Plastic Random Packing Articles

Scrubber Internals

Scrubber internals refers to a group of devices specifically designed to remove particulates and or gasses from industrial exhaust streams. Scrubber internals work together in achieving maximum removal efficiency of pollutants. Each scrubber internal has a specific function in the scrubbing process. The design of scrubber internals can range from very basic to extremely complex depending on the customer’s requirement and the exact application. Various materials can be used in the construction of internals including a vast variety of plastics and metals. Temperatures, contaminates and cost will typically determine the material of construction. For example, KemFlo can manufacture their plastic random packing product the Tri-Pack in a variety of resins including Polypropylene, CPVC, Kynar, Tefzel, Teflon and more. Scrubber internals include the following devices or items: Mist Eliminators are basically metal or plastic wire mesh held together with a grid on either side of the mesh and...

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KemFlo’s Commitment to Customer Service

Providing the highest quality plastic scrubber packing on the market backed by superior customer service is what sets KemFlo apart from other manufactures. KemFlo’s goal is to provide cost effective plastic scrubber packing solutions with the highest level of quality for our customers. We accomplish this by using innovative methods supported by a long history of experience and by utilizing current technological advancements and sound engineering solutions. Our employees are devoted to pursuing the challenges presented as a means to accomplish the end goal. We understand our customer’s demands and are committed to their complete satisfaction through open communication. We understand the demands and expectations our customers face day in and day out which is why we focus on customer service in addition to high quality manufacturing. Having exceptional products such as the high performance plastic scrubber packing Tri-Pack or spherical packing, the Plastic Pall Ring and the Plastic...

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Air Stripping

Contaminated ground water or surface water occurs when manmade products such as gasoline, oil and chemicals get into the water and cause it to become unsafe and unfit for human consumption. Since half of the United States population is dependent on groundwater it is extremely important to protect this resource.  Drinking contaminated groundwater can have serious health effects. Wildlife can also be harmed by contaminated groundwater. A good example are the pesticides and fertilizers that can find their way into groundwater or other water supplies. Other examples of sources of groundwater contamination include storage tanks which may become corroded, crack and develop leaks, Septic systems that are not maintained properly, Hazardous waste that is not properly disposed, landfill runoff, road salts and atmospheric contaminates.  One of the most efficient ways to clean contaminated ground water or surface water is to utilize an air stripper. Air stripping is the process of moving air...

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Air Scrubbing

Air scrubbers are air pollution control devices that use liquid to remove particulate matter or gases from an industrial exhaust or flue gas stream. In comparison to other air pollution control devices, scrubbers are a very efficient way of removing solids, mists, and gases while also providing cooling. They are also capable of handling volatile gases safely. However, scrubbers suffer from high levels of corrosion and produce slurry waste streams which are less convenient for recycling and disposal. Scrubbers are devices that use a liquid to capture and remove pollutants. Through a nozzle or orifice a scrubbing liquid is introduced into the gas stream. The droplets capture the dust particles. This increases the size and mass of the particles, making them easier to collect in a filter or separation process. The scrubbing liquid absorbs and neutralizes gaseous pollutants. Suspended liquid is typically recovered in mist collectors and recycled through the system. A key parameter in the...

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PARTNERING WITH KEMFLO

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...

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KEMFLO PRODUCT HIGHLIGHT: TRI-PACK PLASTIC RANDOM PACKING

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...

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PLASTIC RANDOM PACKING IN COOLING TOWERS

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...

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Private Label and Packaging

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...

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AIR SCRUBBING INTERNALS: PACKING SUPPORTS

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...

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TREATING CONTAMINATED GROUNDWATER

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...

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Biological Filters

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...

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Distillation

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...

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Spherical or Tri-Pack Style Plastic Random Packing

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...

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Kempac Plastic Pall Ring

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...

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PLANT SHUTDOWNS AND EMERGENCY MAINTENANCE

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...

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Troubleshooting Air Scrubber Internals

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...

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Packed Scrubber Components

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...

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KemFlo Plastic Random Packing Products

KemFlo manufactures a complete line of plastic random packing products for a variety of applications including Air Scrubbing, Air Stripping, Distillation, Biological Filtration and many more. KemFlo offers three different styles of plastic random packing, each offering unique physical properties and can be manufactured in a variety of plastic resins. Whatever your plastic random packing application is, KemFlo has a solution. One of KemFlo’s most popular plastic random packing styles is the Tri-Pack. The Tri-Pack is a high-performance packing which helps customer achieve optimum performance from their system. The Tri-Pack is a hollow spherical column packing constructed of a unique network of ribs, struts and drop rods. Its superior geometric shape gives it an advantage over other products on the market. Their spherical shape allows each element to roll into the packed position without forming void areas common to irregular shaped packing. With Tri-Packs there is no need for...

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Custom Plastic Random Packing Capabilities

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...

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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 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...

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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...

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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...

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Corrosion Problems with Wet Scrubbers

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?...

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Water Treatment and Maintenance

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.

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KemFlo Pollution Control Products

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.

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Plastic Random Packing in Trickling Filters

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...

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Selling Kempac Random Packing

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...

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Tri-Pack Makes the Difference

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...

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Using Plastic Random Packing in Aquarium Filtration Systems

KemFlo manufactures the Kempac plastic random packing product line which includes the Tri-Pack orSpherical style, Pall Ring and the Saddle style. While Kempac plastic random packing is utilized innumerous 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 aquariumboth 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 flowingthrough it. There are basically three main types of aquarium filter media: mechanical, biological andchemical. 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 mechanicalfilter in aquarium applications. Aquarium water flows through the mechanical...

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Kempac Manufacturing

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...

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KEMPAC SADDLE STYLE PACKING

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...

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Selecting the Best Resin for Your Application

Resin selection is an extremely important element in determining the most efficient plastic randompacking for your application. Much of the focus in selecting a plastic random packing or scrubberpacking is given to the size and configuration of the packing. While the selection of the size andconfiguration of random packing is critical to the performance of any column, the selection of theproper 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 ofwhich can be very costly in money and down time. While Kemflo can help guide you in the rightdirection when it comes the resin selection of a plastic tower packing for your specific application it isimportant for the customer to research various options in determining the best solution for them andtheir application. The customer must consider the chemical environment and maximum operatingtemperatures...

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