Equipment for the production of air filters for cars. Production of oil filters. Best Inexpensive Oil Filters
The Air Filters group of companies opened its own production facility in 2004 in the city of Fryazino (Moscow region). air filters for ventilation and air conditioning systems.
The first production workshop, whose area was only 200 sq.m, began work with cutting FVE, panel and pocket filters. The products had to be manufactured manually; production produced no more than 20-50 filters per day.
Gradually, the Air Filters group of companies increased production capacity and expanded the range of products. To date production area are more than 5000 sq.m. Over the years of successful production, the number of filters produced per day has increased more than a hundred times. The company's own production capacity is estimated at more than 1.5 million filters per year. Today, the company's production has its own metalworking shop, cutting and sewing shops, warehousing and logistics department.
Our production base consists of 2 main sites (the city of Shchelkovo, Moscow region and the village of Gorodishchi, Vladimir region), which produce pocket, cassette, panel, cartridge, bag, compact and absolute air purification filters. There is also a line for the production of liquid bag filters.
Except production workshop, the company has a development and research department, a quality control department, a supply department, and a chief engineer service, which includes a chief mechanic and a labor protection engineer.
The enterprise is equipped in accordance with the highest technological requirements. In the process of manufacturing filters, high-quality filter materials from world-famous manufacturers, industry leaders, of which our company is the exclusive representative, are used. All manufactured filters are environmentally friendly, manufactured in accordance with specifications and certified in the GOST R system. Production is certified by ISO 9001-2011. Product quality is guaranteed by a system of input and output control. Qualityabsolute purification filters HEPA, ULPA tested on the TOPAS test bench (Germany), the only one in Russia.
We consider the warranty period offered to you to be the main indicator of the level of our work. We guarantee the operation of our products for a year and will diagnose, repair or replace if a defect is detected.
With the opening of its own production, the company's activities ceased to depend on third-party manufacturers. Having our own production facilities, we can guarantee our customers competitive prices, clear production times and quality of products.
The NORDFIL team welcomes you!
We are creating the production of automobile filters from scratch, in Russia, in the city of St. Petersburg on Vasilyevsky Island.
At Spark we will talk about:
How we do it.
What problems do we face and how do we solve them?
What successes are we achieving?
This is our first report from production.
Today from Europe they brought us a machine with a complex scientific name “Coordinate manipulator for sealing”, or in simple terms - a foam filling machine.
This monster is involved in the production of automobile air filters. We will use it at the stage of creating the polyurethane base of the filters (this is what goes around the perimeter).
In the production of air filters, foam filling is the final stage, except for packaging and labeling of the final products.
On this machine we can create polyurethane bases for filters of any geometric shape: square, rectangular, triangular, round, oval, trapezoidal, etc., etc.
For example, there are rectangular shapes on the desktop, and the wheel next to it allows you to create round products.
In this air filter production area, the central part of which will be our foam filling machines, we have already installed:
Belt conveyors for feeding tooling forms to the machine (you can see them around the machine under the black film)
Work tables (the one with a shiny surface) for filter and mold blanks
And in the near future, we will install a polymerization furnace nearby (in the photo on the left, approximately in the place where the rokhlya stands), the tasks and capabilities of which we will write about separately.
After setting up the foam filling machine, we will post a video of its first launch and show how it works.
6 specialists will be involved in this area.
The machine can produce 7,000 products per work shift.
And some angles.
P.S. Posed with the subject:
In a blue jumper - Maksimov Alexander, production manager, worked in the production of automobile filters for more than 15 years.
In a black T-shirt - Bezruchko Alexey, specialist in filter materials.
At least after every 10 thousand mileage, a driver who takes care of his car changes the air filter. Thus, we can conclude that this is a product for which there will always be demand. The production technology is simple, and the equipment for the production of filters for cars is relatively inexpensive, which attracts entrepreneurs who want to master this line of business.
Air filter functions
The main task of a car air filter is to clean the air entering the engine. A good part, provided it is replaced in a timely manner, traps up to 99% of “foreign” particles contained in the air. A high-quality product does not lose its properties throughout its entire service life. In addition to directly filtering the air, it also dampens noise and regulates temperature. Thanks to the air filter, the risks of various damage to the car engine are significantly reduced, and the wear of parts is minimized.
Types of air filters for cars
It is possible to produce air filters for cars from paper, and they can also be inertial oil or carbon. The shape may also be different. Equipment for the production of filters for cars uses special raw materials - cellulose fiber paper. It is protected by a special impregnation, making it resistant to water, oil or fuel. Paper products cope better with their intended purpose, so they are somewhat more expensive than coal products. The filtering ability is further enhanced by the fact that the paper is folded like an accordion.
Various air filter designs
The following types of paper filters are distinguished by shape:
- cylindrical;
- panel;
- frameless.
Cylindrical air filters are mainly used in cars with carburetor-type engines. In modern passenger cars, panel-type products are mainly used. This design is optimal, since with its small volume the filter has a large filtration area.
How to produce filters for cars
The production technology of air filters is quite simple. It consists in the fact that a special rotating drum feeds paper between two rotating cylinders, which bend it, making an accordion. The counter counts the same number of folds. After this, the paper is sent along a conveyor belt to a circular saw, which makes cuts at regular intervals.
The upper and lower parts of the filter are made using aluminum molds coated with liquid wax and liquid polyurethane. All operations with molds, namely waxing, filling with polyurethane, and subsequent movement of the finished product onto a cooling grid, are performed by a manipulator.
The equipment for the production of filters for automobiles is an almost completely automated line, which can easily be serviced by only one worker. His tasks include laying blanks from corrugated paper on the bottom of the filter, removing the finished products from the chute into which they fall after the manipulator finishes its work. Packaging of finished products is also carried out by the line operator. Thus, the full production cycle takes approximately 20 minutes.
You can assemble a line from its component parts. However, by purchasing ready-made, assembled and configured equipment, you can minimize labor costs, maximize productivity, and also protect yourself from problems with maintenance and repair of devices.
It is difficult to overestimate the importance of oil in the functioning system of an internal combustion engine - it is a material intended for cooling and lubricating the rubbing surfaces of parts. During operation vehicle wear products enter it in the form of small solid inclusions, which have an abrasive effect on the lubricated surfaces. The gradual accumulation of foreign elements can lead to rapid engine failure, the replacement of which (regardless of the car brand) will cost a tidy sum.
Special oil filters, manufactured by world-famous suppliers of auto parts, are designed to get rid of the negative impact of wear products and extend the life of one oil fill. The action of the filters is based on the retention of solid inclusions of a certain fraction on thick perforated filter paper, which freely allows oil to pass under the pressure of the oil pump. In this case, the degree of filtration and the speed of the process completely depend on the type of element. Having carefully analyzed the products presented on the market of auto parts and components, we have selected for you the ten best manufacturers of oil filters at the moment. The final selection of applicants was made taking into account the following criteria:
- reviews from car enthusiasts, experts and professionals about their experience using the product line;
- opinions of authoritative publications, results of official tests;
- popularity of the manufacturing company in the domestic market;
- compliance of the quality and operational potential of products with nominal cost.
Best Inexpensive Oil Filters
4 Finwhale
Best price
Country: Germany
Rating (2018): 4.8
A division of the Swiss holding Grunntech AG, engaged in the production and production of filters for passenger cars. The company's product range includes over two hundred varieties of oil filters, the cost of which is slightly higher than the price of domestic designs.
One of the brightest representatives of the division is the Finwhale LF101 filter element, the resource of which lasts approximately 15 thousand kilometers. In fact, the only complaint consumers have about all of the company’s products (and not just this model) concerns the service life. It is low, even on premium models, but the quality of filtration remains high until the end of the resource.
Advantages:
- strict quality control at every stage of assembly;
- low cost of production;
- the presence in the assortment of filters suitable for Russian (VAZ, GAZ), American (Chevrolet, Ford), Asian (Hyundai, Kia) and European (Skoda, Renault) cars;
- good filtration quality (optimal composition of filter paper).
Flaws:
- short service life.
3 Auto unit
The main supplier for the domestic automotive industry
Country Russia
Rating (2018): 4.8
A company focused on the production of filter elements for heavy-duty equipment and passenger cars. It is one of the largest suppliers of auto parts throughout the CIS, which indicates high level manufactured products. This is not surprising - entering the Commonwealth markets gives the company access to foreign filter manufacturing technologies, including oil filters.
As for the domestic Russian market, Avtoagregat products can be found in retail, but in small quantities. Most of the filters go straight to the automobile plants VAZ, GAZ, Ural, KamAZ, etc. The cost is slightly lower than that of foreign competitors.
Advantages:
- low cost;
- the company is a direct supplier of oil filters to the conveyor lines of domestic automakers;
- high quality meeting European standards.
Flaws:
- small quantity of goods in retail sale.
2 BIG Filter
Optimal working resource
Country Russia
Rating (2018): 4.9
One of the leading domestic manufacturers of filter elements, developing low-cost products for the domestic and foreign markets. Supplies oil filters to VAG enterprises located in Russia (for example, the Volkswagen plant in Kaluga).
The company's product range includes more than a hundred types of oil filters, which undergo strict testing at every stage of development. Great attention is paid to the tightness of the valves, which allow oil to leak away during engine downtime. Judging by the reviews, most users prefer to install them right away, as a replacement for standard filters that have exhausted their service life. The company does not rest on its laurels and is constantly expanding its product range.
Advantages:
- they develop filters for both domestic cars (VAZ) and foreign cars;
- good quality filter elements;
- characteristic marking of the company’s filters (green housing).
Flaws:
- not detected.
All oil filters for passenger cars are divided into three types: full-flow, partial-flow and combined. What are their main advantages and what are the main disadvantages – we will find out from the comparison table.
|
Filter type |
pros |
Minuses |
|
Full thread |
Simplicity of design Filtration of the total volume of oil pumped by the oil pump High speed oil purification Instant opening of the bypass valve when the resource is exhausted Avoiding engine overheating through stable oil saturation |
– Small working resource (gets clogged up very quickly) – Provides screening of particles of the largest fraction (80-100 microns) |
|
Partial flow |
Finer filtration due to the selection of fine particles (up to 15 microns) The moment the resource is exhausted instantly affects the operation of the engine Separated oil circuits prevent |
– Cost is higher than full flow filters – The filtration process is slow |
|
Combined |
Includes both types of filters (full and partial flow) Effectively copes with pressure in turbocharged and forced engines (designed mainly for diesel engines) Filters out particles as small as 40 microns |
- High price |
1 BelMag
The best quality of products
Country Russia
Rating (2018): 4.9
A domestic manufacturer of auto parts from Magnitogorsk, which suspended its activities due to a budget deficit. Production Line was launched in 1996 - at that time the purely Russian auto industry needed the part. With the gradual attenuation of the market, the company's products turned out to be unclaimed, which led to a corresponding curtailment of all capacities.
The arrival of the Renault-Nissan concern on the market marked a new stage in the history of the company. The gradual increase in production capacity has led to a good jump in the overall quality of all auto parts. In particular, the production of inexpensive oil filters for VAZ cars (from 2106 to Prior, Grant and Kalin), Renault and Nissan brands has been established.
Advantages:
- wide range of products for various car brands;
- acceptable quality, noted by professionals;
- low cost;
- widespread in the Russian market.
Flaws:
- not identified.
The best manufacturers of oil filters in the mid-price segment
3 SCT
The best combination of price and quality
Country: Germany
Rating (2018): 4.6
A direct, but more modest competitor of the famous German company Mann, the main supplier of oil filters to the CIS countries. It is familiar to domestic consumers firsthand, as evidenced by numerous reviews, and not bad ones at that. Of course, among the entire range of products for foreign and domestic cars, there was a place for several not very successful filters, but this is a rare exception.
The main reason for the company's popularity among ordinary car owners and professionals is its competent pricing policy: this is the very case when such a subtle relationship between price and quality is best seen. Definitely a good option for any popular car, regardless of age and brand.
Advantages:
- ideal price/quality ratio;
- products distributed in Russia;
- good filtration performance.
Flaws:
- The service life of some oil filters leaves much to be desired.
2 Bosch
Profitable price
Country: Germany
Rating (2018): 4.6
To classify Bosch as one of the most serious and the best manufacturers It is impossible to use oil filters for cars, but it is quite possible to assign the title of “good” ones. And this is not due to the quality of the product - on the contrary, it shows the company’s intentions in a more than advantageous light. The fact is that the corporation is a wide-profile manufacturer of “almost everything” - from household equipment and tools to the production of auto parts and components.
As for the oil filters themselves, it should be noted here that, in general, they have excellent adaptability to cleaning the lubricant, which is key advantage, and low operational capability, which can be regarded as a serious drawback. The latter is mitigated only by the insignificant cost of the replacement element, which, in fact, persuades users to purchase oil filters from Bosch.
Advantages:
- low cost;
- excellent filtering ability;
- wide availability in the domestic market.
Flaws:
- resource depletion often occurs earlier than the guaranteed period.
1 GoodWill
The best ratio of price and quality
Country: UK
Rating (2018): 4.8
A very interesting manufacturer of automobile filters, whose product range includes models from all three price segments. Many users note that the service in our country is not very good, but the legitimacy of such statements is highly questionable. The product is widely represented in retail trade, which makes it much easier independent choice the same “oil can” for personal transport.
As for technical characteristics each individual filter, then a lot here depends on the consciousness of the car owner himself (however, as always). The service life is greatly influenced by the frequency of oil changes, its type (synthetic, semi-synthetic), and driving style. It is reliably known that one filter can last for 20 thousand kilometers - taking into account the cost, we get a very profitable investment.
Advantages:
- filters are highly dependent on operation;
- wide distribution of the product on the domestic Russian market;
- good filtration quality, acceptable durability.
Flaws:
- According to users, the range is small.
The best premium oil filter manufacturers
3 Union
The best quality of manufactured products
Country: Japan
Rating (2018): 4.9
Perhaps, best company for the production of automobile filters throughout Asia. Has a brilliant reputation, and not only within his country. Oil filters developed by the company are trusted by the world's leading automakers, largely due to the reliability and quality of filtration.
In terms of innovation, Union cannot be matched by any leading competitor, since the company annually allocates approximately a third (or a quarter) of its total revenue to research and prototype creation. This step helps the Japanese remain among the leaders in the production of oil filters.
Advantages:
- constant search for new technological solutions, financing our own research and creating successful prototypes;
- full compliance of products with high international quality standards;
- stable supply of parts to retail sales on the secondary market.
Flaws:
- not identified.
2 Mahle
The most better parameters durability
Country: Germany
Rating (2018): 4.9
Another representative of the German side, developing automobile filters for the masses. In addition to cooperation with leading automakers, it actively ships some of its products to the secondary market, which served to popularize the brand in Russia. It develops expensive but high-quality oil filters for leading automakers, including VAZ - very often you can see conventional “Priors” with an “oil can” from this particular manufacturer.
It's no joke, but the developers claim that one filter is capable of properly performing its functions up to 50 thousand kilometers - with such a reserve, purchasing Mahle products is a truly profitable investment.
Advantages:
- the nominal resource of each filter is 50,000 kilometers;
- excellent quality achieved through strict production control;
- conceptually more reliable bypass and shut-off valves made of heat-resistant rubber.
Flaws:
- high price.
1 Mann
User selection
Country: Germany
Rating (2018): 5.0
Filterwerk Mann+Hummel GmbH is the full name of a large European company producing oil filters, whose general headquarters is located in Germany. This is a premium supplier of parts to most of the largest automotive companies around the world, whose products undergo not only operational, but also the strictest initial control of raw materials, ensuring the highest quality of consumables.
Every year the company presents more than a dozen the latest developments, which are immediately supplied to the assembly lines of large automakers. Mann products can be found in Volkswagen, Porsche, Nissan, Peugeot, etc. cars. In addition to supplying conveyors, filters are also supplied to the secondary market, but not in very large quantities.
Advantages:
- the largest European corporation cooperating with the world's leading automakers;
- availability of oil filters for domestic cars;
- Strict operational and incoming control of materials.
Flaws:
- a large number of counterfeits in retail sales.
How to choose a good oil filter
When independently selecting an oil filter for your car, we recommend paying attention to a number of important parameters:
- Filter type. As stated earlier, all oil filters are divided into three types: full-flow, partial-flow and combined. The first ensure complete safety of the engine from overheating and oil starvation, the second provide fine but slower filtration, and the third are a kind of symbiosis of the advantages of the first two groups, mutually excluding their disadvantages.
- Filter paper thickness. This parameter significantly affects the working life of the filter. The thicker the paper, the more susceptible it is to clogging and rapid loss of performance. You should also make inquiries about the temperature resistance of the paper, and select a filter based on the temperature at which you most often operate the car (to what temperature the engine heats up).
- Serviceability of the bypass valve. In most cases, measuring the pressure at which the bypass valve opens is not possible (after purchase). However, if such an opportunity does arise, be careful to ensure that the opening pressure is not too low. In this case, the engine will receive unfiltered oil full of solid abrasive inclusions. You can also check the check valve for leaks to prevent oil leaks during shutdown.
- External integrity. A secondary, but very important aspect of the health of the oil filter. Make sure there is no damage to the housing parts and valves, or any tears in the filter paper.
- Manufacturing company. To avoid quick failure of the purchased filter or much more serious damage, give preference to certified products from reputable manufacturers. It is not a fact that a small gain in cost by purchasing a filter of dubious origin will not lead to much greater costs for repairs and restoration of parts in the future.
Foreign brands
First of all, congratulations to MANN+Hummel, which took a convincing first place. We were also pleased with the good results of the top 5 Russian brands - especially considering the fact that in 4 out of 5 cases they produce products in their homeland. In the overall standings, these five took respectively 5th (BIG Filter), 6th (Livny), 8th (Nevsky Filter), 12th (TSN Citron) and 15th (Goodwill) places.
Now about other impressions. Summing up, we studied the distribution of points between brands and found that there is a clear leading group: 10 foreign brands and 5-6 Russian ones. All other brands are losing sharply to this group.
By and large, the point distribution shows that there is room in the market for 15-16 brands designed for a wide audience. Each of them can occupy its own price-quality niche or attract buyers with other advantages that competitors do not have.
The figure can be easily explained by the laws of consumer psychology: even a professional buyer is not able to assimilate more than a dozen brands and maintain close contact with them.
Should other brands die? Not necessary. We were talking about a wide audience, but there are still narrow niches that require special products and a different distribution system: motorsport, military-industrial complex and others. There's enough room for everyone. Provided that manufacturers leave the price war, start searching for their unique buyer and find a unique way to satisfy him.
Top 10 Foreign brands
1 place | 2nd place | 50 million units .
|
3rd place | 4th place | 5th place |
$300 million
| 6th place
| 7th place
|
8th place
| 9th place
| 10th place
|
Top 5 Russian brands
1 place | 2nd place | 3rd place |
4th place | 5th place |
