Challenge

A client approached us to develop a specialised PVC bag system for ozone gas filtration. The solution needed to incorporate activated charcoal while maintaining complete seal integrity, requiring precise engineering and innovative fabrication techniques. The critical requirements included working with ultra-thin 0.25mm PVC material and integrating 90-degree elbow connectors whilst ensuring the activated charcoal could be effectively sealed within the system.

Technical Complexities

The project presented multiple engineering challenges:

·       Achieving consistent welds with exceptionally thin 0.25mm PVC material

·       Developing a complex welded profile that maintained structural integrity

·       Integrating specialised 90-degree elbow connectors without compromising the seal

·       Engineering a method to incorporate activated charcoal whilst enabling high-frequency welding for the final seal

Solution Development

Our Research & Development team approached this challenge through innovative tooling design and process development. Leveraging our expertise in polymer manufacturing, our team:

1.     Sourced precision-engineered 90-degree elbow fittings from Carmo AS to ensure optimal gas flow characteristics

2.     Designed and manufactured bespoke welding tools in-house specifically for creating the external bag profile and integrating the unusual connector configuration

3.     Developed a novel technique for charcoal filling that maintained material integrity while ensuring complete sealing capability during the final welding process

Results

The innovative approach taken by our R&D team resulted in a highly successful outcome for our client. Through the development of our custom tooling solution and novel filling technique, we delivered a filtration system that achieved perfect integration of the activated charcoal while maintaining exceptional weld quality across all production units. The ozone filtration performance met all specifications, and by developing the tooling in-house, we were able to provide our client with a cost-effective solution without compromising on quality or reliability. This project exemplifies our commitment to solving complex engineering challenges through innovative thinking and technical expertise.

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