Laminated Filter Media For Fuel And Water Separation

How the coalescence works

 

A coalescing medium does not filter water out by pore size. It presents a fibre structure with controlled surface energy in which sub-micron water droplets attach, grow and release. Three things have to be true at once:

The upstream structure must capture droplets small enough to be a threat - this is the fine-fibre and meltblown function.

The captured droplets must be able to migrate and merge, which requires a graded structure rather than a uniform one.

The downstream surface must shed the coalesced water, or the element re-entrains it and the separation figure collapses at high flow.

That is why a single-layer sheet cannot do this job, and why the range is built as a laminate.

 

 

We integrate meltblown, ultrasonic, thermal and hot-melt bonding capabilities. These are not interchangeable - each gives a different laminate:

Meltblown adds a fine-fibre layer with very high surface area. This is the layer that captures the sub-micron soot and emulsion droplets that a wet-laid sheet cannot reach.

Ultrasonic bonding joins layers at discrete points without melting the functional layer. It preserves permeability and coalescing behaviour at the bond sites.

Thermal bonding gives a continuous, strong bond where mechanical durability and pleat support matter more than maximum openness.

Hot-melt bonding is the flexible option for dissimilar layers and for short runs where tooling cost dominates.

The result is a set of laminated products with differentiated performance on three axes: long service life, full-life emulsified water separation, and chemical durability against the additive packages and biodiesel blends in modern fuel.

 

Grade	Basis weight (g/m²)	Thickness (mm)	Corrugation depth (mm)	Air permeability @200 Pa (L/m²·s)	Max pore size (µm)	Avg. efficiency ISO 19438 @4 µm (%)
HTLM3051	280	1.05	0.20	20	26	99.9
HTLM351	280	0.85	0.20	25	25	99.3
HTLM8501	290	1.10	0.20	35	25	99.5
HTLM8101	300	0.85	-	35	22	99.9
HTYS3052	266	0.96	0.20	34	35	64.0
HTYS3054	250	1.00	0.20	160	50	30.6
HTLM310	216	0.50	-	29	28	81.5
HTLM6011-5	300	0.95	-	90	40	62.1
HTLM8066	220	0.90	-	160	38	60.5
HTLM8070	226	0.90	-	123	32	83.9
HTLM8080-1	270	0.98	0.20	120	56	74.8
HTYS300	215	0.75	0.20	80	38	69.3
HTYS3001	280	0.96	0.20	14	22	96.8
HTYS3006	205	0.80	0.20	15	26	87.2
HTYS3008	215	0.85	0.20	200	70	54.1
HTLM1770	199	0.78	0.20	310	54	57.5
HTLM8106	288	0.83	-	125	34	60.3

 

How to navigate seventeen grades without a mistake

Read the table by requirement, not by grade name:

Highest particle efficiency (>99%): HTLM3051, HTLM8101, HTLM8501, HTLM351. These are the grades for final-stage fuel filtration on common-rail systems where 4 µm particle count is the acceptance criterion. Note that HTLM3051 and HTLM8101 reach 99.9% at very different thicknesses (1.05 mm vs 0.85 mm) and different pore sizes (26 vs 22 µm) - choose on pleat height and housing volume, not on efficiency alone, since both are effectively at the ceiling.

 

High efficiency with more flow (85–97%): HTYS3001 (96.8% at only 14 L/m²·s - a tight, low-permeability sheet for small high-precision elements), HTYS3006 (87.2%), HTLM8070 (83.9%), HTLM310 (81.5%). These are the practical middle: strong capture with a permeability that allows a smaller element or a higher flow per unit area.

 

Moderate efficiency, high flow (54–75%): HTLM8080-1, HTYS300, HTLM6011-5, HTLM8066, HTLM8106, HTLM1770, HTYS3008. Use these as pre-filter or coalescing stages ahead of a fine final stage - HTLM1770 at 310 L/m²·s is the most open sheet in the group and belongs upstream, not last.

 

Capacity-oriented (30–64%): HTYS3054, HTYS3052, HTLM6011-5. Deliberately open for high dirt-holding in the first stage, or for applications where water separation rather than particle count is the governing requirement.

 

A pairing example. A two-stage diesel system might use HTLM1770 or HTYS3054 as the coalescing/capacity stage and HTLM3051 as the final stage. The first stage takes the load and starts the coalescence; the second delivers the 4 µm count and the final water barrier. Running HTLM3051 alone in a high-dirt application loads it prematurely; running HTYS3054 alone passes the fine fraction.

 

 

 

Applications

Diesel fuel-water separator elements on trucks, buses and heavy equipment

Common-rail fuel filter modules requiring full-life water separation

Marine fuel systems and bunker fuel polishing

Generator set fuel lines in high-humidity and tropical markets

Aviation ground fuel handling where coalescing is specified

Any element built to an emission control standard that specifies emulsified water removal

 

Customisation

The layer stack is the product. We tailor new laminated fuel filtration materials to a customer's requirement rather than only selling the listed builds: layer order, layer count, bonding method, and the balance between capacity and efficiency can all be set. Where a customer has an existing element drawing and a failing bench result, the usual route is to rebuild the stack against the failure mode - premature loading points to more upstream capacity, while a failed water-separation figure points to the downstream surface, not the pore size.

 

 

 

FAQ

 

What does "full life" water separation mean?

That the separation performance holds to the end of the service interval, not only on a new element. Many media separate water well when clean and lose that ability as they load, because the coalescing surface becomes covered. Our laminate is designed against that decay curve.

 

Why is efficiency quoted at 4 µm rather than at a nominal rating?

Because nominal ratings are not comparable between suppliers and say little about the fine fraction that damages high-pressure fuel systems. ISO 19438 at 4 µm is a measured, repeatable figure.

 

Can this media handle biodiesel blends?

Chemical durability against additive packages and fuel blends is a stated design objective of the laminate. Send the blend ratio and we will confirm the specific grade.

 

Does higher efficiency always mean lower flow?

Not linearly. Compare HTYS3001 (96.8% at 14 L/m²·s) with HTLM8101 (99.9% at 35 L/m²·s) - the second is both more efficient and more permeable, because it is a thicker, differently bonded laminate. This is exactly why the grade should be selected from measured data, not from the efficiency number alone.

 

Can you bond our existing layers instead of supplying a finished laminate?

Yes. Bonding capability covers meltblown, ultrasonic, thermal and hot-melt, so a customer-supplied layer stack can be laminated to specification.

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