Developing a Custom Filtration Solution for an Aerospace Customer
Aerospace $3,430 saved Mid-Range ($10K-$100K) Liquid Filtration Filter Failure 2025-07-11

Developing a Custom Filtration Solution for an Aerospace Customer

A practical example of how filtration can make or break food safety.

Unified ROI Framework

Custom-engineered self-sealing Revolution bag filter delivered 50%+ annual cost savings and 10% improved filtration efficiency for a critical aerospace chromate paint booth — a solution TFS developed from scratch with manufacturing partners

Direct ROI
Total Documented
50%+ annual savings on filter costs
Filter Savings
Over 50% annual cost reduction on paint booth bag filters
Labor Savings
Fewer filter changes due to extended filter life
Waste Reduction
Over 50% reduction in chromate-contaminated paint booth filter bag disposal
Operational Excellence
Quality
10% better filtration efficiency — superior overspray capture prevents defects on critical aerospace wing, tail, and fuselage components
Downtime
Extended filter life reduces downtime for filter changes in high-priority paint booth
Safety
Better paint capture reduces chromate overspray exposure risk for workers in bond primer paint booth
Facility Efficiency
Equip Life
Better filtration protects paint booth infrastructure from overspray accumulation
Maintenance
Extended filter life reduces change frequency — fewer disruptions to critical production schedule
ESG Overlay

Custom self-sealing bag filter cuts chromate-contaminated aerospace paint booth waste by over 50% while delivering superior filtration for critical wing and fuselage components

Sustainability
Over 50% reduction in chromate-contaminated filter waste from aerospace paint booth operations
Waste
50%+ reduction in chromate-contaminated paint booth filter bags — significant hazardous waste reduction in aerospace manufacturing
Aerospace Hazardous Waste ReductionCustom EngineeringChromate Exposure ReductionInnovative Design

This case study focuses on Total Filtration Services' success in delivering significant costs savings to a major aerospace customer located in the mid-western region of the United States as a result of its technical expertise and strong relationships with filter manufacturers.

Challenge

The customer’s facility includes a high production bond primer paint booth. Every aluminum part that gets built into a sub-assembly (wings, tail cone, or fuselage) gets a chromate coating from this booth, so keeping it running was of critical importance to the customer.

With production increases, the customer was changing filter bags every 22 hours to avoid filter failures resulting in paint defects and costly
repairs. In addition to issues with short filter life, the existing filter bags required change-outs during production times instead of shift changes, downtime, and lunch times. This was an added cost to the customer due to shutting down the paint-line for 30 minutes to change the filters.

To meet the customer’s needs, TFS sourced a new self-sealing bag filter for the bond primer paint booth that would last longer than the current solution and could be changed on a schedule.

As part of our total filtration management approach, TFS invests the time to learn about the about the key needs for each filter application throughout a customer's facility and regularly partners with top filter manufacturers to develop solutions specific to a customer’s needs. In this situation, the type of bag filter needed for the application did not exist, so a custom solution was required.

TFS worked with Viskon-Aire, now Rensa Filtration - a trusted manufacturer of disposable air filtration products to develop an 8- pocket, frame-less self-sealing bag filter using their proprietary (Revolution) filtration media. With the added surface area of the new filter and the higher quality media, the Viskon-Aire (Rensa) filter lasted 3x longer than the previous product!

partner with tfs today
597_IMG_3180.jpg
Custom Filtration Solution

TFS' ability to deliver timely technical support and call upon trusted manufacturing partners to develop a custom solution has resulted in significant costs savings due as summarized below:

  • The filter model change netted an annual savings of over 50%. In addition to the product cost savings, the filter efficiencies of the Revolution bag exceeded th previously used bag by 10%.
  • The cost of filter change-outs with the previous product was $3,430 per week with the cost of the Viskon-Aire bag being $1,710, resulting in a labor and material cost savings of $1,720 per week.
  • The TFS approach of working with its manufacturing partners to develop a customized solution resulted in an annual cost savings of $82K and allowed the customers to time their filter change-outs to avoid production interruptions and costly downtime.
← Back to all case studies View on totalfiltrationservices.com →