baylor business value analysis 2020 seller scenario · baylor business value analysis 2020 . seller...

Baylor Business Value Analysis 2020 Seller Scenario

Overview

You work for 3M, a major Fortune 500 company that manufactures, markets and sells products that improve lives. 3M is organized into five different business groups: Consumer, Electronics and Energy, Health Care, Industrial, and Safety and Graphics. Working in the Separations Purification and Sciences Division (SPSD), which is in the Healthcare Care Business Group (HCBG), you are a highly accomplished sales professional selling SPSD’s general line of filtration products directly to Automotive Manufacturers. Prospective Customer: Best Car Company

The Best Car Company (BCC) entered the US car manufacturing market 10 year ago. In 2017, the company launched a new line of cars with custom paint color schemes involving high gloss paint. Sales of these cars with the new paint schemes exceeded all forecasted sales. As a result, the Best Car Company has maxed out its production schedule due to the extra time required to paint these cars. BCC produces approximately 200,000 cars annually with total sales of $4B. This new line of cars represents 80% of BCC’s overall volume. Based on experience working with other manufacturers, you know there are three main challenges when painting new cars:

1. Defects in paint caused by “dirt” defects 2. Service life (throughput) of commonly used bag filters 3. Labor needed to change filters

Your Product

3M launched a new line of filters (called the DF Series) with a unique Dual Flow design that fit directly into the current filter assemblies used by BCC painting department. For BCC to adopt your 3M filter product, they would not need to make any changes in their production line.

You have had great success within the automotive paint industry with this new product. At the National Automotive Supply Trade Show last month, you met Dave Rogers (Head Paint Engineer) from the Best Car Company. You had a conversation with Dave as he shared about the great success of their new cars. Dave reiterated how their new paint schemes are one of the main reasons for the success and that he was even surprised how well this new paint resonated with the customer. You felt you developed some rapport with Dave, and you exchanged business cards. While Dave was sharing about BCC’s current success, you learned that BCC was also dealing with slower production times due to changing paint colors during the production process. You briefly spoke about their painting process and learned enough to know that their painting equipment is compatible with 3M’s DF filtration line. In fact, you believe the new 3M DF series filters are a perfect fit for Dave and his paint team. You know how important the paint is to BCC’s success, so you expect that they will be hesitant to make changes to their paint process. The new DF series filters are a great fit for this application but do have a slightly higher initial cost compared to the traditional bag filters. When comparing to bag filters, the total annual cost of the DF series filter is much less when you factor in the benefits. DF Series Benefits

• Provides up to four times the life (throughput) than conventional bag filters • Reduces filter media rupture, contaminate by-pass, and unloading • Simplifies filter installation, removal and disposal • Reduces holdup volume by up to 67% or more (less waste of paint chemicals)

To get Dave’s attention, you decided to send him a short video, explaining the value of the 3M DF filters. You will be sending the video link to Dave in an email.

Competition Process Record a 5-minute video in F 229.01; sign up for a time on your assigned day: March 17, 8:00 – 12:30 Alley Almond Arthur Bain Baniewicz Brewer Burns Butler Chang Compton Corts Curlin Davis Davis Deian Doebbler Duncan Eckerty Fontaine Foster Fuller March 17, 12:30 – 5:00 Galbraith Ginaven Gosnell Greene Haan Hardin Henderson Hills Hodges Jackson Johnson Johnson Kempston Kirkland Kivnani Kresta Lemanski Lively Lyttle Maldonado Matthews March 18, 8:00 – 12:30 McClelland McKenzie Mertens Moore Morrow Myers Nessen Nunn O’Connor Owens Palermo Payne Peckinpah Pieper Rocconi Rodriguez Roper Schaff Scheibmeir Schmidt Scott March 18, 12:30 – 5:00 Shols Short Skelton Smith Smith Smith Stammen Stanton Starks Starr Strahler Vaughn Venable Wassell Whitaker Whitworth Yoos Competition Rubric 15% Introduction/Objective Compelling/ Clearly communicates the objective for the video

15% Rationale for Change Presents compelling reason to change to 3M DF Series Filter system

40% Value Presentation Presents recommended value of using 3M DF Series Filter system

10% Closing Uses strong closing (summarizes points; accomplishes goal)

20% Tone/Length (<5 min) Conveys right tone with fewest words possible (word economy)

1

Features & BenefitsUnique filter design combining a graded-porosity media with 62% greater filter surface area

■■ Longer Service Life - up to 4 times or more that of conventional felt filter bags

■■ Reduced Filter Usage - minimizes product loss, labor, disposal costs, and operator exposure

■■ Increased productivity - less down time for filter change-out

Hold-up volume reduced by 67% compared to conventional bag filters■■ Reduced product loss & related disposal costs

■■ Used element retains less fluid, making it lighter weight for easier removal

■■ Eliminates displacement balloons and associated spillage during change-out

100% downstream support of the filter element ■■ Eliminates filter rupture, contaminant bypass and unloading

■■ Allows operation to higher differential pressures before filter change-out

Superior flow characteristics ■■ Maximizes utilization of filter surface area and maintains low operating pressure drop

■■ Reduces flow per unit area (flux) for improved effluent quality

• Easily retrofits standard bag filter housings

• Provides up to four times or more life than conventional bag filters

• Reduces filter media rupture, contaminant by-pass and unloading

• Simplifies filter installation, removal, and disposal

• Reduces holdup volume by up to 67% or more

3M™ DF Series Filter SystemThe 3M™ DF series filter system is an advanced proven alternative to the use of standard bag filters. Developed using 3M's extensive depth filtration experience, the 3M DF series filter features a true graded-porosity media structure and a 62% increase in the filter surface area. Compared to conventional felt filter bags, 3M DF series filters provide:

• Up to 4 times or more the service life

• Superior contaminant reduction efficiency

• Enhanced flow per filter element

• Reduced losses associated with frequent filter change-outs (production downtime, disposal, and labor costs)

The 3M DF series filter will easily retrofit most existing bag filter housings. To take advantage of the 3M DF series system in applications where bag filter housings are currently in use, simply remove the existing bag support basket, replace it with a 3M DF series support basket, and insert the 3M DF series filter. For new installations, 3M Purification offers a full line of 3M DF series filter housings (page 5).

The 3M™ DF Series Filter System - A Unique Design The 3M DF series element is comprised of two cylinders bonded to a top plate and a lower seal plate. As shown in Figure 1, the fluid enters the top of the filter through flow channels located in the 3M DF series filter top plate. The fluid flows between the inner and outer media cylinders, and then passes through the media and support basket into the clean chamber of the filter housing.

Filter Cartridge Benefits…

...Filter Bag Economy

Figure 1. 3M™ DF Series Flow Path

3M™ DF SeriesFilter Systems

2

The 3M™ DF series design incorporates an innovative new geometry of both filter element and restrainer basket which provides 100% 3 dimensional support of the 3M DF series media. This reduces the potential for filter element rupture and the resulting gross contamination of the downstream effluent with previously reduced particles. The unique design of the 3M DF series element also reduces filter element hold-up fluid volume by 67% compared to conventional bags, minimizing worker exposure to process fluids.

3M™ DF Series Elements Provides Superior Service Life3M utilizes state-of-the-art technology to produce the 3M DF series filter element optimizing both performance and filtrate quality to ensure customer satisfaction. 3M DF series filter elements are sized to replace conventional #1 and #2 bag filters and are available in both polypropylene and polyester materials (including 21 CFR listed materials) with nominal ratings from 1 to 200 micron.

Greater Media Surface Area The 3M DF series filter design provides an increase in filter surface area of 62% when compared to commonly used #1 and #2 bag filters. This additional surface area provides the following benefits

• Low flux (flow rate per unit area): Since filter life is inversely proportional to flux, reducing the flux by 50% can achieve up to a three-fold increase in filter life. Additionally, lower flux improves the retention efficiency of the element.

• Lower initial pressure drop: This increases the time before the recommended change-out pressure is reached.

Greater Contaminant Holding Capacity 3M DF series filters are offered in a graded porosity filter media where two media layers of different porosities are combined. The result is superior contaminant holding capacity. The added capacity is achieved by reducing the larger contaminants in the first layer and the finer contaminants in the tighter, downstream layer (see Figure 2). The configurations of each nominally rated filter media have been optimized to achieve the longest service life. Media migration is reduced by thermally bonding the exterior surface of the downstream media layer.

Figure 2. 3M™ DF Series Graded Porosity MediaFl

ow

Graph 1. Service Life Comparison for 3M™ DF Series Elements and Conventional Bag filters*

0

25

50

75

100

Thro

ughp

ut (%

)

3M™ DF Series Elements Competitor F Competitor FEXCompetitor H Competitor HEX

1 micron 5 micron 10 micron 25 micron

*polyprolylene media

Superior Filter Service LifeExtensive testing, supported by field results, has demonstrated the superior life advantage achieved by 3M™ DF Series elements while obtaining superior efficiencies. As shown in Graph 1, 3M DF Series elements provide for up to 4 times the throughput compared to equivalently rated conventional bag filters (the life of the filters were measured to the same terminal differential pressure).

3M™ DF Series Filter Systems

3

3M™ DF Series Filter Elements

Simple Filter Removal - simply insert the 3M removal tool into the top plate and lift the filter from the housing.

Reduced Hold-Up Volume - a 67% reduction in hold-up volume significantly decreases lost product and disposal costs.

Easy Filter Installation - the 3M DF series filter element is a rigid cylinder that easily slides into the support basket.

Superior Sealing Collar - constructed from molded polypropylene or polyester with an advanced sealing lip that provides a dynamic spring-like seal, the 3M DF series design reduces contaminant bypass.

Support Basket - full support of the filter element ensures filter integrity even under the most demanding conditions by eliminating the potential for media stretching which can open the pore structure and allow larger particles to pass.

Thermal Side Seam - using advanced thermal sealing processes, the 3M DF Series seam reduces the problem of contaminants passing through large needle holes.

Integral Media to Plate Seal - an integral seal between the plastic components and the filter media is ensured by using state-of-the-art ultrasonic welding techniques.

Graded Porosity Media - 3M DF series media consists of 2 layers. The first layer or upstream zone is “open” to reduce the larger contaminant while the downstream zone is “tighter” to reduce the smaller contaminant. This design provides greater contaminant holding capacity and longer life than conventional single layer media.

Increased Surface Area - the unique design provides 62% more area than typical bag filters for longer life and fewer filter change-outs.

Singed Media Surface - many filter bags release fibers that end up in the filtered product. The 3M DF series filter media is thermally treated to reduce loose fibers.

The unique 3M DF Series element design- 62% greater area and a unique graded-porosity media structure provides a service life advantage of up to 4 times greater than conventional filter bags. Other features (sealing collar, media treatment, thermal seaming, ultrasonic bonding of plastic parts to media) ensure that the 3M DF series filter is unsurpassed in quality and performance.

Size Hold-Up Volume (gallons)

#2 3M DF Series 1.4

#2 Standard Bag 4.3

Size Filter Area (ft2)

#2 3M DF Series 6.7

#2 Standard Bag 4.1

4

Graph 2. 3M™ DF Series Water Flow Data*

Dimension 3M™ DF Series Elements#1 Size #2 Size

Nominal Reduction Ratings (micron) 1, 5, 10, 25, 50, 100 and 200*

Filter Diameter (inches/cm) 7/17.8

Filter Length (inches/cm) 14.3/36.3 27.8/70.6

Media Area (ft.²/m²) 3.4/0.32 6.7/0.62

Hold Up Volume per Filter (Gallons/Liters) 0.7/2.6 1.4/6.2* available in polyester only

Chemical 3M™ DF Series MaterialPolypropylene Polyester

Biological Agents Excellent Excellent

Mineral Acids Excellent Good

Organic Acids Excellent Excellent

Alkalies Excellent Poor

Oxidizing Agents Fair Fair

Organic Solvents Fair GoodThe thermal and chemical resistance data presented in this brochure is for guidance only. Factors such as duration, degree of concentration of a substance in a fluid and temperature should also be considered. Thermal and chemical resistance should also be considered when choosing all materials exposed to fluids.

Operating Conditions 3M™ DF Series Polypropylene#1 Size #2 Size

3M™ DF Series Polyester#1 Size #2 Size

Maximum Operating Temperature (°F/°C) 180/82 300/149

Maximum Recommended Flow Rate (gpm/lpm) 75/284 150/568 75/284 150/568

Maximum Forward Differential Pressure 35 psid @ 68°F (2.4 bar @ 20°C)

Recommended Change-out Differential Pressure 20 psid (1.4 bar)

Regulatory Status (see ordering guide)

CFR CompliantAll component materials of the 3M DF Series “PP” polypropylene element and “FE” polyester are listed for food contact per 21 CFR

177.1520.

3M™ DF Series Filter Specifications & Operating ParametersMaterials of ConstructionEach grade of 3M™ DF series filter is manufactured from high performance fibers selected based on extensive media performance testing. No adhesives, binders, or silicone are used in the manufacturing process. The 3M DF series filter element is available in all polypropylene lower seal and top plate construction.

Filter Element Size and Ratings Available 3M DF series elements are available in sizes and ratings to replace standard #1 and #2 filter bags as follows:

Flow Characteristics and Sizing Options Flow vs. differential pressure for a 3M DF series #2 size element and support basket in water is depicted in Graph 2. A typical filter system is often sized for an initial differential pressure of 0.5 to 1 psi (0.04 to 0.07 bar). A lower flow rate per element typically extends the life of the filter system.

3M™ DF Series Filter Element Specifications

Chemical Compatibility TableOperating Parameters by Material and Size

0.2

0

0.4

0.6

0.8

0.02

0.04

0.06

0.08

1.0

1.2

0 50 100

Diff

eren

tial P

ress

ure

(psi

d)

Diff

eren

tial P

ress

ure

(bar

)

Flow (gpm)25 75 125 150

1 & 5 micr

on

10 & 25 micron

50, 100, & 200 micron

0 100 200 300 500400Flow (lpm)

* #2 Size Element and Support Basket Pressure Drop Only, housing pressure losses are not included.


5

Size Material Connection Size/Type Maximum Flow (gpm / lpm)

Maximum Pressure & Temperature Housing Weight Basket Weight Leg Weight

#1304 or 316L S.S.

2" ANSI or DIN Flange

2" NPT or 2" BSPTr

75/284 150 psi @ 300°F*

(10.4 bar @ 149°C)

80 lb/36.3 kg 8 lb/3.6 kg4 lb/1.8 kg

#2 150/568 100 lb/45.4 kg 12 lb/5.4 kg

Size Material Connection Size/Type Maximum Flow (gpm / lpm)

Maximum Pressure & Temperature Housing Weight Basket Weight

#1304 or 316L S.S. 2" NPT

75/284 150 psi @ 300°F*

(10.4 bar @ 149°C)

44 lb/20 kg 8 lb/3.6 kg

#2 150/568 56 lb/25 kg 12 lb/5.4 kg

* Dependent upon the material of the gasket installed.

3M™ DF Series ASME Code Filter Housing Specification

3M™ DF Series DFN Filter Housing Specification

3M™ DF Series Filter Housings3M™ DF series filter housings are designed and manufactured to economically meet demanding applications. The housings are available for #1 and #2 size 3M DF series filters and are constructed from 304 or 316L stainless steel. 3M DF series ASME code housings are designed, fabricated, and "U" stamped in accordance with ASME Section VIII, Division 1 for 150 psi @ 300°F. For those applications not requiring ASME code housings, an economical "DFN" version is available. A variety of inlet/outlet connection styles are available (see specification table below). In addition, custom designs are available on request.

The 3M DF series filter housing allows the user to realize all of the benefits of the 3M DF series filter element. A positive element sealing mechanism reduces bypass of unfiltered fluid into the effluent stream. Since the 3M DF series filter element has more surface area and better flow characteristics, larger conventional bag housings can be eliminated in favor of smaller 3M DF series housings – reducing up-front capital expenditures and installation costs. In addition, the true "in-line" configuration of the inlet and outlet connections allow for installation without the additional piping and elbows required by conventional filter bag housings.

The unique flow configuration of the 3M DF series housing reduces the "dirty chamber" that is common in bag filter housings, thus reducing the potential for cross contamination of dirty fluid into the clean effluent during filter element change-out. 3M DF series housings incorporate a design that results in environmental, health, and safety benefits by allowing used 3M DF series filter element removal without the spillage of, or contact by the operator with, the process fluid.

Features & BenefitsPositive element sealing mechanism

■■ Ensures no bypass of unfiltered fluid into the effluent stream

No dirty fluid chamber■■ Reduces unfiltered fluid from contaminating the clean effluent side of the housing during filter change-out

■■ Reduces operator contact with the fluid

Inline piping configuration ■■ Significantly reduces installation time and costs

■■ Ease of piping for series or parallel installation

Excellent flow characteristics■■ Reduces capital investment since fewer filter elements are required for a given flow rate

6

3M™ DF Series ASME Code Filter Housings

Minimized Dirty Fluid Chamber - the 3M™ DF Series filter element extends to the top of the housing cover to significantly reduce the dirty fluid volume compared to conventional bag filter systems.

3 Eye Nuts - reduce the need for special tools and allows for quick and easy filter element installation and removal.

¼” NPT Connection - for easy vent valve or pressure gauge installation.

O-ring Housing Seal - to provide a positive seal between the housing and the cover when the system is in use.

Double O - ring Element Seal - seals the 3M DF series filter element to the top of the stand pipe (inlet) ensuring no by-pass.

Support Basket - full support of the filter element ensures filter integrity even under the most demanding conditions. Reduces media stretching which can open the media pores and allow larger particles to pass.

Dished Bottom - drains the clean liquid to the housing outlet for better product recovery and cleaner system operation.

Optional Legs (shown below) - adjustable legs can accommodate an inlet/outlet centerline height adjustment of up to 11 inches.

Light weight cover - remains attached to the housing and pivots open to allow easy access for filter change-out. Can be rotated for ideal pivot orientation.

304 or 316L Construction - provides compatibility with a wide range of fluids. Shot blast exterior finish improves appearance and allows for easy cleaning.

ASME Code - meets local and state design requirements for pressure vessels.

Inlet Stand Pipe - directs fluid to the top of the filter housing and inlet channels of the 3M DF Series filter element.

Available Connections - include 2” ANSI flange (shown), 2” NPT, 2” DIN flange or 2” BSPTr to satisfy most common piping requirements.

In-line Bottom Inlet & Outlet - provides easy and cost effective installation by reducing the complexity of the piping scheme. Both the inlet and outlet piping have ½” NPT connections for drains, sample ports or pressure gauge installation.


7

Filter Size

Dimensions (Inches/cm)

A BC D E

Flange Thread Max. Min. Bolt Circle

1DF1 35/89 20/5113/33.2 11.5/29.2 15/38.1 4/10.2 10.5/26.7

1DF2 63/ 60 34/87

Filter SizeDimensions (Inches/cm)

A B C D

1DFN1 29.5/74.9 40/101.612/30.5 5/12.7

1DFN2 43.75/111.1 68.25 /173

3M™ DF Series ASME Code Model Housing

3M™ DF Series DFN Model Housing

3M™ DF Series Filter Housing Dimensions

3M™ DF Series Filter Piping SystemsThe inline bottom inlet and outlet connections offer tremendous flexibility in manifolding the housings for series or parallel filtration. This concept allows for enhanced adaptability in achieving both short and long term flow and process requirements. Manifold piping systems (with and without valves) are available for installing 3M DF Series housings in duplex, triplex, and quadplex configurations. Consult factory for more details.

INLET OUTLET

A

C

D

B

Space Required to removeelement and support basket

3M™ DF Series ASME Code Model Housing 3M™ DF Series DFN Model Housing

8

3M™ DF Series Filter System AccessoriesThe following accessories are available for use with the 3M™ DF Series filter system:

Element Insertion Tool (Part # 60300-31): Constructed from 316 stainless steel, this tool facilitates insertion of 3M DF series elements into the support basket. The tool is designed with curved ends to ensure no damage is done when inserted into the element.

Element Removal Tool (Part # 74132-31): Constructed from 316 stainless steel, this tool facilitates removal of 3M DF series elements from the support basket. The tool is designed with an easy-to-grip handle and locking tabs for proper support of element.

Element Hold Down Spring (Part # 64254-31): Constructed from 316 stainless steel, this spring assembly ensures the 3M DF series element is properly seated in side entry housings to prevent fluid bypass.

Magnet Assembly (Part # 60376- 03): Constructed using 12,000 gauss strength magnets inserted into a 304/304 L stainless steel tube, this magnet assembly provides for improved capture of metallic fines from fluid streams. This assembly is designed for easy insertion and removal is fully supported when inserted into a 3M DF series element.

3M™ DF Series Ele-ment Removal Tool

3M™ DF Series Element Hold Down Spring

3M™ DF Series Magnet

3M™ DF Series Ele-ment Installation Tool

3M™ DF Series Filter ApplicationsCoatings Electrodeposition, Trade Paint, Can Coatings, Dispersions, Paper Coatings, Adhesives, Automotive Paint, Architectural Paint, Printing

Ink, Resins, Coil Coatings

Industrial Parts Washing, Pulp & Paper, Cooling Water, Ground Water, Waste Water, Hydraulic Fluids, Lubricants, Machine Tool Coolants, Transformer Oil

Chemical Acids, Chemicals, Process Water, Alcohols, Glycols, Fuels, Catalyst Recovery, Resins, Alkalines, Esters, Silicones, Aerosol Products, Mineral Oil, Waxes, Solvents

Petrochemicals Fuel Additives, Glycols, Lube Oils, Distillation, Enhanced Oil Recovery, Amines, Fuels, Injection Fluids

Food & Beverage Vegetable Oil, Syrups, Edible Oils, Soft Drinks, Wine, Spirits, Fruit Juice, Beer, Honey, High Fructose Corn Syrup, Vinegar, Liquid Sugar, Bottled Water, Gelatin, Ready to Drink Tea, Sports Drinks

Pharmaceutical Catalyst Recovery, Vitamin Extracts, Bulk Pharmaceutical Chemicals, OTC Solutions, Solvents, Active Pharmaceutical Ingredients, Carbon Reduction, Water Systems, Opthalmics, Lotions

Electronics Etching Baths, Process Water / RO Prefiltration, Photochemicals, Solvents, Printed Circuit Manufacturing

Water Treatment Cooling Water, Process Water, Well Water, Ground Water, Waste Water, RO Prefiltration


9

Existing Bag Filter Housing 3M Purification Basket Information

MFG Model # of Bags Inlet Entry3 Size Adapter Part # Basket Gasket Part #

Basket Part # (316 S.S.)

Basket Part # (316L S.S.)

Filtrek BMB 1 - 17 Side #2 N/A N/A 60382-35 N/A

FSI FS - 85 & Up 1 - 24 Side #2 N/A N/A 60382-384 N/A

FSI FSP- 40 1 Side #1 N/A N/A 60382-324 N/A

FSI FSP- 85 & up 1 - 24 Side #2 N/A N/A 60382-314 60382-39

Filtration Systems 112 1 Over the top #1 60343-31 N/A 60382-32 N/A

Filtration Systems 122 1 Over the top #2 60343-31 N/A 60382-31 60382-39

GAF/AFFCO RB(1,2, or 4) 1 - 4 Over the top #1 60339-31xx1 N/A 60382-32 N/A

GAF/AFFCO RB(1,2, or 4) L 1 - 4 Over the top #2 60339-31xx1 N/A 60382-31 60382-39

GAF/AFFCO RB1 SE 1 Side #1 N/A 60334-3x4422 60382-34 N/A

GAF/AFFCO RB1 L-SE 1 Side #2 N/A 60334-3x4422 60382-33 N/A

GAF/AFFCO RB(2-12)C2L 2 - 12 Side #2 N/A 60334-3x4422 60382-33 N/A

Hayward POLYLINE FLT 4202 1 Side #2 60362-31 N/A 60382-31 60382-39

Hayward TOPLINE TBF 0101 1 Over the top #1 N/A N/A 60382-32 N/A

Hayward TOPLINE TBF 0102 1 Over the top #2 N/A N/A 60382-31 60382-39

Hayward MAXILINE MBF 3 - 24 Side #2 N/A N/A 60382-31 60382-39

Hayward MAXILINE SEMB 3 - 24 Side #2 N/A N/A 60382-31 60382-39

Krystil Klear M88302 (OEM) 1 Side #2 60346-31 N/A 60382-31 60382-39

Krystil Klear L8815 1 Side #1 N/A N/A 60382-32 N/A

Krystil Klear L8830 1 Side #2 N/A N/A 60382-31 60382-39

Parker SB1 or 4 1 or 4 Side #1 60340-31xx1 N/A 60382-32 N/A

Parker SB1 or 4 1 or 4 Side #2 60340-31xx1 N/A 60382-31 60382-39

Rosedale 8 - 15 1 Side #1 N/A N/A 60382-36 N/A

Rosedale D8-15 (Duplex) 2 Side #1 N/A N/A 60382-36 N/A

Rosedale 8 - 30 1 Side #2 N/A N/A 60382-35 N/A

Rosedale D8-30 (Duplex) 2 Side #2 N/A N/A 60382-35 N/A

Rosedale 16 - 48 2 - 23 Side #2 N/A N/A 60382-37 N/A

Strainrite U F1-180 1 - 12 Side #2 N/A N/A 60382-31 60382-39

3M™ DF Series Filter Support Basket

3M™ DF Series Filter Support Basket Ordering Guide (contact factory for manufacturer models not listed)

3M offers a complete line of 3M™ DF series 316 stainless steel support baskets (many available in 316L SS) for use in existing bag filter housings or in the 3M DF series filter housing. The 3M DF series element utilizes a unique basket for proper element support. The 3M DF series filter basket has two concentric stainless steel cylinders to support both the inner and outer filter element sleeves. This unique design ensures media integrity and consistent effluent quality. 3M DF series baskets include the optimum combination of strength and open area to provide proper media support, excellent flow characteristics, and minimal pressure drop.

The 3M DF Series filter support basket ordering guide (below) cross references the competitive filter bag housing manufacturer and model to the correct 3M DF series support basket needed to upgrade to the 3M DF series filter element.

1 Adapter Part Number (includes gasket)

Gasket GAF/AFFCO Parker

Nitrile 60339-31GA 60340-31GA

EPR 60339-31GB 60340-31GB

Fluorocarbon 60339-31GC 60340-31GC

TEV 60339-31GD 60340-31GD

2 Basket Gasket Part Number

Gasket Part Number

Nitrile 60334-36442

EPR 60334-37442

Fluorocarbon 60334-38442

TEV 60334-394423 Hold down Spring (Part # 64254-31) required for all side entry one bag housings

4 Seal Ring & FSI installation tool (Part # 74132-31) required

10

Filter Designation Nominal Reduction Rating (Micron)

Material (Media/Plastic Components)

Element Length (inches) Connection Style

DFG - 3M DF Series

Graded-Porosity

001 - 1 µm

005 - 5 µm

010 - 10 µm

025 - 25 µm

050 - 50 µm

100 - 100 µm

200* - 200 µm

PP - Polypro/Polypro

EE - Polyester/Polyester

EP - Polyester/Polypro

FE - Polyester/Polyester**

1 - 14.3 nominal

2 - 27.8 nominal

C - Open (3M DF series Housings)

R - Closed (Standard Bag Housings)

Number Around 3M™ DF Series Size Housing Material Connection Type Support Legs Support Legs

1 - 1 Around DF1 - #1 Size

2 - #2 Size

B - 304 SS

C - 316L SS

1 - 2" ANSI Flange

2 - 2" NPT

3 - 2" DIN Flange

4 - 2" BSPTr

L - Legs*

N - No legs

GA - Nitrile**

GB - EPR

GC - Fluorocarbon

Number Around 3M™ DF Series Size Housing Material Connection Type Support Legs Support Legs

1 - 1 Around DFN1 - #1 Size

2 - #2 Size

B - 304 SS

C - 316L SS2 - 2" NPT C - Mounting Clips

GA - Nitrile

GB - EPR

GC - Fluorocarbon

3M™ DF Series Filter Element Ordering Guide

3M™ DF Series ASME Code Filter Housing Ordering Guide

3M™ DF Series DFN Filter Housing Ordering Guide

*Available in single layer polyester material (Code EE) only** 21CFR Materials, available in 1, and 5 only

*Housing Legs (when ordered separately) 98848-01 **Limits housing operating temperature to 250°F (121°C)


11

Filter Cartridge Benefits... Filter Bag Economy

3M™ DF Series Filter Accessories

3M™ DF Series Element Installation Tool Part # 60300-31

3M™ DF Series Magnet Part # 60376-03

3M™ DF Series Element Removal Tool Part # 74132-31

3M™ DF Series Element Hold Down Spring Part # 64254-31

Filter Cartridge Benefit 3M™ DF Series Element Standard Bag Filter

High Dirt Holding Capacity Yes No

Rigid construction provided by the media or additional support components (i.e. cage and core) Yes No

Installation/Removal convenience-ease of use Yes No

Predictable retention even under elevated differential pressure Yes No

Reduced hold-up volume Yes No

3M Purifi cation Inc.400 Research ParkwayMeriden, CT 06450U.S.A.Phone (800) 243-6894 (203) 237-5541Fax (203) 630-4530www.3Mpurifi cation.com

Important NoticeThe information described in this literature is accurate to the best of our knowledge. A variety of factors, however, can affect the performance of the Product(s) in a particular application, some of which are uniquely within your knowledge and control. INFORMATION IS SUPPLIED UPON THE CONDITION THAT THE PERSONS RECEIVING THE SAME WILL MAKE THEIR OWN DETERMINATION AS TO ITS SUITABILITY FOR THEIR USE. IN NO EVENT WILL 3M PURIFICATION INC. BE RESPONSIBLE FOR DAMAGES OF ANY NATURE WHATSOEVER RESULTING FROM THE USE OF OR RELIANCE UPON INFORMATION.

It is your responsibility to determine if additional testing or information is required and if this product is fi t for a particular purpose and suitable in your specifi c application.

3M PURIFICATION INC. MAKES NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH INFORMATION REFERS.

Limitation of Liability3M Purifi cation Inc. will not be liable for any loss or damage arising from the use of the Product(s), whether direct, indirect, special, incidental, or consequential, regardless of the legal theory asserted, including warranty, contract, negligence or strict liability. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

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Filtration System Improves Performance of Pre-Treatment and Electrodeposition Stages of an Automotive Assembly Plant

By Pauline Paul, Sales Application Support Specialist, Scientific Applications Support Services 3M Purification Inc.

Reprinted with permission from the Society of Automotive Engineers, SAE World Congress 2007, “Advances in Coating Technology” - Session SP 2074.

In this re-print from the SAE Technical Paper series, novel filtration system and innovative filter elements both refer to the 3MTM DF Series Filter Element System.

Compared to conventional filter bags, 3M DF series filter elements offers up to four times more service life, superior contaminant reduction efficiency, enhanced flow, and reduced costs associated with frequent filter change-out. The 3M DF series filter elements will easily retrofit most existing bag filter housings.

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Abstract A filtration study was performed at an auto assembly plant on phosphate and electro deposition systems. Information was collected on a) service life; b) weight of contaminants trapped per filter; c) filter integrity; d) quality - average daily hood “dirt” counts; e) cost sav-ings as well as operators’ comments. A filtration system lasted not only 3.2 times longer but also trapped 4.8 times more “dirt” than the standard bag/magnetic rod system when evaluated in the dip-cleaning stage. The superior performance of the innovative filter system was even more striking in the first city water, spray-rinse stage. For example, an increase of 5.3 times the life was observed and the weight of contaminants trapped during that time was 6.5 times the standard filter bags without the assistance of magnetic rods. Additionally, after six months the average hood “daily dirt counts” dropped by at least 87% once the new filtra-tion system was installed. During the first year of conversion, the assembly plant attributed at least $160,000 in cost savings to the innovative filter system. Part of the savings came from the elimination of “oil logs” in the electro-deposition tank. This plant is now applying this filter system on all filtration stages in the pre-treatment and electro-deposition areas.

IntroductionIt is commonly known in the automotive industry that many surface defects lie in poorly cleaned bodies prior to applying an electro-deposition coating. For example, oils and greases are known to cause “craters” and metal fines greater than 40 µm are visible to the human eye resulting in automobile surfaces having to be re-worked. Re-working a vehicle is not only costly and labor intensive, but “the look” is never quite the same, particularly for metallic finishes, resulting in reduced customer satisfaction. Oils, greases and metal debris (“weld balls”) not only cause surface defects but can also cause serious corrosion problems if not reduced before applying a phosphate coating as “the uniformity and weight of the coating is dependent on the metal being totally clean”.1 These problems, in turn, result in a higher level of warranty claims and subsequent reduction in profitability as well as quality reputation for the automotive companies.

Filter bags inserted in canister filter housings are commonly used to reduce particu-lates from various fluids in the pre-treatment and electro-deposition areas. Many users encounter a number of problems with bag filtration systems in these areas. A major problem is lower efficiency (the ability of a filter to retain a contaminant, expressed as the ratio of the concentration of contaminant in the feed stream to the concentration of contaminant in the effluent 2) due to the stitched seam of the filter bags. For example, the filter medium may be rated as 1 µm; however, the diameter of the sewing needle may be 100 to 150 µm in diameter.

Additionally, the standard filter bag is not fully supported as the bag does not conform exactly to the shape of the support basket. Since the standard filter bag is generally lon-ger than its support basket, many times the unsupported part of the bag, i.e. the bottom area, can burst thereby releasing contaminants downstream. Figure 1 is a photograph of a burst bag which had been in service at an automotive assembly plant

Innovative Filtration SystemThe filter system has a unique flow path. (Figure 2 is a cross-sectional diagram of the filter element.) It is comprised of two porous cylinders ultrasonically-bonded to a rigid top-plate as well as a rigid, lower seal-plate. The fluid enters through flow channels in the top-plate and then flows between the inner and outer cylinders, which are com-prised of two “sleeves” of filter media. The fluid then flows through both “sleeves” into the closed chamber of the housing.

The high-performance fibrous media of the innovative filtration system is comprised of an open porous pre filtration layer integrated with a more efficient final layer. (Figure 3 on the next page, shows a photomicrograph of the layered filter medium.) This gradient-porosity medium has greater capacity/life (time in service before it plugs with accumulated solids3) than an equally thick homogenous medium. The two sleeve construction results in a 62% increase in surface area compared to standard filter bags. This, in turn, reduces the flux (volumetric flow rate/area of medium) which leads to a decrease in initial pressure drop, increased dirt-holding capacity4 and improved efficiency.

Figure 1 —Filter Bag; Poor Support causes bags to burst

Figure 2 —Unique Flow Path of Filtration System

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Case StudyAn auto assembly plant wanted to improve the quality of pre-treatment fluids, in particular the dip-cleaning and city-water, spray rinse which is located after the cleaning tank. Figure 4 below, is a schematic of a typi-cal pre-treatment area in an automotive plant.

Baseline data was collected for the existing filter-bag system. Magnets were inserted in each filter bag to boost efficiency and extend filter service life. After the baseline data was collected, the innovative filter elements were installed under the same process conditions except no magnets were used.

Trial ConditionsBaseline data was collected on the filter bags used in the dip cleaner recirculation system. Similarly, baseline data was also collected on the first city-water, rinse spray recirculation system. (This system immedi-ately follows the dip-cleaner stage as is shown in Figure 4.) The innova-tive filters were also installed for the same period of time in the same locations.

• Both filter systems were run continuously, 24 hours a day, Monday through Friday.

• Change out differential pressure: 10 - 12 psid.

• Stainless steel basket was installed to fully support each innovative filter element.

• Standard stainless steel basket was used to support each standard filter bag.

• No magnetic rods were installed in the housing vessels when the innovative filters were installed.

• Magnetic rods were installed in each competitive filter bag while in service.

Dip Cleaner• Fluid: alkaline immersion cleaner, blended with city water.

• Housings: #2-size bag housings, with filter baskets in each of the housings.

• Filter Micron Rating: 10 µm, nominally-rated, polypropylene filter.

• Magnetic rods (filter bags only): At least one inserted in each filter and two inserted in the upstream fluid within the housing.

Figure 3 —Graded Porosity of Innovative Filter Media

Figure 4—Schematic of Pre-treatment Area in an Automotive Plant (*initial trials performed at these stages)

City-Water Spray Rinse• Fluid: City water.

• Housings: #2-size bag housings with filter baskets inserted in each of the housings.

• Filter Micron Rating: 10 µm, nominally-rated polypropylene filter.

• Magnetic rods (for filter bags only): At least one inserted in each filter and two inserted in the upstream fluid within the housing

ProceduresInformation was collected on a) service life; b) weight of contaminants trapped per filter; c) filter integrity; d) average daily hood “dirt” counts and e) ease of use as well as operators’ comments on the difference between both filtration systems. Specific details on the proce-dures used are outlined below.

Service LifeThe end point of the service life was defined as the point when the differential pressure across the housings reached 10 - 12 psid. The differential pressures were periodically recorded (once per hour).

Determination of Weight of Contaminants Trapped per FilterPrior to installation, each filter was weighed and indelibly marked for future identification. After the end point of the service life, i.e. 10 - 12 psid, the “spent” filters were reduced from the filter housings. The metals fines from each of the magnetic rods inserted in each of the bag filters were scraped into its cor-responding bag. The filters were fully dried and reweighed. The difference between the weight of the unused filter and the dried spent filter was recorded as the dirt-holding capac-ity.

Filter IntegrityWhen reducing the filters, the operators would document if filters burst while in service or if there were any problems in insertion or reduction.

Quality - Average Daily Hood “Dirt” Defects The hoods of each vehicle exiting the electro-deposition (e-coat) oven were inspected by an experienced inspector. The total amount of hood “dirt” counts per day was divided by the number of vehicles processed on that day. The aver-age daily hood “dirt” count was recorded for a period of six months, i.e. three months baseline (bag filters installed) and three months having the innovative filtration system installed. The average daily hood counts were normalized, i.e. “1.0” was assigned to bag filter’s average daily hood count value.

Results and DiscussionService LifeThe innovative filters lasted 3.3 times longer than the standard filter bags in the Dip-Cleaning Stage. Figure 5 is a histogram of the com-parison in service life. The innovative filters lasted on average 21 hours whereas the bag filters only lasted on average 6.4 hours.

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The innovative filters lasted 5.3 times longer than the standard filter bags in the First City-Water Rinse Stage. Figure 6 is a histogram of the comparison of service life. The innovative filters lasted on average 50.8 hours whereas the bag filters only lasted on average 9.6 hours.

The longer service life exhibited by the innovative filtration system can be attributed, in part, to the lower flux through this filter as reducing flux, increases life exponentially.5 Another factor contributing to the longer service life of the innovative filter is the graded-porosity construction of the media. This type of construction increases dirt-holding capacity over homogenous, [non graded porosity] material.7 The media in the filter bag used in the collection of the baseline date was of non graded porosity construction

Weights of Contiminants Trapped Per FilterEven though the innovative filter elements did not have magnets inserted while in service, more “dirt” was retained. Figure 7 is a comparison in the amount of con-taminants trapped per filter for the Dip-Cleaning Stage. The innovative filter elements trapped 4.8 times more “dirt” on a weight basis. They trapped on average 633.7 grams per filter whereas the bag filter/magnet setup only trapped on average 133.3 grams.

There was an even more striking difference in contami-nants trapped per filter in the First City Water Rinse Stage. Figure 8 on the n is a comparison in the amount of contaminants trapped per filter. The innovative filter ele-ments held 6.5 times more “dirt” on a weight basis. They trapped on average 307.2 grams per filter whereas the bag filter/magnet setup only trapped on average 47.4 grams per filter.

The city-water rinse fluid was kept cleaner as the in-novative filters were able to trap more debris than the bag filter/magnet system. The contaminant-reduction rate (weight of contaminants/time) was 6.06 g/hour whereas the contaminant-reduction rate for the filter bag/magnet system was only 4.9 g/hour at this stage.

Filter Integrity Although not included in the data analyses, several of the standard filter bags burst during the baseline-data collec-tion phase. This indicates some of the filter bags could not sustain either start-up conditions - when the flow to the housing is suddenly introduced after a filter change-out - or when differential pressures got too high and seams burst. In contrast, no innovative filter elements burst as its design allows for the basket to fully support the media

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Figure 6 —City Water-Comparison of Service Life

Figure 7 —Dip Cleaning Contaminants Trapped

Quality - Average Daily Hood “Dirt” Counts There was a striking reduction in hood “dirt” defect counts after the innovative filtration system was installed. For example, defect counts dropped precipitously and they remained extremely low throughout the remaining three months of the trial. There was over 87.1% reduction in the average daily hood “dirt” counts while this innovative filtration system was in service as shown in Figure 9.

Additionally, even though the filter bags had very short service lives, they were less efficient at reducing “dirt” than the innova-tive filtration system. The innovative filtration system was able to consistently maintain cleaner tank fluids which, in turn, ac-counted for at least a seven-fold reduction in hood “dirt” counts. Quality was also improved by not having to shut down the filter system as often since the innovative filters lasted much longer between change-outs. During filter change-outs, vehicles are still depositing contaminants into cleaning tanks which, in turn, temporarily causes a rise in the fluid contaminant levels. Besides reducing more particulates from each stage, the innovative filter elements also trapped crater-causing oil.

Cost SavingsUpon reviewing the results of the six-month trial, the plant adopted the innovative filtration system in all of the filtration stages in both the pre-treatment and the electro-deposition areas. They discovered within a matter of a few months the filters lasted longer between change-outs which in turn reduced not only labor costs but also filter disposal costs. Additionally, they were able to reduce filter pore sizes for various stages to reduce defect rates even further while still not increasing labor costs. In fact they saved over $160,000 in the first year using the innova-tive filtration system.8

LaborInstead of frequently changing out filters, the operators now spend their time making the manufacturing process more robust, i.e. cleaning nozzles, ovens, etc. Since the innovative filtration elements are more predictable and last so much longer, shift scheduling is easier allowing for certain maintenance work to be performed during the week rather than weekends.

Reduced “oil logs”In the past the plant would use “oil logs” in the e-coat tank. These “logs” would absorb oils from this tank. Once they began using the innovative elements they had no need to purchase these expensive items.

Reduced filter useSignificant savings resulted from reduced filter usage as the innovative elements lasted over five times longer. Additionally, less inventory is required, freeing up storage space and reducing inventory costs.

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Figure 8 —City Water Rinse Stage- Contaminants Trapped per Filter

Figure 9 —Hood Defectivity Rate-Normalized

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Conclusion Cost savings (over $160,000 in the first year of service) were achieved as the innovative filtration system not only reduced labor costs but also caused filter, disposal, and inventory costs to sharply drop. The innovative filter elements were more efficient at reducing particulates from tank fluids. This, in turn, accounted for a dramatic reduction (87.1%) in hood “dirt” counts. Defects caused by these particulates can be a source of future warranty claims. As a result the savings realized by converting to the innovative filtration system was probably greater than $160,000 in the first year.

The innovative filtration system was so successful at reducing crater-causing lubricants that “oil logs” are no longer needed.

The contaminant-reduction rate (grams/hour) in the city water spray rinse was 23% higher when the innovative filter system was installed. Bodies are cleaner in each pre-treatment stage and “dirt” drawn into the electro deposition (e-coat) bath is minimized.

No innovative filters burst during the trial whereas several standard filter bags did. The innovative filter element is fully supported minimiz-ing the risk of burst elements and sudden release of contaminants back into the fluid.

The innovative filters lasted up to 5.3 times longer than the standard filter bags. Instead of changing out filters, the operators now spend their time making the process more robust.

Overall, the innovative filtration system reduced operating costs, optimized process efficiency and contributed to a significant improvement in first-time pass.

References1. Zbiegien, J. “Preparation and Pretreatment of Painted Parts” Electrocoat 2000 Conference Proceedings, p.71(2000)2. Schroeder, H.; G, Simonetti, J. A.; and Meltzer, T. H. “Prediction of Filtration Efficiency from Integrity Test Data,” Fluid Filtration

Liquid, Vol II, ASTM Special Technical Publication 975, Philadelphia, PA, p.27 (1986) 3. Johnston, P. R. Fundamentals of Fluid Filtration, First Edition, Tall Oaks Publishing, Inc, Littleton, CO, p. viii (1990)4. Purchas, D. B. “Dirt-Holding Capacity,” Handbook of Filter Media, First Edition, Elsevier Advanced Technology, Oxford, England, p.34

(1996)5. Repetti, R.V. and Ponchick, A.R “Selecting the Most Economic Cartridge Filter,” Chemical Processing, pgs 33-38 ( February, 2004)6. Uberoi, Tony “Effectively Select In-Line Filters,” Chem. Eng. Prog., 88, p.75 (March, 1992) 7. Johnston, P. R. “Life or Capacity of the Filter Medium, ” Fundamentals of Fluid Filtration, First Edition, Tall Oaks Publishing, Inc,

Littleton, CO, p.63 (1990)8. Auto Assembly engineer in charge of project - Private communication with author May 2005

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3M is a trademark of 3M Company.© 2012 3M Company. All rights reserved.

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3M Purification Inc.400 Research ParkwayMeriden, CT 06450U.S.A. (800) 243-6894(203) 237-5541Fax (203) 630-4530www.3Mpurification.com

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Important NoticeThe information described in this literature is accurate to the best of our knowledge. A variety of factors, however, can affect the performance of the product(s) in a particular application, some of which are uniquely within your knowledge and control. INFORMATION IS SUPPLIED UPON THE CONDITION THAT THE PERSONS RECEIVING THE SAME WILL MAKE THEIR OWN DETERMINATION AS TO ITS SUITABILITY FOR THEIR USE. IN NO EVENT WILL 3M PURIFICATION INC. BE RESPONSIBLE FOR DAMAGES OF ANY NATURE WHATSOEVER RESULTING FROM THE USE OF OR RELIANCE UPON INFORMATION.

It is your responsibility to determine if additional testing or information is required and if this product is fit for a particular purpose and suitable in your specific application.

3M PURIFICATION INC. MAKES NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH INFORMATION REFERS.

Limitation of Liability3M Purification Inc. will not be liable for any loss or damage arising from the use of the Product(s), whether direct, indirect, special, incidental, or consequential, regardless of the legal theory asserted, including warranty, contract, negligence or strict liability. Some states and countries do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

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