Plastic Random Packing Articles

Increases in production and the demands for more environmentally friendly processes has highlighted the importance of mass transfer equipment and products such as plastic random packing. While all components and internals of an air scrubber or air stripper are important, the plastic random packing plays an extremely critical roll in the overall efficiency of a system. We have seen a significant increase in the attention given to the specific design of a particular tower packing style and more focus on its size, surface area and configuration as it relates to performance. More attention has also been given to the plastic random packing’s material of construction. Customers are increasingly performing product life span analysis and long term operating cost evaluations in an effort to get the most out of their system’s performance. This is why Kem-Group USA offers a diverse line of plastic random packing products in a variety of configurations and materials. Tower packing styles include...

As a leading manufacturer and supplier of plastic random packing Kem Group USA is continuously evaluating our supply chain management, manufacturing processes, customer service and research development efforts to ensure that we can meet or exceed our customer’s expectations and needs. The random packing industry has faced numerous challenges over the last few yours such as COVID which have created shortages in raw material availability and increased cost. Kem Group USA has worked closely with suppliers and customers to minimize any negative affect to our efforts to plastic random packing. In addition to our continuous efforts to control the cost of our finished products we offer an extremely diverse random packing product line which gives our customers a variety of options from both an application and design position. Our Tower packing product line includes the high performance Tri-Pack who’s design results in efficient mass transfer and lower operational cost. The Tri-Pack is...

If random packing is required for your application, Kem Group USA can help you determine the most efficient and economical plastic random packing. As a leading manufacturer of plastic random packing Kem Group USA offers random packing in a variety of sizes, configurations and materials. Kem Group offers the Tri-Pack, Pall Ring, Saddles and KemFlake random packing in a multiple sizes and resins. The following should be considered what selecting the plastic random packing best suited for your application:Uniform DistributionRandom Packing should facilitate even distribution of liquid and or gases through out the packed bed and be free of void spaces and channels. Some random packing products such as the Tri-Pack are specifically designed to avoid settling and nesting so that uniformed distribution through a packed bed can be achieved.The Surface Area of the Random PackingToo much surface area can impede proper gas and liquid contact and results in higher pressure drop resulting in...

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...

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 EngineerDeer 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...

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...

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...

As facilities across the country prepare for the upcoming Fall turnaround season, they face many new challenges. The COVID virus has caused disruptions in raw material availability, manufacturing, logistics and labor shortages. It has also changed the way business is done so facilities, manufactures and suppliers have had to adapt. Planning ahead this turnaround season will be critical to the success of upcoming projects but as we all know emergency situations happen. Quick turn requirements during turnarounds are very common and can create enormous complications. In many turnaround situations process equipment and components cannot be inspected until the equipment is offline. If during the inspection it is determined that the plastic random packing needs to be replaced there is typically a narrow window of time to have the plastic tower packing on site and installed. That is why KemFlo is working hard to ensure that sufficient inventory levels of the Tri-Packs, Pall Rings and...

KemFlo, best known for manufacturing plastic random packing, is pleased to announce that they are opening a new facility in Houston this Fall. This addition will not only increase our capabilities in servicing the United States of America, it will also allow us to better service our international customers as well. Increased demand for KemFlo’s plastic random packing products such as the Tri-Pack, Pall Ring and Plastic Saddles has facilitated the opening of the new facility in Houston, Texas. The new facility will help ensure that our customers continue to receive high quality products in a timely manner. Houston, Texas was selected for the new location based on its proximity to major chemical plants along the Gulf Coast and its many logistical advantages to servicing the Southern United States of America. The new facility will be located just West of town in the Katy area and will act as both a distribution center and manufacturing facility with complete injection molding...

Scrubber tower packing is an essential part of the system by providing an area for liquid and gas contact. Without proper or sufficient liquid gas contact a scrubber will not produce the designed results and could result it costly repairs and redesigns. Special consideration should be given to the selection of scrubber tower packing. Things to consider when evaluating and selecting scrubber tower packing include. Size, configuration, surface area, weight, void space and material of construction. Scrubber Tower packing is manufactured in a variety of materials including thermoplastics, metals and ceramics. To determine the most suitable material of construction for your random packing the operating temperature and the composition of the gas and liquid must be considered. Applications that involve higher temperatures or highly corrosive elements may require high performance or exotic materials. For example, KemFlo manufactures plastic random packing in a variety of thermoplastic resins...

Kemflo has been manufacturing plastic random packing since the 1980s and had developed a worldwide reputation for quality and efficiency.  Kemflo’s vast experience in injection molding a wide range of thermoplastics sets it apart from other plastic random packing manufacturers. Kemflo produces multiple styles of plastic tower packing including the Tripack, Pall Ring and Plastic Saddle style random packing. Each plastic random packing style is available in three different sizes and a variety of resins.  Some of the resins that Kemflo manufactures their plastic tower packing in include polypropylene, polyethylene, polypropylene with glass fill, polyvinylchloride, CPVC, Kynar, Tefzel, Teflon and Halar. Other resins are available upon request. Working with a vast array of thermoplastic resins, including high performance resins, requires skill, experience and a very high level of quality assurance.  Everything from the design of the mold and tooling to the final product requires strict...

Kemflo is well known for their plastic random packing product line which includes three styles including the Tripacks, Pall Ring and saddle plastic random packing.  Now Kemflo offers a variety of column internals to compliment their plastic tower packing products through a third-party partner in the United States. Kemflo is continuously seeking ways to support our customers and provide high quality products that not only meet but exceed our customer’s expectations.   Kemflo manufactures three different styles of plastic random media including the Tripacks, Pall Ring and Saddles plastic random packing style.  The Tri-packs is a hollow spherical column packing that is designed with a network of ribs, struts and drop rods.  Unlike irregular shaped plastic random media the Tri-Packs is specifically designed to roll into the packed bed without creating any void areas within the packed bed unlike other plastic random media styles.  The unique design of Tri-Packs offers predictable and...

​While Kemflo may be best known for their Kempac plastic random packing product line, we are also known for our tank accessory product line also referred to as AIK. In addition to our plastic random packing product line which includes the Tripack, Pall Ring and Plastic Saddle style, we manufacture a variety of tank accessory products under the AIK product name. The AIK product line includes the following products:  Man-Way Covers: Our new and improved Man-Way Covers and Rims are constructed from High Density Polyethylene which provide excellent impact properties especially in cold weather. The newly designed center air breather provides optimum venting performance and extremely easy to install and remove air breather which is designed with a tether connection that fastens into the rim helping to reduce misplacement. The Man-Way Lids are offered in closed and vented versions depending on the customer’s specifications. We also offer a variety of lid vents.  Private labeling is...

Kemflo has been a leader in the injection molding industry since 1988, manufacturing a broad range of products for numerous industries including industrial, energy, chemical, medical, construction, agricultural and environmental. Kemflo’s manufacturing capabilities are demonstrated by the diversity of the products that they manufacture which include but are not limited to pipe fittings, plastic scrubber packing, chevron mist eliminators, electrical components, pool / spa fittings, tank manway covers, specialty tank accessories, medical equipment connections and many more products. Kemflo separates itself from other plastic injection molding companies by offering their customer a host of inhouse services including product design, prototyping, mold making , post mold capabilities, assembly capabilities and a complete quality assurance program. Whether a customer needs assistance in manufacturing an existing product or a customer product Kemflo can has the experience and capabilities to...

Plastic Random Packing such as the Tripacks and Plastic Pall Ring manufactured by Kemflo are used in numerous applications such air scrubbing, air stripping, distillation and biological filtration to name a few. One of the most common application for plastic random packing is for use in cooling towers. A cooling tower is basically a specifically designed heat exchanger which function is to cool water from an industrial process or from an air conditioning condenser. Water that has been heated by an air conditioning condenser or industrial process is pumped into the cooling tower through a series of pipes. The heated water is introduced into the cooling tower through a network of spray nozzles located near the top of the system. The spray nozzles evenly distribute the heated water over a bed of fill or media. The bed of fill is typically plastic random media supported by a grate. The size of the packed bed depends on the volume of water and air. It is very important to ensure that the...

Kemflo has been manufacturing high quality plastic injection molded parts and products since 1988. In addition to manufacturing KemFlo offers product design and engineering, prototyping, mold making and design, post molding capabilities and quality assurance program that id second to none. Expanding our capabilities and services to meet our customer’s needs has always been an important focus for KemFlo. Our primary goal at KemFlo is to provide cost effective product solutions with the highest level of quality for our customers. In order to achieve this we are constantly evaluating our customer’s needs to ensure that we have the capabilities and services to meet and exceed those needs. KemFlo has a vast amount of experience in manufacturing numerous products and parts for multiple industries including Industrial, oil and gas, chemical, medical, agricultural, energy, construction, environmental and more. Over the years Kemflo has added a number of value added services to meet our...

One of the most important air scrubbing internal components is the random packing support. The design, configuration and positioning of the packing support is critical in ensuring optimal system performance. The specifics of a particular system, the design criteria as well as the cost will determine the packing support’s style, size, thickness and material of construction. The design criteria will help determine if a standard packing support is sufficient or will a gas injection packing support be required. The open area of a packing support must be designed such that the specified plastic random packing cannot fall through its openings. Whether the Tripack or Pall Ring packing is required for a specific system, the design of the packing support must consider the exact dimensions of the plastic tower packing. For example, if you are designing to support the 2” Pall Ring packing you can contact KemFlo for exact part dimensions. The operating temperature as well as the chemical or...

Contaminated ground water is one of the important challenges that we will face in the future. Over half of the United States population depends on groundwater as their source for drinking water. Groundwater is also a major source of water for irrigation. It is in everyone’s interest to protect ground water and ensure its use for generations to come. Unfortunately, groundwater is susceptible to pollutants. Man-made products such as oil, gas and chemicals may get into the groundwater making it unfit for human consumption. Drinking contaminated ground water can have very serious health effects such as hepatitis, dysentery and various forms of cancer. Ground water can also harm wildlife and vegetation. Sources of groundwater contamination include: Industrial storage tanks which may corrode, crack and develop leaks. There are over ten million storage tanks buried in the United states alone. Septic systems are another source. If a septic system is improperly designed or maintained it may...

One of the most common applications for Kemflo’s Kempac plastic random media is biological filtration. Kemflo’s Tri-Pack style, Plastic Pall Ring or Plastic Saddle packing are ideal for use is biological filtration applications. From small systems to large systems Kemflo has a plastic random media for you. Most modern biological filters have a bed of plastic random media over which wastewater is continuously distributed. The plastic random media bed can range in depth from one to more than ten meters deep. Wastewater is applied uniformly over the plastic random media by filter feeds and distribution systems. An underdrain system is provided to collect filter effluent for transport to a clarifier for solids separation. A biological filter does not actually purify wastewater by any filtering or straining action, but by absorption and biological oxidation of the soluble. Organic matter in the wastewater. Wastewater applied to a biological filter usually has undergone primary treatment...

Distillation is a common application where KemFlo’s plastic random media is utilized. KemFlo’s plastic random media has many advantages including overall efficiency, corrosion resistance, durability and weight. KemFlo manufactures their plastic random media under the Kempac brand name and offer a Tri-Pack style, plastic Pall Ring and plastic Saddle packing. All three packing styles are available in three different sizes and a variety of resins. Available resins include Polypropylene, Polypropylene with glass, CPVC, PVC, PVDF and more. Distillation is a commonly used process for separating mixtures based on differences in the conditions required to change phase of components of the mixture. To separate a mixture of liquids, the liquid can be heated to force components, which have different boiling points, into the gas phase. The gas is then condensed back into liquid form and collected. Repeating the process on the collected liquid to improve the purity of the product is called double...

For over thirty years KemFlo has been manufacturing high quality injection molded products utilizing numerous materials and resins.  KemFlo offers complete product design, prototyping, mold making, post molding capabilities and assembly capabilities. Our custom capabilities and experience allows us to take a customer’s idea and turn it into an actual product.  Kemflo’s quality assurance program ensures that all products meet or exceed our customer’s standards. Our quality assurance program involves a review process where the product is evaluated for fit and function, engineering requirements and product validation. We manufacture products for a variety of industries including Industrial, Chemical, Agricultural, Environmental and more.   One of KemFlo’s most successful products lines is their plastic random packing line which is marketed under the Kempac brand name.  The Kempac family of products include three styles of plastic random packing including the Tri-Pack, Pall Ring and...

Kemflo, established in 1988, has developed a solid reputation for the design and manufacturing of high quality injection molded products. KemFlo has extensive experience in the injection molding of a wide range of thermoplastic resins both in commodity and specialty type resins. Our wide range of services in part, design, prototyping, mold design and post mold services allows us to provide our customers with a single complete source for their injection molding needs. Today Kemflo provides products and services into many different markets and has accumulated a wealth of experience in materials, design and processes. One of KemFlo’s most successful product lines is the Kempac plastic random packing line.  The Kempac plastic random packing line includes several different styles of high performance packing including the Tri-Pack style, plastic saddle packing and the plastic Pall Ring.   The Kempac plastic Pall Ring is a Robust ring featuring an open wall construction which efficiently...

Plant shutdowns and emergency maintenance at any chemical plant, refinery or manufacturing facility across the country creates many challenges for those involved. Whether the shutdown is planned or not, proper planning is critical to successfully completing the job. Planning ahead to meet any potential shutdown or maintenance situation can save a facility significant time and money. Planning ahead can also help ensure that the proper products and equipment are available when needed. Keeping an inventory of long lead time or hard to find products can give a facility a major advantage in managing shutdown and emergency maintenance jobs. An emergency inventory may or may not be possible for many facilities due to a variety of reasons such as cost and storage room for the inventory. KemFlo understands the challenges that facilities around the world face which is why we have significantly increased our manufacturing capabilities for producing the Tri-Packs, Saddle style and Pall Ring...

Having to troubleshoot air scrubber internals can be a complex process because there are so many things that can contribute to an under performing system. Air scrubber internals are typically designed based on very specific process data and performance parameters. Many details must be considered in the design and selection on Air scrubber internals such as material selection, configuration of the part and cost to name a few. All scrubber internals must be designed to work to gather in order to achieve maximum efficiency. Because there are so many factors involved in designing air scrubber internals troubleshooting an under-performing system can be complex and time consuming. The first task that should be addressed when troubleshooting an air scrubber is to confirm and check all calculations and design data. In some cases a simple adjustment in the scrubber pressure or liquid rate may fix the efficiency issue. You can also consider making adjustments to the systems operations and...

KemFlo specializes in the manufacturing of plastic random packing which is utilized in air scrubbing, air stripping and other mass transfer applications. KemFlo is unique in that they have the ability to manufacture their plastic random packing in a variety of resins. While Polypropylene is the most common resin used in manufacturing plastic random packing, KemFlo also manufactures plastic random packing in specialty resins such as CPVC, PVDF, Polypropylene with glass, PFA and more. Please visit our website or call us for a complete list of available resins. Kemflo offers three different styles of scrubber packing, the Tri-Pack style, Pall Ring and Saddle. The Tri-Pack is available in 1”, 2” and 3.5”. The Pall Ring is available in 1”, 2” and 3.5”. The Saddle is available in 1”, 2” and 3”. While the packing type and size is one of the most important elements in the design of a scrubber there are other important components to consider such as packing supports, bed limiters, mist...

KemFlo is known for manufacturing plastic tower packing in multiple configurations and in a variety of resins. In addition to manufacturing the highest quality plastic random packing on the market under the Kempac brand name, KemFlo also has the capabilities to manufacture custom plastic random packing to your specific specification. Kemflo can take your product from design to production. The process includes product design / engineering, prototyping, mold design, mold making, production and quality assurance. Product Design: Kemflo offers complete design and engineering services. Our engineering staff will work closely with you to ensure that your plastic random packing is designed in the most efficient and cost effective way possible. KemFlo works with the latest in computer aided design software. KemFlo’s engineering department utilizes both 2D platform as well as the most advanced 3D software such as SolidWorks, Siemens PLD and Pro Engineer. KemFlo’s 31 years of experience in...

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 hasaccumulated 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...

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...

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...

Corrosion is one of the most challenging and costly issues seen across all markets worldwide. Billions of dollars are spent dealing with the effects and in the prevention of corrosion. Engineers are tasked with the job of designing in such a way that minimizes the effects of corrosion. Luckily there are many high performance materials and systems for engineers to utilize in their efforts to combat the effects of corrosion. Cost and material availability must be weighed against long term performance of a system. Air pollution control engineers must consider the following design criteria when designing wet scrubbing equipment:king.com. Technical performance: Does the unit consistently meet the specified air cleaning efficiency? Reliability: What are its weaknesses and how can we protect against damage or failure? Outage: How much of an outage can be tolerated without loss and how quickly can the unit be repaired or replaced? Cost: What is the most cost effective system?...

The importance of developing a proper maintenance plan before an air stripper or scrubber goes into service can not be overstated. Protect the investment you made in your column by reducing or eliminating the affects that scaling and fouling has on plastic tower packing and internals.

For over 30 years KemFlo has been manufacturing high quality injection molded products for the industrial, agricultural, environmental, construction and medical industries. Kemflo offers product design and engineering, prototyping, mold design, mold making and has complete assembly capabilities.

KemFlo’s Kempac plastic random packing is used in numerous applications where acombination of surface area and open space are required. KemFlo manufactures threedifferent styles of plastic random media including the Tri-Pack, Pall Ring and Saddle Style, eachwith distinct physical properties in regards to geometric surface area and void space. One ofthe more common applications for plastic random media are trickling filters. Trickling filters are one of the oldest water treatment processes in the United States andaround the world. The first trickling filter was built in Europe in the late 1800’s. In general, thetrickling filter is an aerobic treatment system which utilizes microorganisms attached to plasticrandom packing or some other media to remove organic matter from wastewater that passesover it. This is also referred to as an attached growth process. Trickling filters remove ammonianitrogen by oxidizing it to nitrate nitrogen. This process is known as nitrification. Nitrification...

When customer contact KemFlo regarding plastic random packing they typically have an idea of what they are looking for in general terms but rely on Kemflo’s sales team to walk them through the various options in selecting the best random packing for their specific application. Every customer’s needs are different. Some customers are looking to optimize the performance of their scrubber while other are more concerned with overall cost, but most customers are looking for a balance between performance and operating cost. Therefore, it is important to present customer with all available plastic random packing options. Typically the discussion begins with what style of packing the customer is looking for. Do they want a high performance packing such as the Tripack or do they want a more basic packing such as the Pall Ring or plastic saddle style? KemFlo’s Tripack plastic random packing is a high performance plastic random packing which is uniquely designed with a network of rids, structs...

A major municipality in Southern Florida was experiencing significant problems with several odor control scrubbers. Heightened levels of Hydrogen Sulfide gas had resulted in major odor issues. In addition to the significant odor issues they were experiencing due to high levels of Hydrogen Sulfide there was also a problem with corrosion. The high levels of Hydrogen Sulfide gas was also greatly accelerating the rate of corrosion of the scrubber equipment. After a through inspection of the scrubber units the maintenance supervisor discovered that the plastic random packing had become brittle and was breaking into small pieces. The broken pieces of plastic random packing were collecting at the bottom of the scrubber restricting the liquid and gas flow. The flow restriction or plugging of the unit prevented the scrubbers from functioning properly resulting in increased odor and corrosion. The facility maintenance supervisor wanted to find a plastic random packing that was more efficient...