sealing phase. Our equipment not only helped them quickly identify potential issues but also prompted them to re-evaluate their entire production workflow, focusing on better control of the sealing process.
Results and Impact
This collaboration provided the customer with more than just testing equipment support; it led to an overall enhancement in their production quality management. By refining the sealing process and addressing production details, they gradually increased the pass rate of their rectangular filter cartridges, ensuring that each batch met the high standards of their end customers.
This case once again highlights the critical role that testing equipment plays in quality control. Our equipment helped the customer swiftly identify and resolve potential manufacturing defects, avoiding greater financial losses and preventing a trust crisis with their customers. For any manufacturing company, using qualified materials, fine-tuned production techniques, and efficient testing methods are essential to ensuring product quality. We are proud to have supported this customer through a difficult period and to have contributed to their long-term success.
At SCPUR, we remain committed to providing accurate and reliable testing equipment, helping customers continuously improve their product quality and strengthen their competitive edge in the market.
