You don’t always see it. It is not always quantified. But it always pays.
In every industrial system, from a packaging line to a chemical processing plant, filtration quality has a direct impact on efficiency, maintenance and safety. And yet, it remains one of the most undervalued aspects in many facilities.
At Sistemiza we see it every week: poorly selected filters, postponed maintenance, oversized solutions or – even worse – products without certification that end up being more expensive than it seemed. Because when we talk about leakage, the mistake is not paid for at the beginning… it is paid later.
The problem is not the filter, it is what does not filter
A catastrophe is not necessary. An accumulation of small inefficiencies is enough:
- A pressure drop that forces pumps to work harder than necessary
- A poorly purified fluid that degrades valves, seals and sensors
- A cartridge that does not retain what was promised, and lets particles or moisture pass through
- A system that consumes more energy due to solids dragging
On the surface, everything is still working. But underneath, the system begins to degrade. And when the unforeseen stop arrives, it is already late.
Where do the costs appear?
The most obvious are those that can be measured: replacement of components, hours of intervention, non-conforming product. But there are others that are rarely reflected in the balance sheet:
- Higher electricity consumption due to lack of hydraulic efficiency
- Increase in purges and discharges due to the need for cleaning
- Loss of traceability due to contamination
- Delays due to last-minute adjustments
That’s why we include more than just a filter in every filtration proposal we deliver: we include a system vision.
Real cases, real consequences
In a biofuel treatment plant, the choice of a generic cartridge for a coalescing separator led to a 40% drop in efficiency in the recovery of the final product. Estimated cost in 3 months: more than €18,000 in losses due to water dragging and extra maintenance.
In a food-grade compressed air line, a non-ISO testing system allowed moisture to enter the control valves. The result: two weeks of intermittent shutdowns, a complete overhaul of the control system, and deterioration of internal insulation.
In both cases, the filter was there. But it was not the right filter.
Cheap costs more
The big mistake is to think that all filters work. That it is enough to look at the size or the flow. But this is not the case.
Our synthetic basket filters, for example, are designed for applications where separation efficiency goes up to 0.01 microns, with textile filter media, fiberglass, and structural support compatible with aggressive fluids. We test them according to ISO12500-3 (solid particle efficiency) and ISO12500-4 (coalescing water), as well as oil tests according to ISO 16889 and bubble point according to ISO 2942. They are rigorously manufactured filters, designed to last, not to fill a line in an Excel sheet.
We work with standards that other brands do not offer, and we collaborate with well-known manufacturers such as Cleanova, Airpel, Dollinger, Allied Filters and Micronics on a per-application basis.
From our in-line solutions for filtration of aggressive liquids, to self-cleaning systems with Bernoulli technology, backflush or rotary scrapers, including air filters, coalescing or bags.
Why do filter systems fail?
We could say that there are three main causes:
- Incorrect system selection, due to ignorance of fluid behavior, inlet conditions, presence of solids, or regulatory requirements.
- Low-quality components, without certification or traceability, that lose efficiency over time and fail just when they are needed most.
- Absence of scheduled maintenance, which turns a protection system into a blind spot in the process.
But beyond that, there is a common cause: lack of process culture. Leakage is seen as an accessory, not critical infrastructure. Until something goes wrong.
Investing in filtration is investing in continuity
The solution is not to spend more. It’s designing better.
At Sistemiza, each filtration system is based on a comprehensive analysis of the process. We consider the type of fluid, operating pressure and temperature, expected contaminants, material compatibility, and service conditions.
From a water line for emergency showers – such as the ones we are currently developing – to a multi-stage filtration network for a hydraulic oil loop, the key is to understand that filtering is deciding: deciding to protect, deciding to optimize, deciding to guarantee.
Conclusion: everything starts with a good filter
There is no process without impurities. But there are ways to stop them before they cause problems.
And that’s where design, engineering and expertise come in.
A good leak is one that you don’t notice is there… because everything flows. And when everything flows, production doesn’t stop, equipment lasts longer, and costs are reduced.
That’s why, in every project, we ask ourselves the same question:
Are we filtering enough… or just enough?