Stacked Disc Module Cartridge Filter
Depth Filtration and Adsorption in a Single Module: 0.2–60 µm
The stacked disc module cartridge filter is a lenticular depth module with cellulose, diatomaceous earth and activated carbon layers. On wine, beer, fruit juice, pharmaceutical and cosmetics lines, it is an enclosed, hygienic alternative to sheet filter presses.
30
0.2–60 µm
2–11
ISO 9001:2015
Stacked Disc Module Technical Specifications
The stacked disc module cartridge filter is a compact depth filter module made of cellulose-based cells stacked between polypropylene separators and working in an enclosed stainless housing. The diatomaceous earth and resin-reinforced sheet reduces haze-forming colloids and yeast load along with particles, without affecting the product’s taste or colour. This makes it the hygienic, enclosed alternative to sheet filter presses on wine, beer, fruit juice, syrup, vegetable oil, pharmaceutical and cosmetics lines.
Filtration grades from 0.2 µm to 60 µm, combined with cellulose fibre and activated carbon media series, suit coarse clarification, colour and odour removal and bioburden reduction tasks. Because the cartridges are made in 8″, 12″ and 16″ diameters, with 7 or 8 cells for 8″ and 9, 12, 15 or 16 cells for 12″ and 16″, with DOE or SOE (8″ only) connections and silicone, EPDM, NBR or Viton gasket options, they can be configured to suit your existing housing.
The right module is not chosen by micron rating alone. The media must be matched to the clarity and adsorption requirement, the diameter and number of cells to the line flow, and the gasket to the fluid chemistry and sanitisation temperature. When this match is right, the module brings the product to the target clarity in a single pass and protects the membrane stage.
Key Technical and Structural Features
- Filter Media
- Natural Cellulose Fibre
- With Diatomaceous Earth (DE / Perlite)
- Activated Carbon Impregnated Depth Layer
- Filtration Range
- Grades for clarification, bioburden reduction and coarse particle retention in the 0.2–60 µm range.
- Module Diameter and Dimensions
- 8″, 12″ (Ø291 mm) and 16″ (Ø402 mm) Diameter
- 8″: 7 / 8 Cells · 12″ and 16″: 9 / 12 / 15 / 16 Cells
- Operating Compatibility
- Food & Beverage Processes
- Beer, Wine and Beverage Clarification
- Biopharma and Pharmaceutical Industry
- Cosmetics and Chemical Lines
- Construction Type
- Hermetically sealed stacked disc (lenticular) module architecture with double separator support.
- Connection Types
- DOE (Flat Gasket, Standard)
- SOE (Double O-Ring, 8″ only)
- Production Model
- Standard industrial series production, with the flexibility to adapt lenses and housings to process flow.
- Quality Control
- Post-production verification of differential pressure integrity, appearance, dimensional tolerances and micron rating.
| # | 8" · 8 cells · Area 0.26 m² | 12" · 16 cells · Area 1.8 m² | 16" · 16 cells · Area 3.7 m² |
|---|---|---|---|
| 1 | 10 L/min 0.20 bar | 75 L/min 0.20 bar | 145 L/min 0.20 bar |
| 2 | 20 L/min 0.40 bar | 150 L/min 0.40 bar | 290 L/min 0.40 bar |
| 3 | 30 L/min 0.70 bar | 230 L/min 0.70 bar | 445 L/min 0.70 bar |
| 4 | 40 L/min 1.00 bar | 300 L/min 1.00 bar | 580 L/min 1.00 bar |
| 5 | 48 L/min 1.50 bar | 380 L/min 1.50 bar | 740 L/min 1.50 bar |
Flow and Pressure Drop in a Lenticular Module
In stacked disc filter cartridges, water flow rate varies with module size, number of cells and effective filter surface area. Thanks to the double separator structure, differential pressure stays balanced at high flow rates; with ΔP ratings of max. 2.5 bar for cellulose media and 2.0 bar for activated carbon media at 25 °C, and 1.0 bar at 80 °C, stable filtration is achieved in wine, beer, fruit juice and pharmaceutical production. As the filter surface area increases, the flow load per unit area decreases and service life is extended.
Balanced Pressure Drop at High Flow
- Balanced Differential Pressure
- High Particle Retention Capacity
- Long Service Life
- Energy Efficiency
- Wide Size Compatibility
Filtration Architecture and Working Principle
The key difference of stacked disc filter cartridges is their multi-layer depth filtration architecture, made of filter cells stacked on top of one another. The unfiltered liquid moves from the outer surface of each cell into the filter sheet; particles and colloids are separated by mechanical retention and adsorption throughout the full depth of the media.
Double Separator Architecture
Each filter cell is supported by a double polypropylene separator in contact with the upper and lower surfaces of the filter sheet. The double separator wraps the sheet from both sides and locks it mechanically; this design gives higher structural strength than conventional modules.
Depth Filtration Principle
The unfiltered liquid moves from the outer surface of the cartridge into the filter sheet; particles are separated by mechanical retention and adsorption throughout the full thickness of the media. In depth filtration, the contaminant load is spread over the entire media volume, giving higher particle retention capacity than surface filtration.
Central Core and Cage Assembly
The module is built from an ordered arrangement of separators, filter sheets and cell separators. The central core and cage system locks the layers together and ensures integrity. Filter sheets fitted leak-tight distribute flow evenly over the filter area. SIP can be applied only to the backwashable version; standard modules cannot be steam-sterilised.
Physical Construction and Effective Surface Area
| Size | Number of Cells | Diameter | Height | Surface Area |
|---|---|---|---|---|
| 12" | 9 Cells | 291 mm | 175 mm | 1.0 m² |
| 12" | 15 Cells | 291 mm | 275 mm | 1.7 m² |
| 12" | 16 Cells | 291 mm | 273 mm | 1.8 m² |
Raw Material and Structural Engineering Design
Our cellulose fibre series provides clarification and particle removal with resin, perlite and diatomaceous earth components, while our activated carbon series removes odours, colour compounds, organic pigments and metal ions with the same module construction. In both series, each filter sheet is individually supported between double polypropylene separators and gasketed. Particles are retained not only at the surface but throughout the full thickness of the sheet. This delays surface clogging, extends the cartridge change interval and lowers total operating costs.
| Filter Media | Cellulose Fibre and Activated Carbon |
|---|---|
| Filtration Type | Depth filtration |
| Micron Ratings | 0.2–0.4 · 0.4–0.6 · 0.6–1 · 1–3 · 2–5 · 3–7 · 10–15 · 25–30 · 40–50 · 50–60 µm · Activated carbon: 5 µm |
| Core / Support Structure | Polypropylene (PP) core and separator |
| O-Ring Gasket | Cellulose: Silicone, EPDM, NBR, Viton, E-FKM · Activated carbon: Silicone, EPDM, NBR |
| End Cap Type | DOE (flat gasket) · SOE (double O-ring, 8″ only) |
| Outer Diameter (Standard) | 8″ · 12″ (Ø291 mm) · 16″ (Ø402 mm) |
| Number of Cells | 7 Cells (8" SOE) · 8 Cells (8" SOE) · 9 / 12 / 15 / 16 Cells (12", 16") |
| Module Configuration | 8", 12", 16" Diameter · 7, 8, 9, 12, 15 and 16 Cell Options (DOE and SOE) |
Filter Material Chemical Compatibility Guide
In stacked disc cartridges, chemical resistance is determined by the media type and gasket material. Cellulose fibre media perform well with water-based solutions, dilute acids, alcohols, vegetable oils and fermented beverages; activated carbon media also remove organic pigments, odours and metal ions with high adsorption capacity. The gasket material (silicone, EPDM, NBR, Viton) must be chosen according to the chemistry of the process liquid; correct compatibility is decisive for process safety and filter life. Detailed values are given in the tables below.
E: Excellent · G: Good · F: Fair · P: Poor · N/R: Not recommended
Gas and Vapour Environments
| Chemical Group | Example Chemical | Cellulose Fibre | Activated Carbon |
|---|---|---|---|
| Low-Pressure Steam | Hot Sanitisation (≤100 °C) | G | G |
| Dry Air | Industrial Process Air | E | E |
| Oxidising Gases | Chlorine, Ozone Emissions | P | F |
| Acidic Gases | SO₂, NOx Emissions | F | G |
| Hydrocarbon Vapours | Petrol, Solvent Vapours | G | E |
E: Excellent · G: Good · F: Fair · P: Poor · N/R: Not recommended
Liquid Chemicals
| Chemical Group | Example Chemical | Cellulose Fibre | Activated Carbon |
|---|---|---|---|
| Dilute Acids | HCl, H₂SO₄ (<30%) | G | E |
| Concentrated Acids | H₂SO₄ (>70%), Fuming HCl | P | P |
| Oxidising Acids | Nitric Acid, Chromic Acid | N/R | P |
| Weak Acids | Acetic, Phosphoric Acid | G | E |
| Organic Solvents | Alcohols, Ketones, Esters | G | E |
| Strong Bases | NaOH, KOH Solutions | P | G |
| Inorganic Salts | NaCl, CaCl₂, Al₂(SO₄)₃ | E | E |
Operating Conditions
The performance of stacked disc filter cartridges depends not only on filtration precision but also on their ability to suit operating conditions. With a maximum operating temperature of 80 °C, differential pressure capacity of 2.5 bar for cellulose media and 2.0 bar for activated carbon media at 25 °C, and a wide range of chemical compatibility, Prosestim stacked disc filter solutions are configured to maintain process continuity, support equipment safety and deliver long-term operating efficiency. ISO 9001:2015 certified production and EU 10/2011-compliant material selection deliver reliable depth filtration performance across different industrial applications.
| Technical Parameter | Cellulose Fibre | Activated Carbon |
|---|---|---|
| Maximum Operating Temperature | 80 °C (176 °F) | 80 °C (176 °F) |
| Maximum Differential Pressure (25 °C) | 2.5 bar (36 psi) | 2.0 bar (29 psi) |
| Maximum Differential Pressure (80 °C) | 1.0 bar (14.5 psi) | 1.0 bar (14.5 psi) |
| Maximum Backwash Pressure | 0.5 bar (7.25 psi) @ max. 60 °C (backwashable version) | - |
| Sterilisation (SIP) | Backwashable version only: 125 °C, 30 min, max. 3 cycles, steam pressure <2 bar | - |
| Hot Water Sanitisation | 85 °C, 25–30 min | - |
Sterilisation and Disinfection
Backwash Note
Stacked disc modules in the backwashable version can be washed in the reverse of the filtration direction with cold water or hot water at up to 60 °C (140 °F) for 5–10 minutes at a differential pressure of no more than 0.5 bar (7.25 psi). Standard modules can be washed only under limited conditions.
Cleaning efficiency can vary depending on many different parameters, such as the nature of the process liquid, the contaminant load and the backwash pressure applied.
Sanitisation and Backwash Methods
| Method | Temperature | Duration / Cycles |
|---|---|---|
| Steam-in-Place Sterilisation (SIP) | 125 °C (backwashable version only) | 30 minutes, max. 3 cycles, steam pressure <2 bar |
| Hot Water Sanitisation | Max. 85 °C (185 °F) | 25–30 minutes |
| Backwashing (backwashable version only) | Cold water or max. 60 °C (140 °F) | 5–10 minutes, max. 0.5 bar ΔP |
Engineer's Note
- Senior Process Engineer
- 15+ Years of Field Experience
- Field-Test Approved
Stacked disc filter cartridges are designed especially for processes with a high solids load that require clarification and particle removal. However, the mistake we see most often in the field is applying a flow disproportionate to the filter surface area. For ideal efficiency, we recommend that system flow does not exceed 75% of the module’s capacity and that the flux calculation is based on the filter surface area.
When should it be chosen?
Used in processes with a high solids load such as wine, beer, fruit juice, edible oil and syrup, and for clarification and bioburden reduction in pharmaceutical and cosmetics production.
When should it not be chosen?
On lines containing concentrated strong acids (pH < 2) or strong bases (pH > 11), and in aromatic hydrocarbon and chlorinated solvent environments, cellulose fibre media may not be suitable; please contact our technical team for these applications.
- Pre-Filtration and Capacity Protection
- With a high particle and colloid load, pre-filtration extends the depth life of the stacked disc module.
- Differential Pressure (ΔP) Monitoring
- Check the calibration of the inlet/outlet differential pressure gauges regularly; plan module replacement when the differential pressure reaches 1.5 bar.
- Sealing and Lubricant Selection
- To keep the module adapter gaskets flexible, do not use mineral oil during installation; use only process-compatible silicone grease.
Industry Applications
Filter cartridges suited to different process needs are used across a wide range of industrial applications to protect product quality, safeguard equipment and support production continuity.
01
Vegetable Oil
Clarity, purity and shelf life in vegetable oil and refining.
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02
Pipe and Profile
Cooling water filtration in pipe and profile extrusion.
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03
Paint Industry
Surface quality and pigment filtration in the paint industry.
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04
Glass Industry
Furnace and process filtration in the glass industry.
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05
Dialysis Centers
Water preparation and process filtration in dialysis centers.
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06
Foundry Industry
Equipment protection and dust filtration in foundries.
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07
Industrial Oil
Filtration in industrial oil production and recovery.
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08
Energy and Biogas
Maximum efficiency and turbine protection in energy and biogas.
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09
Recycling
Filtration for efficiency and environmental compliance in recycling.
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10
Food and Beverage
Hygienic filtration in food and beverage.
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11
Pharmaceuticals and Biotechnology
GMP-compliant sterile filtration in pharmaceuticals and biotechnology.
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12
Paper and Packaging
Process water filtration in paper and packaging.
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13
Chemical Industry
Corrosion-resistant, safe filtration in the chemical industry.
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14
Cosmetics
Microbiological safety and precision filtration in cosmetics.
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15
Machinery
Precision and technical filtration in the machinery industry.
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16
Printing and Ink
Flawless color and print quality in printing and ink.
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17
Metal and Surface Treatment
Flawless surfaces and bath stability in metal and surface treatment.
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18
Forest Products
Resin and glue filtration in forest products and furniture.
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19
Automotive
Precision process filtration for zero defects in automotive manufacturing.
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20
Oil and Petrochemicals
Equipment protection and process safety in oil and petrochemicals.
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21
Plastic Packaging
Precision process filtration and raw material purity in plastic packaging.
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22
Plastic Injection Molding
Cooling and hydraulic filtration in plastic injection molding.
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23
Water and Environment
Recovery filtration in water and environmental technologies.
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24
Shipyards and Marine
Operational safety and efficiency in shipyards and marine.
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Stacked Disc Module Cartridge Filter
Your Questions Answered
Frequently Asked Questions
At Prosestim, we are committed to answering your questions and providing technical support for our filtration solutions.
What is a stacked disc cartridge filter and how does it work?
A stacked disc cartridge is a depth filter module made of independent filter cells stacked on top of one another. 7 or 8 cells in 8″ modules and 9, 12, 15 or 16 cells in 12″ and 16″ modules are combined into a single compact unit that works inside an enclosed stainless housing. It replaces conventional plate-and-frame presses.
Retention happens through two mechanisms. In mechanical retention, the tortuous pore structure captures particles in the depth of the material rather than at the surface. In adsorption, the positive charge that the diatomaceous earth and resin system gives the matrix retains negatively charged colloids and haze formers smaller than the pore diameter. This gives a much higher dirt-holding capacity than a membrane cartridge of the same micron rating.
What is the number of cells and filter area for 12" and 16" cartridges?
The standard diameter of a 12-inch module is Ø291 mm and of a 16-inch module Ø402 mm. A 12-inch 16-cell module is about 273 mm high. Cell options are 7 or 8 for the 8-inch module and 9, 12, 15 or 16 for the 12- and 16-inch modules; the effective filter area of a 12-inch 16-cell module is 1.8 m². Note: the wet weight of large-diameter double-layer models can exceed 25 kg, so handling assistance is needed.
How do I choose the right micron rating?
The range is from 0.2 to 60 microns. 10–60 microns are used for coarse filtration, 1–10 microns for clarification, 0.4–1.0 microns for fine filtration and 0.2–0.4 microns for microbial reduction. These values are nominal, not absolute. Thanks to adsorption, a depth filter also retains below its nominal rating, but it cannot be validated as a sterilising filter. If sterile filtration is required, the stacked disc module is not the final stage but the protective stage ahead of the membrane. Do not choose by the water permeability figures in the catalogue. These are laboratory values that characterise the sheet, not recommended flow rates. A low flux almost always gives a longer service life and better economics.
What is the difference between cellulose with diatomaceous earth and pure cellulose media?
Conventional media are a mix of cellulose, diatomaceous earth and resin, with an ash content of 16–58%. Pure cellulose premium media contain no minerals, with an ash content below 1%.
The advantage of media with diatomaceous earth is strong adsorption; the disadvantages are that they release calcium and magnesium into the product and have a low wet burst strength (40–110 kPa). Pure cellulose has a burst strength above 150 kPa and high fidelity of taste and colour, but its retention is more mechanical.
Three special cases: for spirits and flavourings, series with reduced calcium and magnesium content are used, otherwise haze forms later in the bottle. Pharmaceuticals require series with documented endotoxin values (such as <0.025 EU/ml after 25 l/m² WFI). For high viscosity and particle loads, high-strength coarse series are preferred.
How do I determine when to change the cartridge (maximum differential pressure)?
The maximum operating temperature is 80 °C, and the maximum differential pressure at 25 °C is 2.5 bar for cellulose media and 2.0 bar for activated carbon media. The recommended differential pressure for module replacement is 1.5 bar. Looking only at the drop in flow is misleading, because flow can be maintained by increasing pump pressure, and that is what really damages the filter. In microorganism removal applications, 1.5 bar must not be exceeded. At high differential pressure the matrix compresses and retained microorganisms can pass downstream. The filter stays intact, but microbiological safety is lost.
How is the cartridge washed, sanitised and sterilised?
Flushing before first use is mandatory: 50 l/m², at 1.25–1.5 times the process flow and with water at no more than 85 °C. If skipped, loose particles and odour pass straight into the product. After flushing, the system must be tested for leak-tightness at the maximum operating pressure.
For hot water sanitisation, once 85 °C is reached at the housing outlet, circulate for 25–30 minutes, then rinse with purified water until the outlet water is odourless.
Steam-in-place sterilisation (SIP) can be done only with the backwashable version: 125 °C, 30 minutes, no more than 3 cycles and steam pressure below 2 bar. Standard modules cannot be steam-sterilised. Contact our technical team to determine the right model for your application.
Do backwashable module cartridges really extend service life?
Yes. Backwashable cartridges are regenerated by washing in the reverse of the filtration direction, first with cold and then with hot water. Typical parameters: maximum differential pressure of 0.5 bar, cold water or hot water at up to 60 °C, 5–10 minutes. According to manufacturer data, backwashing can typically extend module life by 30–50%.
Conventional cartridges cannot withstand this; because the sheets are exposed, reverse water pressure tears them. The solution comes from two designs: a honeycomb polyester woven layer placed between the cells (which gives every cell an equal inlet and protects the sheet), or a double separator structure that supports the media from both the inlet and outlet sides.
Application requirement: even if no separate kit is needed, stainless intermediate plates and lower and upper guide plates must be used.
Realistic expectation: in theory, cost falls as the number of cycles increases, but retention performance declines slightly with every cycle. On critical microbiological stages, limit the number of cycles and support the decision with turbidity and microbiology data.
Can cartridges from different brands be used interchangeably?
Dimensions are standard (12″ Ø291 mm, 16″ Ø402 mm, height about 273–275 mm), so most cartridges physically fit. Real compatibility, however, depends on the adapter type, gasket material and the housing’s compression system. If any of these do not match, the fluid bypasses the filter.
12″ and 16″ modules work with a flat-gasket (DOE) adapter; the double O-ring (SOE) option is available only for 8″ modules. Versions with grounding assemblies are available for ATEX environments. For gaskets, silicone is standard, EPDM is used for hot water and steam, NBR for oils and hydrocarbons, Viton for aggressive chemicals and E-FKM for wide chemical compatibility. In the activated carbon series, only silicone, EPDM and NBR gaskets can be chosen.
Legislation must also be checked. In food and beverage, the EU 1935/2004 and EU 10/2011 food-contact compliance standards are required, plus LFGB for Germany. Note: not every cartridge that fits the same housing has the same scope. For some industrial series, the manufacturer explicitly states that they are not suitable for food contact. Matching only micron rating and size can put you outside the regulations; before changing, read the intended-use and restrictions sections of the technical bulletin.
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