Mustard Screen Development | Producing High-Quality Powder and Throughput

Client: A European manufacturer of self-cleaning filters
Application: Self-Cleaning Filtration for Fibre and Gel-Rich Process Streams
Industry: Filtration

Self-cleaning filters are widely used across industry to separate solids from liquid process streams, most commonly using wedge wire screens with reciprocating plungers or rotating scrapers.

• ActionLaser worked with a self-cleaning filter manufacturer on a solution that;
• Overcomes wedge wire failure in fibrous streams
• Improves the filtration of gelatinous materials
• Supports consistent self-cleaning operation
• Fully engineered OEM integration
• Proven long-term industrial adoption
• Expands addressable filtration markets

While effective at many tasks, wedge wire screens struggle to process fine fibrous materials or gelatinous, shape-changing particles. Fibres can staple across slots and resist removal, while gels deform under pressure, pass through the slot opening, and reform downstream, blocking screens; reducing filtration efficiency and reliability. A European manufacturer of self-cleaning filters encountered these limitations when targeting fibre and the gel-containing feedstocks.

The manufacturer evaluated laser-drilled circular hole screens supplied by ActionLaser, which eliminated both failure modes. Fibres were far less prone to snagging and could be effectively removed by scrapers. At the same time, gelatinous particles were unable to deform through the circular apertures and were reliably discharged as solids.

Following successful trials, the manufacturer made significant engineering and manufacturing investments to integrate LaserScreens into its product range. These included internal support systems to prevent screen distortion under pressure differentials and refined cutting and welding techniques for thin laser-drilled materials (0.45-0.9mm) to maintain smooth working surfaces.

Circular hole geometry prevents fibre stapling and enables effective scraper cleaning, overcoming wedge wire failure in fibrous streams. The solution improves the filtration of gelatinous materials, as shape-changing particles cannot deform and pass through circular holes. Smooth laser-drilled surfaces reduce snagging and scraper wear, supporting consistent self-cleaning operation.

Over more than 25 years, the partnership has grown into one of ActionLaser’s largest OEM relationships. LaserScreens enabled reliable operation in filtration applications previously constrained by wedge wire limitations, delivering long-term performance, reduced blockage risk, and expanded market capacity.