KemFlo manufactures the Kempac plastic random packing product line which includes the Tri-Pack or
Spherical style, Pall Ring and the Saddle style. While Kempac plastic random packing is utilized in
numerous applications, one of the more interesting applications is its use in aquarium filtration systems.
Aquarium filtration systems are an extremely important element in the overall health of an aquarium
both small and large. Filters facilitate the nitrogen cycle and help to keep aquarium inhabitants healthy.
Filter media is basically anything placed in a filter system that alters the quality of the water flowing
through it. There are basically three main types of aquarium filter media: mechanical, biological and
chemical.

Mechanical filter media removes unsightly particles and debris from the aquarium water such as sludge,
dust, fish excrement and uneaten food. Kempac plastic random packing may be used as a mechanical
filter in aquarium applications. Aquarium water flows through the mechanical filter media and particles
are strained out. Regular maintenance of the filter media is required in order to prevent build up. The
media strains solids from water passing through it which is vital for the efficiency of your biological
media. Special consideration should be given to the material of construction in regards to the filter
media to ensure that it does not interfere with the chemistry of the water. Kemflo offers the Tri-Pack,
Pall Ring and Saddle style plastic random media in a NSF certified polypropylene resin which is ideal for
applications where water quality is important. Mechanical media is available in many different
configurations and sizes. KemFlo offers the Tri-Pack in 1”, 2” and 3.5, the Pall Ring in 1”, 2” and 3.5” and
the Saddle style packing in 1”, 2” and 3”.

Biological media is material that provides housing got nitrifying bacteria that breaks down pollutants
into a less toxic form. Biological Media does not need to be replaced unless it becomes too clogged to
function. Nitrifying bacteria grows and lives on the packing material. The bacteria extracts oxygen from
water flowing through media filter. If the media becomes clogged decreasing water flow, it could starve
the system of oxygen and food causing the bacteria to die. An abundance of ammonia and nitrite
causes the bacteria to reproduce. Once the bacteria have become established in the biological media
they are difficult to destroy. There are various types of materials that can be used for biological media.
Plastic random packing provides a combination of surface area and open area in order to facilitate
bacteria growth and also provide enough open area for water flow. The Kempac Tri-Pack or Pall Ring are
excellent options for this type of filtering system.

Chemical media is effective at removing a variety of impurities, such as copper, chlorine, dissolved
proteins and more. The two most common forms of chemical media are activated carbons and resins.
Activated Carbon is filled with microscopic pores that cause certain organic or inorganic materials to
stick to them. When all of the pores are filled the carbon is no monger effective. Ion exchange resins
work by attracting specific molecules to adhere to them. Some attract ammonia or nitrate and some
remove dissolved organics.

For more information on the Kempac plastic random packing product line including the Tri-Pack, Pall
Ring and Plastic Saddle style random packing, please visit our website at www.kempac-packing.com.

In many cases our Kempac plastic random packing is utilized in extremely critical applications so not only does the packing need to be of the highest quality and meet high performance standards, we must have the capabilities to manufacturer packing quickly and efficiently supply it to our customer’s facility or job site. Kempac is manufactured and distributed by KemFlo. Manufacturing capabilities are an extremely important element in the supply of plastic tower packing which is why KemFlo has made significant investments in machinery, tooling and personnel.  KemFlo’s production facility features a number of injection molding presses ranging in multiple sizes and capacity. Such investments have been made in robotic arms and a bulk storage central material handling system. Kemflo is constantly evaluating their manufacturing processes to ensure that they are utilizing the latest advancements in injection molding technology in order to stay abreast of a highly critical industry and product line. In addition to having some of the most technically advanced machinery and equipment in the industry, Kemflo employees a highly trained equipment maintenance crew who ensures that production equipment and tools are maintained at all times.  KemFlo also has in house tool repair capabilities to ensure that all product tools and molds are ready for use. KemFlo has the capabilities to produce large quantities of plastic tower packing. KemFlo also has the capabilities to produce packing in specialty resins faster and more efficiently than any other company in North America. Manufacturing plastic tower packing in resins such as Glass Filled Polypropylene, CPVC, PVDF, Tefzel and Halar in a very timely manner are well within our capabilities. So whether you require a small amount of packing or a large amount of packing we can help. KemFlo manufacturing capabilities are supported by in house product design and engineering, prototyping, mold design, post molding capabilities, assembly capabilities and a very advanced quality assurance program.  KemFlo’s quality assurance program starts when a product is first introduced whether it is an existing or new product design. Our quality control department is continuously reviewing products for fit and function to ensure that all engineering requirements are met. KemFlo is committed to meet the quality and standards expected by our customers. Products are manufactured under the guidelines and certifications set out by CSA, NSF and UL. KemFlo’s plastic tower packing is shipped in five or ten cubic foot cardboard boxes or forty cubic foot supersacks depending on the type of packing and the individual customer’s requirement. KemFlo stocks plastic random packing in Houston, Texas and Canada. In addition to standard materials such as Polypropylene, we also stock CPVC, PVDF and other specialty resins. KemFlo manufactures several different styles of plastic tower packing including the Tri-Pack, Pall Ring and Saddle. The Tri-Pack is manufactured in 1”, 2” and 3.5”.  The Tri-Pack is a high performance packing constructed of a unique network of ribs, struts and drip rods. This packing is distinguished from other plastic random packing styles due to its superior geometric shape. KemFlo also manufactures a Pall Ring style packing that is available in 1”, 2” and 3.5”. the Pall Ring is a robust packing featuring an open wall construction which maintains even liquid distribution. The Saddle style packing is another option offered by KemFlo. The Saddle packing is offered in 1”, 2” and 3”. All packing styles are available in a variety of resins. For more information on Kempac please visit our website at www.kempac-packing.com .

Kemflo is one of the leading injection molding companies in North America and offers a complete range of services which support their extensive manufacturing capabilities.  KemFlo offers product design, prototyping, mold design, mold making, post molding capabilities, automated assembly and complete injection molding capabilities. KemFlo manufactures a variety of products that are used in numerous industries including industrial, chemical, agricultural, medical, construction and more.  One of Kemflo’s most successful product lines is their plastic random packing product line which is manufactured under the brand name Kempac. KemFlo manufactures multiple styles of plastic random packing including a spherical or Tri-Pack style, Pall Ring style and a saddle style tower packing. As with all products manufactured by KemFlo their Kempac product line is subjected to an extremely demanding quality assurance program. This ensures that our customers receive a high quality product that will perform in the most demanding environments.  

While there are numerous styles of plastic random packing on the market today, saddle style tower packing has been in use for many years.  Saddle style packing was one of the first styles of plastic random packing on the market. There are various takes on the saddle style packing and its overall design.  All types of Saddle packing performs differently so engineering calculations should be done based on the specific Saddle packing specification. Saddle packing is manufactured in a variety of materials such as plastics, ceramics and metals.  KemFlo manufactures their saddle packing in a variety of high performance plastics including Polypropylene, glass filled Polypropylene, High Density Polyethylene, Low Density Polyethylene, PVC, CPVC and PVDF. Please note that more resins are available upon request.  Also, KemFlo’s standard Polypropylene resin is certified by NFS to standard 61 for water treatment applications.  

Typical Saddle Style random packing is not considered a high performance packing due to its lack of surface area and overall design.  The high capacity Kempac plastic saddle offers distinct advantages over the conventional saddle design. The serrated edges of the Kempac Saddle style plastic random packing promote high mass transfer rates through effective liquid surface renewal.  The serrated edges of the Kempac saddle packing reduces bed settling during operation and assist to maintain packing free space and create lower column pressure drop. The Kempac Saddle Style packing is available in 1”, 2” and 3” sizes. They are available in five cubic foot or ten cubic foot cardboard boxes as well as forty cubic foot super sacks.  The proper installation is by dry dumping with reasonable care. The Kempac Saddle style plastic tower packing is utilized in a variety of applications including scrubbing, stripping, absorption, distillation, extraction, humidification, biological filtration and more.  

In addition to the saddle style packing KemFlo also manufactures a Tri-Pack style and a Pall Ring style plastic random packing. Each style of packing is available in a variety of sizes and they too are available in numerous high performance resins. Both the Tri-Pack and Pall Ring packing styles are available in 1” 2” and 3.5” sizes. A complete list of available resins can be found on our website. Please visit our website at www.kempac-packing.com for more information on Kempac plastic random packing or give us a call.  

Resin selection is an extremely important element in determining the most efficient plastic random
packing for your application. Much of the focus in selecting a plastic random packing or scrubber
packing is given to the size and configuration of the packing. While the selection of the size and
configuration of random packing is critical to the performance of any column, the selection of the
proper resin must not be over looked. Selecting the proper resin can increase the life of your system,
increase the time between maintenance and servicing the system and prevent material failure, all of
which can be very costly in money and down time. While Kemflo can help guide you in the right
direction when it comes the resin selection of a plastic tower packing for your specific application it is
important for the customer to research various options in determining the best solution for them and
their application. The customer must consider the chemical environment and maximum operating
temperatures among other variables when selecting the best resin for their tower packing. It is very
important that the process data and operating conditions are considered in this process.

Kemflo offers Kempac plastic random packing in a variety of resins to meet the most demanding
environments. Kemflo’s Kempac plastic random packing line includes the Tri-Pack style, Pall Ring, and
saddle style packing. The Tri-Pack style is available in 1”, 2” and 3.5”. The Pall Ring is available in 1”, 2”
and 3.5”. The Saddle style packing is available in 1”, 2” and 3”. All styles of Tower packing are available
in a variety of resins including but not limited to Polypropylene, Polyethylene, PVC, CPVC, Kynar (PVDF),
Tefzel, Teflon, Halar and more. Kemflo also has the capabilities to add various additives to the resins
such as glass which increases the resins heat resistance or talc which makes the product sink. If you have
a specific resin you would like for us to manufacture your plastic random packing out of, please feel free
to contact us to discuss.

The resins that we utilize are thermoplastics. Thermoplastics are heated then cooled in a mold to form a
part. Once the parts are cooled, they revert to their original state and can be re-melted and cooled
again. For this reason, thermoplastics are easier to reuse and recycle. They comprise most of the
manufactured polymer resins on the market today and are used in the injection molding process.
Thermoplastics are categorized by family and type. They fall into three broad categories or groups;
commodity resins, engineering resins, and specialty or high-performance resins. The high-performance
resins also come with a higher cost. That is why commodity resins are often used for many everyday
applications. Commodity resins are easy to process and are inexpensive. They are often found in typical
mass produced items like packaging. Engineering resins are more expensive but offer better strength
and resistance to chemicals and environmental exposure.

Within each of these families, some resins have different morphology. Morphology describes the
arrangement of molecules in a resin and fall into two categories, amorphous and semi-crystalline.
Amorphous resins have the following characteristics: they shrink less when cooled, offer better
transparency, work well for tight-tolerance applications, tend to be brittle and lack chemical
resistance. Semi-crystalline resins have the following characteristics: tend to be opaque, offer excellent
abrasion and chemical resistance, are less brittle and have higher shrinkage rates.
Some of the more common resins that plastic random packing is available in include:

Polypropylene Resin which is relatively inexpensive, flexible, tough, chemical resistant and fatigue
resistant. This is the most common resin from plastic random packing. Much of the inventory that we
keep for the Tri-Pack, Pall Ring and plastic Saddle are in polypropylene. Kemflo uses NSF polypropylene
resin to ensure a high quality product. Polypropylene packing is typically good for temperatures below
180 degrees F.

Chlorinated Polyvinyl Chloride (CPVC) Resin is another very versatile resin with a temperature rating of
up to 200 degrees F. Many plastic random packing manufactures do not offer this resin because it is a
very thick resin making it very difficult to manufacture in. KemFlo has no problem utilizing CPVC to
manufacture their plastic random packing.

Polyvinylidene Fluoride (PVDF) is a high-end resin with very good chemical resistance and a
temperature rating of up to 280 degrees F. This resin is commonly used in chemical scrubbers. Kemflo
keeps this resin in stock and can produce PVDF product quickly and economically.

For more information on Kemflo’s Tri-Pack, Pall Ring or Saddle style packings and the available resins for
these products, please feel free to visit our website at www.kempac-packing.com.