Designed for continuous and large batch operations with mission-critical reliability.
Planning for Redundant & Continuous Systems
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.
Key Considerations
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 :
Variable Frequency Drive (VFD) pump with DCS/PLC control
Automated valves, vent systems, and inline sensors
Jacketed piping for temperature control
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
Filter Cake Discharge Options
Depending on your media and process:
Wet Cake Discharge (WCD) : Requires plant water or filtered product and discharges solids as a slurry
Dry Cake Discharge (DCD) : Requires plant air for vibration and discharges cake below filter in low moisture chunks
Sparkler will help select the best discharge mode based on your product, solids, and process goals.
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
Operating Costs
Filter Media Cost
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.
Maintenance Cost
Multi-filter systems are designed for reliability, but critical systems must plan:
Gaskets changes : Every 3—12 months
Spare rods, bolts, screens, etc : Keep in stock for quick changeovers
Filter Aid Cost
High-throughput systems may require substantial volumes of filter aid
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.
Additional Engineering Notes
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
Additional Engineering Resources
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.
Evaluate cycle time for maximum throughput and minimal downtime
Optimize filter placement and redundancy to ensure uptime and system flexibility
Pinpoint process improvements that enhance efficiency and reduce operating costs
Review and advise on P&IDs, catching potential issues before they become costly problems
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.