Multi-Filter Systems

Project Planning with Sparkler Filters

Multi-Filter Systems

Designed for continuous and large batch operations with mission-critical reliability.

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Planning for Redundant & Continuous Systems

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For high volume operations requiring maximum reliability and minimal downtime, a multi-filter system is essential. Whether you're running 24/7 or managing multiple processing stages, Sparkler helps you design scalable systems with built-in redundancy, automation, and support.

Filter system
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Key Considerations

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System Architecture Examples

One Online / One Standby (Repeat as Needed)

  • Delivers ~99% uptime for continuous processing
  • Ideal for systems where plant shutdowns allow maintenance on filters or systems not reliant on upstream or downstream processes

Three-Unit Redundancy (Online / Standby / Spare)

  • Engineered for 100% uptime, even during upset conditions
  • Mitigates risks associated with unplanned shutdowns, maintenance, or part failures

Integrated Multi-Filter Configurations (e.g., MCRO or VF)

Depending on your process, you may need :

  • Filters are deployed in tandem for simultaneous filtration and cleaning
  • Especially effective in chemical , mining , and high-throughput applications
  • Sparkler engineers help configure proper sequence timing, automation control logic, and overall synchronization and implementation into plant

Auxiliary Piping & Process Integration

Larger systems typically require custom process infrastructure but may include :

  • Feed, return, and bypass loops
  • Variable Frequency Drive (VFD) pump with DCS/PLC control
  • Automated valves, vent systems, and inline sensors
  • Jacketed piping for temperature control
Mineral Recovery

Sparkler works with your team to identify all required auxiliary equipment and ensure a seamless system layout.

Note Regarding Pumps : Centrifugal pumps are preferred in all Sparkler Filters as they produce less cake disturbance. A pulsation dampener or similar equipment is recommended on double diaphragm and other pumps. Filter cake resistance should be calculated in pump head. Ex. dP x 2.31 / specific gravity = Head.

Instrumentation, Automation & Monitoring

To support system optimization, Sparkler can integrate:

  • Differential pressure gauges : Cycle can be determined by Dp or time. Click here for more information regarding process tips
  • Level sensors and turbidity meters
  • Pressure relief valves
  • Sight glass ports
  • Full integration with your plant’s DCS or PLC systems
  • Alarms to alert of potential bypass due to precoat, filter media or mechanical upset conditions
Self-Cleaning Efficiency

Filter Cake Discharge Options

Depending on your media and process:

Sparkler will help select the best discharge mode based on your product, solids, and process goals.

Filter Mounting & Access

Depending on your media and process:

  • Sparkler MCRO’s are typically mounted on I-Beams (Provided by Sparkler)
  • Allow ample space for cover removal, inspection, maintenance and cleaning
  • Sparkler can provide hoist specs and footprint planning for all systems
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Operating Costs

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Filter Media Cost
Sparkler Media Solutions
Broad Media Compatibility

Media costs vary widely depending on application, media type, retention rating, and process conditions

Sparkler HPF and Nutsche filters are known for offering the lowest consumable media cost in the industry.

Meanwhile, Sparkler VF and MCRO filters deliver exceptional media longevity thanks to the patented high pressure cleaning system, which regenerates filter media more effectively than competitive methods—reducing media replacement frequency, longer cycle times and lowering long-term operating costs.

Multi-filter systems are designed for reliability, but critical systems must plan:

Increased Safety Hazards
  • Gaskets changes : Every 3—12 months
  • Spare rods, bolts, screens, etc : Keep in stock for quick changeovers

High-throughput systems may require substantial volumes of filter aid

Sparkler Media Solutions
Broad Media Compatibility
  • Bodyfeed ratios of 1:1 can result in DE usage ranging from a few pounds to thousands of pounds per week in our largest filters
  • Sparkler works with DE/AC suppliers to model usage and optimize cost
  • Filter aids nearly always reduce total operating costs by improving cycle time and reducing labor far in excess of the cost of the filter aid. Sparkler can assist with accurate DE usage estimates.
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Additional Engineering Notes

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  • Overhead hoists are required for horizontal filters — Sparkler provides weight specs
  • In vertical tank setups, the cover is removed for cleaning — plan for flexible piping or move rigid piping to tank ports
  • dP monitoring is essential — we help train your operators to spot media blinding and manage efficiency losses
  • Spare parts should be planned proactively — most are custom-built with 1–120+ day lead times
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Additional Engineering Resources

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  • Filters purchased directly from Sparkler come with a lifetime technical support warranty. We can help with planning, implementation, and optimization.
  • Sparkler also offers engineering services to assist with new projects and non-Sparkler equipment. Check out the links below to learn more.
    • Discovery : Helping you identify best filtration solution
    • Engineering : Innovative Engineering Solutions for Filtration Systems
    • Process Improvement : Maximizing Filtration Efficiency, Reducing Costs, and Im-proving Performance
    • Project consulting : Strategic Consulting for Equipment Selection, Bid Evalua-tion, and Process Feasibility

We don’t just provide equipment — we deliver a partnership built to optimize your application, streamline site planning and commissioning, and drive long-term success.

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Evaluate cycle time for maximum throughput and minimal downtime

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Optimize filter placement and redundancy to ensure uptime and system flexibility

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Pinpoint process improvements that enhance efficiency and reduce operating costs

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Review and advise on P&IDs, catching potential issues before they become costly problems

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Lifetime Filter support — to keep your operations optimized for the life of the filter

Because when failure isn’t an option, Sparkler stays in the trench with you — through startup, through challenges, and for the life of the filter.

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Optional Finishes & Treatments
Standard Flow Precoat Bodyfeed
Dry Cake Discharge transport
Dry cake discharge container
Dry Cake Discharge Collection Tray
Dry Cake Discharge Filter Setup
Sparkler WCD system integrated with rotary drum filter for slurry separation.
Wet Cake Discharge connected to slurry tank and pump system for solids removal.
Wet Cake Discharge with Slurry Pit
Wet Cake Discharge filter setup
Mineral Recovery
Nutsche filter type