Practical solutions for filtration challenges

Filtration systems are expected to deliver reliable performance every day, whether they are protecting a sterile pharmaceutical process, clarifying a beverage before packaging, or removing particles from compressed air. In practice, even well-designed systems can run into trouble. Changes in operating conditions, equipment wear, or feed quality can cause problems that affect product integrity, raise costs, and shorten filter life. The best way to avoid these setbacks is to understand why they happen and how to prevent them. Below, we explore some of the most common filtration challenges across industries and share practical ways to solve them. Click on a challenge to learn more about its root cause and how to resolve it effectively.

Bypass happens when liquid or gas slips around the filter element instead of passing through it. This is often caused by damaged or incorrectly seated O-rings, worn sealing surfaces, or using the wrong cartridge code for the housing. In some cases, incorrect torque during installation can leave a gap just large enough for contaminants to pass.

Good installation practices are the first defense. Inspect all seals during each change-out and replace O-rings instead of reusing them. Confirm that the cartridge fits the housing correctly and tighten it according to the manufacturer's specifications. In critical processes, run an integrity test such as a bubble point or diffusion check before resuming operation. Standardizing these steps with an installation checklist helps prevent future bypass events.

A filter can sometimes add contamination instead of removing it. Media shedding occurs when fibers or particles from the filter material are released into the product stream. This can happen with low-quality wound cartridges, degraded depth filters, or membranes damaged by pressure surges. Rough handling during installation or running elements outside their rated limits can aggravate the problem.

Using continuous-filament wound cartridges or thermally bonded fibers reduces the risk of shedding. Bring systems up to pressure gradually to protect the media and use housing designs that keep internal turbulence low. In sensitive applications such as beverage clarification or sterile production, flush the filter before use to remove loose particles.

Filtration elements are engineered to operate within specific pressure ranges, but real-world process conditions don’t always stay within those limits. Sudden pressure spikes, caused by quick valve closures, pump startups, or abrupt flow reversals, can damage cartridges or housings. This can lead to ruptured seams, collapsed pleats, or permanently deformed filter elements, all of which compromise filtration performance and may even release contaminants downstream. Systems with inconsistent or poorly regulated flow are especially at risk.

To prevent pressure-related damage, it’s essential to use soft-start pumps, slow-closing valves, and pulsation dampeners. Installing pressure regulators, relief valves, and flow restrictors at key locations adds an additional layer of protection. If pressure fluctuations are suspected, using a pressure logger can help identify when spikes occur and how severe they are, enabling targeted improvements before failures happen

In filtration systems that use granular media or loosely packed materials, uneven flow can lead to channeling, where the fluid finds the path of least resistance and bypasses much of the filtration surface. This creates “short-circuiting,” reducing the contact time between the media and the product, which in turn lowers removal efficiency. Channeling can be difficult to detect because pressure readings may appear normal even when actual filtration is compromised.

To avoid this, it’s important to ensure even flow distribution through the system. In liquid processes, this can be achieved by upgrading distribution plates, using properly packed media, or switching to structured filtration designs that resist displacement. Regular inspection of flow distribution components and pressure drop consistency across the bed can also help detect early signs of channeling. As explained in our guide on types of process filtration, methods like depth filtration or crossflow filtration are specifically designed to manage particle load and maintain consistent flow, helping reduce risks such as channeling.

In high-purity applications, the filter itself can release unwanted compounds into the product. These may come from polymer additives, adhesives, or residues from sterilization, which can affect taste, odor, or assay results. Even trace amounts of these substances can compromise sensitive formulations or trigger compliance issues.
 

Using low-extractables filter media for these processes and flushing them before use helps remove residual manufacturing aids. It is also essential to review supplier data to confirm regulatory compliance. In industries such as food, beverage (wine, beer, non-alcoholic), and pharmaceuticals, independent testing or third-party certification may be required to verify safety and performance. Taking these steps ensures your filtration system supports product integrity at every stage.

Many plants still rely solely on differential pressure as the trigger for filter replacement. While differential pressure (dP) is a valuable indicator, it should be combined with other metrics such as product quality trends, particle counts, or microbiological data. In some cases, filters can continue performing effectively beyond the arbitrary dP limit, while in others, quality issues may appear before dP rises significantly.
 

Developing a multi-factor change-out strategy allows for more efficient use of filter life without compromising quality. By logging operational data and trending performance over time, operators can optimize maintenance intervals, reduce costs, and minimize downtime.

Atlas Copco offers a wide portfolio of process filtration solutions designed to address these exact challenges:

• Stainless steel filter housings such as SMH, SLH, SGH, with precise sealing to prevent bypass and maintain performance.
  
  
• Pleated depth cartridges like PFP-A⁺, PFP-D⁺, and continuous-filament wound filters like  PWP that minimize fiber shedding and protect downstream quality
  
  
• Sterile air and gas filters like SMT-G for microbial control without reducing flow rates
  
  
• Low-extractables membrane filters like SME⁺ and SMV for sensitive food, beverage, and pharmaceutical applications.

Choosing the right combination of these solutions helps plants maintain consistent product quality, extend filter life, and reduce downtime.

Issues such as bypass, media shedding, fouling, and start-up errors might not be avoidable but with proper installation practices, high-quality components, and a preventive maintenance approach, most can be stopped before they cause disruption. Recognizing early signs and acting quickly keeps processes stable and costs under control. Supported by well-designed equipment and a structured maintenance plan, a filtration system can run for years with minimal interruption, protecting both production and reputation. Reach out to our filtration experts to learn more about the best solution for your application.