1.

Raw materials should be measured by weight, not volume, and burn-out material
should be dehydrated before weighing it for use in filter mixture.
2. To determine the appropriate clay:burn-out ratio,we will characterize both clay:burn-out material
to identify there composition
3. Filter Mixture Preparation (MIXING STAGE ):-The appropriate clay:burn-out ratio
should be determined at project outset, and used consistently throughout production. If the ratio is
changed, the filter efficacy must be confirmed. Factories should work with an experienced
ceramic filter technician to aid in determining the appropriate filter mixture ratio for raw
materials. This will also help new factories start reliable, quality-controlled production.
4. A mortar mixer operating at 40-50 rpms is recommended. Dry materials should be mixed
together for a minimum of 10 minutes in a 40-50 rpm mortar mixer; if using a slower mixer,
mixing time should be extended. Hand mixing is not recommended because of the difficulty of
obtaining a homogeneous mixture; however, a drum cement mixer will be used. ln every case,
the goal is the even distribution of materials. When the mixture appears homogeneous, the
measured amount of water should be added gradually to the mix. The water can be sprinkled into
the mix by hand, with a watering can, Once all the water has been added, the
ingredients should be mixed for a minimum of 10 minutes and until a homogeneous mixture is
achieved.
5. Mixed dry materials should be inspected visually for even distribution of clay and burnout before
adding water. Wet filter mixture should also be inspected visually to confirm
even mixing.
6. Wedging, Pounding, Kneading, Pug Mill
Before a filter is pressed, the filter mixture should be manually
kneaded, wedged and/or thrust against the surface to remove air
bubbles, reduce imperfections in the clay, and aid in aligning and
compacting the clay particles, which can improve consistency and
strength. The filter mixture should be processed through a pug mill, if available. Filter mixture
should be wedged or kneaded before pressing.
7. A standard weight of filter mixture should be used to press each filter. Filters should be pressed
the same day the filter mixture is prepared. A press with a mold should be used to form the filter
shape. The main requirements for a press are these: 1) even pressure distribution; 2) a
consistent amount of pressure; and, 3) an ergonomic design that is safe for employees. Filter
Press with Cement Mold, DR (FilterPure 2009) k, the design of the press should be taken into
consideration. The PFP Dutch Press (Figure 5-7) is designed for a
20-ton capacity jack
 ,
Figure 5-7: PFP Dutch Press-flat-bottomed (10-liter capacity)
For flat-bottomed filters, the mold can be installed on the press either male above and female
below, or female above and male below. Molds must be checked for proper alignment by cutting
a freshly pressed filter lengthwise, in half and then quarters, with a piece of wire or fishing line.
The wall and base thicknesses should be measured and compared at various heights with calipers
( Annex F). The mold should be aligned so that there is no variation in thickness either
throughout the filter walls or the base of the filter.
8. A press with a high-quality mold should be used to press the filter into shape and, to
prevent warping, the filter should be handled as little as possible after pressing.
9. Mold Release(Demoulding) stage:- Some form of mold release is required to prevent
the filter mixture from sticking to the mold. Plastic bags are the most common form of mold
release used by filter factories and can be used as a mold release with any type of mold material.
Plastic bags typically leave crease marks on the pressed filters requiring additional surface
finishing of the pressed filter. Oils, such as coconut or palm oil can also be used,
10. Filters should be stored in conditions that allow for slow and even drying. They should
be protected from direct sun, wind, and rain. Artificial drying from the wet stage is not
recommended.
11. Surface Finishing and Drying:- Once leather-hard, each filter should be stamped with a
batch number, serial number,and logo. Surface finishing may be carried out at this stage.
12. Filters should be inspected visually after pressing and periodically throughout the
drying process for deformation, uneven drying, and cracks or holes. . Rejected filters
should be destroyed and the mixture should not be reused to make filters.