From initial planning to seamless operation — Sparkler is your partner every step of the way.
Planning for Single Filter Systems
For batch or intermittent processes, a single filter can meet your needs — but success depends on thoughtful planning. Below are key elements to consider when designing your filtration setup.
Click here for continuous or multi-filter systems.
Key Considerations
Auxiliary Piping & Pumping Requirements
Basic systems require a feed source tank and pump, piping, and valves. If precoating is involved, a dedicated precoat tank and pump are highly recommended but can also share tankage with the feed tank in bootstrap operations. More complex configurations may also include:
Piping for air or nitrogen blowdown
Jacketed vessels and related liquid for heating or cooling
Automated valves for system integration and timing sequences Sparkler works with you to identify and integrate all necessary components.
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.
Note Regarding Piping : In vertical tank setups, the cover is removed or moved to the side for cleaning and maintenance — plan for flexible piping or move rigid piping to tank ports.
We’ll help define your startup, operating, and critical spares based on run times, media lifespan, and maintenance windows.
Note : Most parts are custom-made, with lead times ranging from 1 to over 120 days depending on the item. For critical systems, we recommend planning and stocking appropriate spares to avoid unplanned downtime.
Filter Changeouts & Labor Requirements
Horizontal Plate Filters typically require 10–45 minutes for filter changeouts, depending on the model size and configuration.
Nutsche Filters can often be regenerated in minutes, offering quick turnaround between batches.
Vertical Plate Filters offer zero labor for filter change outs, as media remains in place. However, they come with higher upfront costs and increased maintenance needs due to automation and moving components.
Downtime can be significantly reduced in HPF applications by utilizing a spare cartridge.
Instrumentation & Safety
Differential pressure gauges (inlet vs. outlet) are essential for performance monitoring.
If cake drying or pressure draining is required, ensure access to plant air, nitrogen, or other gas.
Pressure relief valves should be included on the vessel or in the piping system for safety and to prevent equipment damage.
Space & Tools
Leave ample clearance around the filter for cleaning and maintenance.
Torque wrenches are required in most filters for consistent gasket sealing and safe closure.
Overhead hoists are typically needed for horizontal filters — Sparkler will provide lifting weight specs.
Customization & Drawings
Click here for a complete view of specs and options.
Every Sparkler Filter is fully customizable.
Approval drawings are provided, and your team is invited to collaborate with our engineers to ensure a seamless integration with your facility.
Operating Costs
Filter Media Cost
HPF filters offer the lowest consumable cost in the industry—in some cases saving up to $2,500 per day compared to disposable
cartridges and other technologies.
Media costs vary by application, ranging from under $1 per sheet on small 8" horizontal filters to several hundred dollars per plate
on vertical plate bag filters, depending on media type, retention rating, and process conditions.
Maintenance Cost
Sparkler filters are known for their exceptionally low maintenance when operated correctly.
Gaskets : Typically replaced every 3—12 months
Plates, rods, bolts, etc : Often last several years
Filter Aid Cost
Precoating is very cost-efficient (e.g., 1 lb of DE per 5 ft2 of filter area).
Bodyfeed is typically introduced ata 1:1 ratio to process solids. Minimal costs in relation to product quantity.
Filter aids nearly always reduce total operating costs by improving. bid evaluation cycle time and reducing labor. Sparkler
can assist with accurate DE usage estimates.
Click here for a detailed description of the total cost of ownership related to equipment.
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 Improving Performance
Project consulting : Strategic Consulting for Equipment Selection, Bid Evaluation, and Process Feasibility