In our current economic landscape of escalating energy costs and an increasing public demand for better indoor air quality, the ‘best’ commercial air filter is no longer a nice-to-have, but a necessity. Even if your current air filter meets most of your particle capture efficiency targets, it could still be costing your business significant amounts of extra money.
This article analyzes the various data-driven solutions available for filter selection, enabling strategic filter purchases with numerous beneficial impacts, rather than merely purchasing a product.
What are the technical nuances and financial implications involved in filter selection? Selecting a filter that is engineered to last longer and cut costs associated with energy, labour, and waste makes more sense than ever. So what should you be looking for? Let’s examine the possibilities.
The New Standard: Why MERV is Just the Starting Point
The MERV rating of the air filter is critical to achieving your contaminant capture efficiency, ensuring you get the cleanest air possible and your money’s worth. But MERV ratings are only a good starting point, which often won’t show the whole picture.
Initial vs Final Pressure Drop vs Average Pressure Drop – why is it crucial to understand the difference?
This measure directly impacts the energy consumption of HVAC system fans (Pstatic∝kW). Air filter media designed and produced to provide the lowest average pressure drop over the life of the filter, along with a pleat design that stays open and utilizes the full surface area of the media, therefore lasting longer and needing fewer changeouts, is what you should be looking for when procuring air filters. These are two key metrics to consider when evaluating the total cost of ownership (TCO), as they can help reduce costs.
The Importance of an Air Filter’s Dust Holding Capacity
The more dust a filter is designed to hold, the longer it will last. As mentioned previously, increased media surface area through a better pleat design can greatly increase longevity. A dual-layer media can capture both coarse and fine particles. A more robust filter with stronger structural components maintains pleat integrity and prevents media from sagging under even the harshest conditions. A higher dust holding capacity will demand far fewer replacements, less labour for changeouts and maintenance, and less waste to handle and dispose of, helping you meet your sustainability goals and lowering labour requirements.
Why is ASHRAE Standard 52.2-2017 crucial in filter selection?
ASHRAE 52.2 is considered much superior to the previous version because it provides a standardized, repeatable laboratory-based method for measuring a filter’s efficiency for specific particle sizes, using the MERV rating system. This allows for more reliable comparisons between filters, a more targeted selection process based on real-world contaminants, and a true standard for facilities managers to ensure performance meets minimum requirements. In mission-critical facilities, regular MERV ratings are insufficient because they don’t account for detailed performance testing across all particle sizes.
Specifically, PM1 and PM2.5 particles can cause significant damage to human health and equipment, including that used in semiconductors. The 52.2 Standard allows for testing a filter with the removal of any enhanced electrostatic charge in order to demonstrate the filter’s true efficiency throughout its service life and this is identified with a MERV “A” rating. It covers all particles from as small as 0.3 µm to as large as 10 µm.
Deconstructing the “Best”: A Technical Breakdown of the Best Air Filters for Different Applications
Pleated Panel Filters
All pleated panel filters use synthetic media, with nanofibre technology achieving higher efficiencies. They feature added moisture-resistance and a degree of recyclability. Note that lower-quality synthetic filters tend to lose efficiency as their electrostatic charge dissipates. They also have less dust-holding capacity and require more frequent replacement.
Look for an air filter with a radial pleat design to ensure the entire surface area of the media is exposed to the airstream to hold dust evenly and minimize pressure drop. Another thing to look for is a welded wire grid on the downstream side of the media to keep the pleats in formation even through the toughest conditions.
The 30/30 Dual 9® pleated filter features a two-stage filtration media. The first layer is a high-lofted, coarse fibre that captures larger particles, and the second layer (downstream) is a high-density fine-fibre layer designed to capture smaller particles. Given its sophisticated design, it has a much higher dust-holding capacity, which allows it to maintain its capture efficiency up to four times that of standard commercial air filter pleat designs. This prevents clogging. It is constructed with a moisture-resistant frame. It features a performance guarantee of up to 12 months. Another major feature is its low average pressure drop over its life, meaning it requires less energy to push air through the filter. At a commercial facility, substantial savings in energy costs can be achieved.
Pleated filters work exceptionally well as prefilters to extend the life of more expensive final filters, and as primary filters in less demanding applications.
Bag Filters
The best bag filters available, such as the Hi-Flo ES®, feature controlled media spacing (CMS). The pockets are precisely spaced to prevent any collapsing or touching. The advantage of such a design is that it allows for even airflow distribution across the entire filter surface for the highest dust loading capacity and less clogging. It has a lower average pressure drop and a long filter life.
Hi-Flo ES®
The best bag filters also feature high-quality media with high-loft, micro-fine fibre. It is designed to capture sub-micron particles while maintaining a low resistance to airflow. They also feature durable frames and support for structural integrity. They are well-suited for hospitals and medical facilities, office buildings and schools, or other commercial/industrial applications best at MERV 13A or higher;
V-Bank Filters
V-bank filters feature a rigid, V-shaped design for each of the filter banks. This innovative design is designed to provide a much greater area of media within a much more compact frame compared to conventional rigid filter designs. The dust-holding capacity for compact V-bank filters, e.g., Camfil Durafil® particulate filter or the CityCarb® combination particulate filter and molecular filter for gases, is far superior to conventional filters and offers a longer service life compared to panel filters or bag filters. Also, because of their large surface area and high DHC, and lower average pressure drop, they are very cost-effective solutions in commercial air filtration in terms of reduced energy consumption and less frequent filter changes.
V-Bank filters can be used for industrial processes such as food and beverage production and pharmaceutical production for product quality and safety. They can also be used in commercial and public buildings, such as schools, hospitals, data centres, hotels, and museums, to enhance the health and well-being, as well as the comfort, of building users.
Durafil® Compac
HEPA V-Bank filters
Other V-Bank style filters include HEPA filters such as the Absolute VG®, which provides ultimate clean air and saves a maximum amount of energy. It features a leak-free frame and gasket seal. It has a particle capture efficiency of 99.97% to 99.9995% at 0.3µ. It can be used in pharmaceutical and healthcare settings such as production facilities and cleanrooms.
Absolute VG®
Opti-Pac high-efficiency filter
Another great option amongst the best commercial air filters available on the market is the Opti-Pac. Here are some of its notable features:
● Design: It is a box-style filter with a compact 4-inch depth, making it suitable for installations where space is a concern.
● Media: The filter media is made of wet-laid microfine glass with a “Close-Pleat” design and thermoplastic resin separators.
● Performance: The design ensures uniform airflow and full use of the media area, leading to low pressure drop, high dust-holding capacity, and extended service life, which helps reduce energy costs.
● Construction: It features a high wet-strength beverage board frame for structural integrity, durability, and moisture resistance. The frame is bonded to the media to prevent air bypass.
● Efficiency: The Opti-Pac is available in various efficiency ratings, including MERV 11, MERV 13, MERV 14, and MERV 15.
The TCO Framework: A Procurement and Engineering Collaboration
It is crucial for those involved with procurement and engineering to work together to determine how purchase options will affect performance and cost savings over the life of the filter. Companies often have five-year plans in business to maximize business efficiency and profit. Commercial air filtration should also be thought of in the same manner. The best commercial air filters will save the most money in the long term if they reduce lifecycle costs. The main objective when choosing the best filter is 1. To make sure it is going to last the longest, 2. Use the lowest amount of energy, and 3. Require less maintenance.
Initial Cost vs. Lifecycle Cost
Due to the overall slowing economy, teams are shifting their focus to the “lowest bid” mentality. However, the lowest initial cost can lead to future pain and a loss of profit. In determining the total cost of ownership of an air filtration solution, the following formula must be applied: TCO=Cinitial+Cenergy+Clabour+Cdisposal.
Energy Consumption: The primary driver of energy savings is the reduction in fan energy, which can account for a significant portion of the total life cycle cost of an air filtration system.
It is based on:
- Average Filter Pressure Drop (ΔP): The resistance the filter presents to airflow over its entire lifespan. A lower average pressure drop means the fan works less, saving energy.
- Airflow (Q): The volume of air moving through the system.
- Operating Time (T): The number of hours the fan operates per year.
- Fan Efficiency (η): The efficiency of the fan motor.
- Cost of Power (Pc): The cost of electricity per kilowatt-hour.
Labour & Maintenance: Some facilities have reported saving two weeks of labour from fewer filter changeouts due to higher DHC.
Disposal: Commercial enterprises can save up to 50% on disposal costs by switching to longer-lasting air filters.
Risk Mitigation: Poor IAQ can lead to numerous negative consequences, including employee and customer discomfort, reduced engagement due to lower well-being, staff absences resulting from poor health, non-compliance with building standards, reduced rental income, reputational damage, and product liability in food and beverage production or pharmaceutical product production. High-quality air filters can mitigate these risks.
Clean Air Solutions and Expertise from Camfil
Life Cycle Analysis: Utilizing the latest software, Camfil’s experts can provide accurate projections of cost savings across all sectors of commercial air filtration, offering a better bottom line and numerous options to achieve improved air quality, enhanced airflow, and reduced energy consumption.
Sustainability: By purchasing the longest-lasting filters, using the most advanced filter media, and reducing filter buys, you can achieve your sustainability goals.
Compliance: Camfil can help you achieve compliance with building, labour, and health codes and provide lists of best practices to help improve your operations.
Camfil provides expertise from engineers in conducting site assessments, pressure drop data, and custom solutions in every area of business:
● Commercial & Public Buildings
● Food & Beverage
● Life Sciences & Healthcare
● Data Centers
● Warehouses & Distribution Centers
● Manufacturing
● Energy Production
Conclusion
An air filter manufacturer should aim to be more than just a supplier of air filters; it should be a value-added partner, sharing information and expertise to provide accurate projections of cost savings and guide facilities in achieving the best possible indoor air quality.
Choosing the “best” commercial filter must be a data-driven choice based on TCO, system suitability, and performance, not just the initial cost of air filters.
Partner with Camfil for a reliable filtration audit and see how your company or facility can have significant operational efficiencies and savings.
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Q & A on Choosing the Best Commercial Air Filter
Why does choosing commercial HVAC filters require more consideration than just an air filter’s MERV rating?
A: Although MERV ratings show how well a filter captures particles, they don’t take lifetime, energy efficiency, or total cost of ownership (TCO) into consideration. Filters with the lowest average pressure drop and highest dust-holding capacity can significantly reduce HVAC-related energy and maintenance costs, making them a wise long-term investment.
What is the difference between initial, final, and average pressure drop in air filters?
A filter’s initial pressure drop represents its resistance when it is brand-new, its final pressure drop occurs when it is completely loaded and has reached the end of its filter life, and its average pressure drop represents its performance over time. HVAC efficiency and operating costs are directly impacted by a reduced average pressure drop since it results in longer filter life and lower energy usage.
What is the impact of dust-holding capacity on the life cycle cost and performance of HVAC filters?
A: Higher dust-holding capacity filters save labour and waste disposal expenses, last longer, and need fewer changeouts. This capacity is increased by features like improved pleat design and dual-layer media, which cut TCO and improve sustainability.
Describe ASHRAE Standard 52.2-2017 and explain its significance.
A proper technique for assessing filter effectiveness across particle sizes, including PM1 and PM2.5, is offered by ASHRAE 52.2-2017. It guarantees that filters fulfill performance standards and permits more precise comparisons, particularly in mission-critical settings. A MERV “A” rating, which denotes real efficiency without electrostatic enhancement, are given to filters evaluated in accordance with this standard. This standard is much more reliable.
What makes pleated panel filters effective for commercial HVAC systems?
A: High-quality pleated panel filters use advanced media, a radial pleat design, and welded wire grids to maintain their structure. Due to its dual-stage filtration, excellent dust-holding capacity, and minimal pressure drop, products such as the 30/30 Dual 9 are perfect for extending service life and reducing energy consumption.
How do bag filters like the Hi-Flo ES improve HVAC performance?
A: Bag filters with controlled media spacing (CMS) ensure even airflow and prevent pocket collapse. Sub-micron particles are captured by high-loft micro-fibre media with minimal resistance. For commercial buildings, schools, and hospitals that need MERV 13A or above, these filters are perfect.
What are the benefits of V-bank filters in commercial HVAC systems?
A: V-bank filters have a wide media surface area and a compact design, which results in a lower average pressure drop and a higher dust-holding capacity. They are appropriate for sectors including public buildings, food processing, and pharmaceutical production and are cost-effective since they need less energy and require fewer changeouts.
Why choose HEPA V-bank filters like the Absolute VG for clean air applications?
A: HEPA V-bank filters offer optimal energy savings, better particle capture, and leak-free design.They are perfect for settings like data centres, healthcare facilities, and high-tech industries that need the cleanest air.
Camfil has air filtration experts who can help you improve your indoor air quality (IAQ) with expertise in addressing regional challenges and operational needs. Whether you seek to control hazardous emissions or improve the IAQ in your workplace, Camfil can help. To find a local rep, use this contact form, and someone will reach out to you. Contact form
About Camfil Canada Clean Air Solutions
For more than 60 years, Camfil has been helping people breathe cleaner air. As a leading manufacturer of premium clean air solutions, we provide commercial and industrial systems for air filtration and air pollution control that enhance worker and equipment productivity, reduce energy consumption, and benefit both human health and the environment.
Media Contact:
Phillip Ilijevski
Tel: 905-660-0688
Camfil Canada Inc.