If you are involved in the manufacturing or wastewater treatment industry and work as a plant manager, a process engineer, or a purchasing or Environmental Health and Safety (EHS) professional, then you may be looking for a solution to remove harmful pollutants and odors from your process exhaust streams before they are released into the atmosphere and contaminate the outside air. Industrial scrubbers are a technology that can fulfill these needs.

In order to remove gas pollutants and odors from exhaust streams, industrial scrubbers serve as pollution filtration systems that use solids (in “dry scrubbers”) or water or other liquids (in “wet scrubbers”). A few advantages of industrial scrubbers include low-risk processing of incendiary gases, its ability to handle high-temperature, high-humidity gas streams without temperature limit or condensation problems, no secondary dust sources, and its ability to neutralize corrosive gases and absorb gas and solid particulate matter with the use of a single device. Furthermore, small spaces can accommodate industrial scrubbers which ensures lower capital costs and site placement flexibility. The Kem-Group is proud to manufacture the most critical component of an industrial scrubber the random packing. Kem-Group manufactures plastic random packing in a variety of styles and thermoplastics. Some of the styles of plastic random packing manufactured by Kem-Group include Tri-Pack, Pall Ring, Saddle and Kemflake. These random packing styles are available in resins such as Polypropylene, CPVC, PVC, PVDF, Tefzel and more.

Dry Vs. Wet Scrubbers
Industrial scrubbers can be classified as “wet” or “dry.” Although dry scrubbers typically are unable to remove pollutants to the same extent as wet scrubbers, they are ideal for use in facilities without the necessary infrastructure to handle released wastewater.

Without use of liquids, dry scrubbers remove contaminants from exhaust gases. Alternatively, they make use of a dry reaction material (a “sorbent”), such as alkaline slurry, and are generally used to remove acid from gases by passing the gas through the sorbent “dust” to enhance binding.
Unlike dry scrubbers, wet scrubbers pass contaminated gas through a liquid that is intended to remove pollutants. More than 99 percent of airborne particulate matter may be removed using wet scrubbers, which are a flexible and affordable pollution control device.

How Wet Scrubbers Work
The most frequently used solvent for removing inorganic pollutants is water. In the most fundamental configuration, contaminated gas is sent through water that is enclosed in a metal or composite container. The water then absorbs the contaminants, and clean gas exits the scrubber.
Other liquids, in addition to water, can be used as absorbing solutions capable of removing various contaminants. The chemical composition of the absorbing solutions can be altered to change the overall charge. Since the charge of pollutants varies, wet scrubbers are filled with the liquid that will bind the most effectively to remove the contaminate from the gas. The most common scrubbing liquid used for acid-gas control (e.g., HCl, SO2, or both) is caustic solution (sodium hydroxide, NaOH), though sodium carbonate (Na2CO3) and calcium hydroxide (slaked lime, Ca [OH]2) can also be used.

Wet Scrubbing of Particulate Matter
By trapping them in liquid droplets, wet scrubbers may remove particle debris. Following the collection of the droplets, the polluting gases are dissolved or absorbed by the liquid. A mist eliminator must be used to separate any droplets from the outlet gas stream that are present in the scrubber’s incoming gas. Additionally, the produced scrubbing liquid needs to be cleaned before it can be released into the environment or used again in the plant.

The amount of power applied to a wet scrubber determines how well it can capture particulate matter. To achieve high removal efficiency, a mist eliminator that is correctly constructed and kept is also crucial.

Wet scrubbers are typically the only single air pollution management technology that can eliminate both pollutants when the gas stream contains gases and particle matter.

Packed-Bed Wet Scrubbers
Absorbers are wet scrubbers used to remove gaseous pollutants. High removal efficiencies in absorbers require good gas-to-liquid contact. A bed of plastic random packing is utilized to provide the gas-to liquid contact. To remove gaseous pollutants, various wet-scrubber designs are used, with one of the most popular sub-categories of wet scrubber known as Packed-Bed, Packed-Tower, or “acid gas” (when they are used to control inorganic gases).

Even though they can also accumulate solid particles, packed bed scrubbers are often used for the treatment of gas. In the chemical, aluminum, coke and ferroalloy, food and agricultural, and chromium electroplating sectors, as well as in acid plants, fertilizer plants, steel mills, and asphalt plants, packed-bed scrubbers are often employed.

Applicable Pollutants for Packed-Bed Wet Scrubbers
Packed-Bed wet scrubbers are used to control inorganic fumes, vapors, and gases, Volatile Organic Compounds (VOC) as well as Particulate Matter (PM) and Hazardous Air Pollutants (HAP) in particulate form (PMHAP)

How Packed-Bed Scrubbers Operate
Through inertial or diffusional impaction, interaction with a sorbent or reagent slurry, or absorption into liquid solvent, packed-bed scrubbers effectively eliminate air contaminants.

Packed-bed scrubbers have a chamber with layers of random packing media such as the Tri-Pack packing style to create a large surface area for liquid-particle contact. The effectiveness of the low gas-phase pressure drop and gas-liquid contact is influenced by the packing’s shape, weight, surface area, and price. A plate towards the bottom of the scrubber serves as support for the packing.

Waste gas is forced into the scrubber’s chamber and flows vertically or horizontally through the packing, while scrubbing liquid is used above the packing. This permits the liquid to flow down through the bed to coat the plastic random packing thus creating a layer of film. The gas stream flows up the chamber (“counter-current” to the liquid) in vertical designs (packed towers). Some packed beds, on the other hand, are designed horizontally to allow gas flow across the packing (“cross-current”).

The waste produced falls to the bottom of the chamber as the cleaned gas is then channeled through a mist eliminator incorporated into the structure’s top.

Advantages of Packed-Bed Wet Scrubbers
The advantages of Packed-Bed wet scrubbers include relatively low pressure drop, its use of Fiberglass-reinforced plastic (FRP) construction, its capability of achieving relatively high mass-transfer efficiencies, its relatively low capital cost and small space requirements, its ability to collect Particulate Matter (PM) as well as gases and the opportunity to change the height and/or type of scrubber packing media.

For more information on Kem-Group’s plastic random packing styles such as the Tri-Pack, Pall Ring, Saddle or Kemflake please visit our website at .


At Kemflo we value our customer’s opinions and commits regarding our plastic random packing and our service. We pride ourselves on providing the highest quality plastic random packing in the industry and superior service. Our goal is to provide customers with high quality, high performance random packing at an economical price. Here is some of what our customers are saying about us.

Scrubber packing is an essential part of our process so when it needs to be replaced we need a dependable source that we can count on. Whether we are in an emergency situation or performing maintenance, KemFlo always provides fast and reliable service.

Joe T.
Process Engineer
Deer Park, Texas


We switched to KemFlo’s Tri-Pack tower packing after years of dealing with under performing scrubber units. We found that the previous tower packing was not providing sufficient surface area. After installing the Tri-Pack plastic random packing we saw an immediate improvement in efficiency and an increase in the performance life of the tower packing.

Sara J.
Chemical Engineer
Little Rock, Arkansas


Our facility experienced a major failure which resulted in the loss of tower internals and plastic tower packing. With production down we were loosing money. Our process requires the use of PVDF plastic random packing which is not an off the shelf product. KemFlo was able to expedite the tower packing and get it to the job site quickly limiting down time.

Gary L.
Baton Rouge, Louisiana


KemFlo has been one of our best and most reliable vendors for a number of years. As a manufacturer of industrial scrubbers we utilize plastic random packing for our new units as well as after market customer support. It’s important for our company to respond to our customer requirements quickly and accurately so we expect a high level of service from our vendors. KemFlo has always provided us with a very high level of service such as responding to request for quotations quickly, working closely with logistical companies to ensure prompt deliveries, jump through hoops to ensure deliveries are met and more. We have developed a strong working relationship with KemFlo.

Nathan H.
Cleveland, OH


I have worked with the team at KemFlo for over ten years and have always received excellent service. KemFlo goes the extra mile to ensure we receive our plastic random packing when we need it.

Laura E.
Tampa, FL


uring an emergency shut-down we required several hundred cubic feet of the 2” Tri-Pack in PVDF material. We had a every tight window in which to receive and install the tower packing so that we could bring the system back into service. KemFlo was able to produce the Tri-Packs in PVDF and ship the packing via hot shot with time to spare.

David H.
Maintenance Manager
Houston, Texas


KemFlo manufactures plastic random packing in a variety of styles and sizes including the Tri-Pack, Pall Ring, Saddles and Kemflake. All Plastic tower packing styles are available in a variety of materials including polypropylene, polypropylene with glass, CPVC, PVDF and more. Special packaging is available upon request. Please feel free to contact us or visit our website at for more information regarding the products we manufacture.

Kempac Plastic Random Packing Project Samples

Kempac plastic random packing has been utilized in numerous applications in order to improve system performance and decrease operational cost. The Kempac plastic random packing product line includes a number of packing media styles, sizes and configurations giving customers many solutions to meet their specific application. The Kempac product line which includes the Tri-Pack, Pall Ring, Saddle and KemFlake gives customer a variety of sizes, surface areas and other physical properties to choose from. The following are a few sample projects in which Kempac plastic tower packing was utilized.

Chemical Plant in Southern Louisiana was experiencing a lack of efficiency in several HCL scrubbers. During routine maintenance it was discovered that the inefficiencies were likely due to numerous void areas within the packed bed of the scrubber. They wanted to consider a packing style that was less prone to nesting and which would eliminate the possibilities of void area with in the packed media bed. This particular customer selected the Tri-Pack plastic random packing style due to its spherical geometric shape which allows each individual Tri-Pack to roll into the packed position with out forming void areas which are common to irregular shaped random packing styles. The change in packing styles resulted in an increase in scrubber operational efficiency.

A fishery in Washington state was utilizing a biological filtration system which cultivates the growth of bacteria that breaks down fish waste making the water safe for fish. Excessive bacterial or too little can negatively affect a system’s oxygen levels resulting in increased chances of disease and lower production. The maintenance operators of the facility discovered that the gravel filtration system that they were using was too dense and did not provide adequate open area within the gravel bed. After careful consideration the customer chose the Kempac Pall Ring which provided the ideal combination of surface area and open area. They also required that the plastic packing media not float so the packing was manufactured with a special polypropylene which had a specific gravity that was greater that one. The end result was that the Pall Ring style random packing helped to regulate proper bacterial growth and is now utilized in all biological filtration systems at this facility.

A company in South Texas who designs and manufactures skid mounted scrubbers was looking for an alternative to the metal packing that they were using. They specialized in customizing the skid mounted scrubbers to their customer’s specific applications many of which involved VOC scrubbing, nitrogen oxide, hydrogen sulfide and ammonia removal. They switched to the Tri-Pack plastic random scrubber packing due to the fact that it offered a tremendous amount of flexibility in design, was lighter in weigh, easier to install and was more cost effective compared to the metal packing that they were utilizing. A significant savings was realized by this customer without sacrificing design efficiencies.

For more information on KemFlo’s plastic random packing product line please visit our website at or give us a call. We would be happy to discuss your specific application and how we can help.

High Oil and Gas Prices and Plastic Random Packing

KemFlo utilizes various types of high performance plastic resins in the manufacturing of our plastic random packing product line which includes the Tri-Pack, Pall Ring, Saddles and KemFlake. These high performance plastic resins are created by hydrocarbons which come from the crude oil refining process. As with many products high oil prices affect plastic random tower packing in a number of challenging ways from manufacturing to logistics. Raw material cost of plastics such as polypropylene, polyethylene, Kynar and Tefzel have a direct correlation with the cost of oil so the higher the cost of oil per barrel the higher the cost of all plastic products such as plastic random packing. Plastic raw materials cost are quick to rise with the cost of oil but much slower to react as oil prices decrease. Therefore a spike in oil and gas prices can have long term affects on industry.

Planning ahead is key to minimizing the affects of an oil and gas price spike in the market. One of KemFlo’s strategies regarding this issue is to secure significant amounts of raw material as well as increase inventory levels at both distribution locations. Another major challenge that high oil and gas prices affect are logistical and transportation cost. High gas prices increase the cost to transport raw material to our manufacturing facility and increases the transportation cost to get plastic tower packing to our customers. KemFlo’s logistics team works closely with our network of transportation companies to find our customers the best rates possible.

Logistics and coordinating shipping can be very time consuming for our customers which is why KemFlo offers shipping assistance for our plastic random packing product line. We have also addressed rising oil and gas cost by adding an additional distribution center in Houston, Texas. The new distribution center will carry a variety of products including the Tri-Pack, Pall Ring, Saddle and KemFlake. All styles of plastic random packing carried at our Houston distribution center will be available in multiple sizes and resins. Our Houston, Texas facility will offer many advantages to our customers including more competitive logistic options especially to our customers in the Southern region of America and we will also have better access to raw material supplies due to the abundance of petrochemical facilities located in the Gulf Coast area. Having distribution centers that service both the Northern and Southern regions of the United States helps to keep our customer’s shipping cost and transit times down. Providing substantial access to our tower packing product line is an important measure in ensuring that our customer receive product in the most efficient and cost effective manner possible. The price of oil and gas in one of many long term challenges that our industry will face so it is extremely important for KemFlo to continuously evaluate how we do business and how we can better service our customer.

For more information regarding KemFlo’s plastic random packing product line including the Tri-Pack, Pall Ring, Saddle and KemFlake please visit our website at or contact us by phone.


Most plastic random packing manufacturers only offer a limited number of packing styles, sizes and available resins in which they can manufacturer their products out of. This can limit a customer’s options and an engineer’s ability to design a system specific to their or their clients needs. Plastic random tower packing is used in a wide range of applications, so it is extremely important that we at KemFlo give our customers options in which to work with. Our goal is to provide our customer with as many solutions and tools as possible, helping to ensure a successful design and system.
KemFlo’s Kempac plastic random packing product line offers the following solutions:

Tri-Pack: The Tri-Pack is a high performance plastic random packing that has become one of the most popular styles of tower packing on the market today due to its many features and advantages. The Tri-Pack is made up of a unique network of ribs, structs and drop rods which provide excellent liquid gas contact. It’s spherical design ensured even distribution with in the packed bed and prevents nesting or voids. The Tri-Pack offers the ideal combination of surface area and void space maximizing mass transfer capabilities while avoiding excessive surface area which can prevent proper gas liquid contact and increase operating cost. With multiple sizes available including 1”, 2” and 3.5”, the Tri-Pack offers significant design capabilities.

Visit the Tri-Pack Product Page

Pall Ring: The Pall Ring style tower packing is a traditional design similar to many metal random packing styles. The robust design of the Pall Ring features open wall construction reinforced with structs all of which provides significant surface area for liquid gas contact and provides strength to the overall design of the product. The Pall Ring is available in three sizes including 1”, 2” and 3.5”.

Visit the Pall Rings Product Page

Kemlox Saddles: KemFlo’s Kemlox Saddle style plastic random tower packing media is a modern take on an old school packing design. Added serrated edges promote high mass transfer rates by providing additional surface area for liquid gas contact. The serrated edges also help reduce packed bed settling and create lower column pressure drop. The Kemlox Saddle is available in 1”, 2” and 3” sizes.

Visit the Kemlox Saddles Product Page

Kemflake: The Kemflake is KemFlo’s newest addition to their Kempac plastic random packing product line. The Kemflake is a versatile, high performance packing that has been proven to provide superior capacity, high mass transfer capabilities and lower pressure drop. The Kemflake performs excellent in a variety of applications including scrubbing, air stripping, absorption and extraction. Available in one size 3.66” inch diameter by 1,18” thick.

Visit the Kemflake Product Page

All of the above plastic tower packing styles are available in a variety of standard and high performance resins including but not limited to Polypropylene both NSF and Non-NSF approved, Polypropylene with glass, Polyethylene, Polyvinylchloride PVC, CPVC, PVDF and more. Please feel free to contact us for other available resins. All resins used the KemFlo’s manufacturing process are traceable back to its source to ensure quality control.

For more information on KemFlo’s Kempac plastic random packing product line please visit our website at or give us a call. As always we look forward to earning your business.