KemFlo – Injection Molding Experts

KemFlo has been manufacturing injection molded products since 1988 and has developed a reputation for producing some of the highest quality parts in the industry. KemFlo manufactures everything from the simplest plastic injected molded part to some of the most complex plastic products in a wide range of thermoplastic resins in both commodity and specialty resins. KemFlo provides products and services into many different markets and has
accumulated a wealth of experience in materials, design and processes. Some of the markets that kemFlo manufactures products and parts for include industrial, chemical, energy, agricultural, medical, environmental and more.

The key to KemFlo’s success is our focus on seven key functions including product design, prototyping, mold making, production, post molding capabilities assembly capabilities and quality assurance. All functions are important in manufacturing quality products such as KemFlo’s Kempac plastic random packing product line which includes three different styles including the Tri-Pack, Pall Ring and Saddle style packing. Each style of plastic random packing is manufactured in three different sizes.

The overall injection molding process involves three phases product design, mold design and manufacturing. Product design is a very important part of the production process. This is the stage in which costly mistakes are avoided and smart design can produce efficient and cost effective parts. During this stage our engineering staff works with the latest in computer aided design software as well as the most advanced 3D software. This allows KemFlo to provide customers with the bast engineering solution for their requirement. Mold design is extremely
critical to the overall process. The mold or die must be designed specifically for injection mold manufacturing. Molds are commonly made from hardened steel, Aluminum, Copper alloy or other high-end metals. The number of parts required per cycle and the material the part will be made from will determine the mold’s material of construction. After a product or part has been properly designed and the mold is completed, production can begin. Thermoplastic resin in pellet from is fed through a hopper into a heating barrel. The resin is heated to the proper melting temperature and then pressure us used to force the melted resin into the mold. Once the mold is filled it is then cooled before being ejected from the mold resulting is a finished part or product.

An excellent example of this process is KemFlo’s Kempac plastic random packing product line which involves multiple product configurations, sizes and resins. KemFlo manufactures the spherical style or Tri-Pack in three different sizes including 1”, 2” and 3.5”. KemFlo also offers the Tri-Pack in a variety of resins including Polypropylene, Polypropylene with glass, PVC, CPVC, Kynar, Tefzel and many more. The Tri-Pack is constructed of a complex network of ribs, structs and drip rods. It is very important that the Tripack be free from flashing to ensure proper functioning in very critical applications. To ensure there is no flashing the mold must be properly designed and maintained. The same goes for the Pall Ring style tower packing and the Saddle style tower packing which are both manufactured various sizes and resins.

For more information regarding KemFlo products please visit or visit for specific information on plastic random packing products.

Packed-bed Scrubbers

Packed-bed scrubbers consist of a chamber containing plastic random packing material, such as KemFlo’s Kempac plastic tower packing (Tripack, Pall Ring or Plastic Saddle), that provide a large surface area for liquid-particle contact. The packing is held in place by a bed limiter and supported by a packing support. Scrubbing liquid is evenly introduced through a liquid distributor located above the packing and flows down through the plastic scrubber packing. The liquid coats the plastic tower packing and establishes a thin film. The pollutant to be absorbed must be soluble in the fluid.

In packed-bed scrubbers, the gas stream flows up the chamber (countercurrent to the liquid). Some packed beds are designed horizontally for gas flow across the packing (crosscurrent). Physical absorption depends on properties of the gas stream and liquid solvent, such as density and viscosity, as well as specific characteristics of the pollutant(s) in the gas and the liquid stream. These properties are temperature dependent, and lower temperatures generally favor absorption of gases by the solvent. Chemical absorption may be limited by the rate of reaction. Water is the most common solvent used to remove inorganic contaminants. Pollutant removal may be enhanced by manipulating the chemistry of the absorbing solution so that it reacts with the pollutant. Caustic solution (sodium hydroxide, NaOH) is the most common scrubbing liquid used for acid-gas control (e.g., HCl, SO2, or both), though sodium carbonate (Na2CO3) and calcium hydroxide (slaked lime, Ca[OH]2) are also used.

VOC Control:

Absorption is a commonly applied operation in chemical processing. It is used as a raw material and/or a product recovery technique in separation and purification of gaseous streams containing high concentrations of organics (e.g., in natural gas purification and coke by-product recovery operations). In absorption, the organics in the gas stream are dissolved in a liquid solvent. The contact between the absorbing liquid and the vent gas is accomplished in counter current spray towers, scrubbers, or packed columns. The use of absorption as the primary control technique for organic vapors is subject to several limiting factors. One factor is the availability of a suitable solvent. The VOC must be soluble in the absorbing liquid and even then, for any given absorbent liquid, only VOC that are soluble can be removed. Some common solvents that may be useful for volatile organics include water, mineral oils, or other nonvolatile petroleum oils. Water is used to absorb VOC having relatively high water solubilities. Amphiphilic block copolymers added to water can make hydrophobic VOC dissolve in water. Other solvents such as hydrocarbon oils are used for VOC that have low water solubilities, though only in industries where large volumes of these oils are available (e.g., petroleum refineries and petrochemical plants). Another consideration in the application of absorption as a control technique is the treatment or disposal of the material removed from the absorber. In most cases, the scrubbing liquid containing the VOC is regenerated in an operation known as stripping, in which the VOC is desorbed from the absorbent liquid, typically at elevated temperatures and/or under vacuum. The VOC is then recovered as a liquid by a condenser.

PM Control:

In packed-bed scrubbers, the gas stream is forced to follow a circuitous path through the plastic tower packing material, on which much of the PM impacts. The liquid on the plastic tower packing collects the PM and flows down the chamber towards the drain at the bottom of the tower. A mist eliminator is typically positioned above the packing and scrubbing liquid supply. Any scrubbing liquid and wetted PM entrained in the exiting gas stream will be removed by the mist eliminator and returned to drain through the plastic random packing.


Advantages of packed-bed towers include:

  1. Relatively low pressure drop;
  2. Capable of achieving relatively high mass-transfer efficiencies;
  3. The height and/or type of packing can be changed to improve mass transfer without purchasing new equipment;
  4. Relatively low capital cost;
  5. Relatively small space requirements; and
  6. Ability to collect PM as well as gases.

Wet scrubbers generate waste in the form of a slurry. This creates the need for both wastewater treatment and solid waste disposal. Initially, the slurry is treated to separate the solid waste from the water. The treated water can then be reused or discharged. Once the water is removed, the remaining waste will be in the form of a solid or sludge. If the solid waste is nontoxic, it can generally be landfilled. Hazardous wastes will have more stringent procedures for disposal. In some cases, the solid waste may have value and can be sold or recycled. For more information on Kempac plastic random packing please visit our website at


Since 1988 KemFlo has been manufacturing high quality injection molded parts and products for a variety of applications and industries. KemFlo has designed and manufactured parts for numerous industries including chemical, industrial, energy, medical, environmental, agricultural and more. KemFlo has built a solid reputation for the design and manufacturing of injection molded parts. From the simplest to the most complex plastic injection molded parts Kemflo has the experience and expertise to assist from the conceptual stages to the finished product. Our goal is to provide cost effective solutions with the highest level of quality for our customers. To ensure this KemFlo makes significant investments in state of the art machinery, tooling, research and development, quality control, training and customer service.

Kemflo manufactures a high performance plastic random packing product line under the brand name Kempac. The Kempac plastic random packing line includes three styles of packing, the Tri-Pack, Pall Ring and Saddle style plastic random packing. In order to improve our service to our customers across the United States and abroad, we are seeking partnerships with manufactures representative, distributors and OEMs / Original Equipment Manufacturers. We are specifically looking for partnerships regarding our plastic random packing product line but would consider for other product lines and custom products as well. Regarding our plastic tower packing product line, we are seeking partnerships with individuals or companies who have experience in selling mass transfer process equipment to a variety of industries. More specifically those individuals and companies who have experience in selling the Tri-Pack, Pall Ring and Saddle style plastic tower packing.

KemFlo manufactures three different styles of high performance plastic tower packings each in three different sizes. Each style of packing is available in a variety of resins including polypropylene, polyethylene, PVC, CPVC, PVDF, Halar, PFA and more. The Tripack, Pall Ring and Saddle Style tower packing are available in 1”, 2” and 3.5” in order to meet the customer’s specific requirement. Please note that other resin types are available upon request.

The Tri-Pack is a hollow spherical column packing constructed of a network of ribs, struts and drip rods. The spherical shape of the Tri-pack makes this product unique compared to other styles of plastic tower packings. The Tri-Pack offers reliable and predictable performance and one of the most efficient packing media types available anywhere.

KemFlo’s Pall Ring tower packing is a robust ring featuring an open area wall construction which maintains even liquid distribution. The Pall Ring has reinforced structs provide additional surface area for gas and liquid contact which provides a higher level of efficiency.

The Saddle style plastic random packing features serrated edges which promote high mass transfer rates through effective liquid surface renewal. The serrated edges of Kemflo’s saddle style packing also reduce bed settling during operation and help to maintain packing free space and create lower pressure drop.

Kemflo also offers special packaging and labeling, product literature, product samples, and product support. Special discounts and protected territories and or accounts may also be available to select partners. For more information on KemFlo’s plastic tower packing product line please visit our website at or call Jason at 281-787-4061.

Common Pall Ring Applications

Kempac’s Pall Ring tower packing is a very versatile plastic random packing that had proven to be an excellent option for many applications.  While Pall Ring tower packing has been in use for many years, Kemflo has made adjustments to their version of the Pall Ring over the years, making it more efficient and more durable.  KemFlo achieved this by improving its surface area to void space ratio and by increasing the wall thickness. KemFlo’s Pall Ring is designed specifically to maintain even liquid water distribution.  The interior struts provide significant surface area for gas and liquid contact which is essential for mass transfer.  The robust struts also provide strong support for the outer ring.  

One of the more common applications where Pall Ring tower packing is commonly used is in air scrubbers.  An air scrubber is basically a filtration system which removes particles, gases and chemicals from the air within the system or unit. These systems draw air in and pass it through a series of stages within the unit. The unit may be a vertical or horizontal column and include various stages in addition to the plastic random packing such as liquid distributors, random packing support grids, random packing hold down grids, gas feed pipes and mist eliminators. The Pall Ring helps to maximize vapor and liquid contact in an air scrubber, maximizing the system’s overall efficiency. The pall ring helps to spread the surface area uniformly which helps to improve gas liquid contact.  The Pall Ring has superior spread of surface area compared to many other types and styles of plastic random packing. 

Pall Ring tower packing is also commonly utilized in biological applications such as trickling filters.  Trickling filters are basically a water treatment system that utilizes microorganisms attached to plastic random packing or some other media to remove organic matter from wastewater that passes through it. The Pall Ring style packing provides an excellent combination of surface area for the microorganisms to attach to and open area which allows the flow of oxygen and liquid required to keep the microorganisms alive and healthy.  

Air Stripping is another application where Pall Ring tower packing is often used due to its design and durability.  In air stripping is the process of using air to remove contaminates from groundwater.  Contaminated water is pumped through the top of a column and sprayed over plastic random packing such as the pall ring.  The water trickles down through the open are of the packing while are is blown into the bottom of the column. The plastic tower packing provides an area for the air and wastewater to mix thus facilitating the rate of evaporation.  Air is collected at the top of the column where it can be tested and treated. Other common application for the Pall Ring may include absorption, distillation, extraction, humidification, dehumidification and de-aerating.    

KemFlo manufactured the Pall Ring in 1”, 2” and 3.5” sizes and is available in a variety of resins including polypropylene, polyethylene, PVC, CPVC, PVDF and more.  In addition to Pall Ring tower packing Kemflo also manufactures a Plastic Ring random packing and a Tri-Pack plastic random plastic packing.  For more information on Kempac’s plastic random packing products please visit our website at