Improved performance and maximum energy savings in critical processes

• Unique membrane air filter medium with high collection efficiency, superior mechanical strength, chemical resistance, and up to 50% lower operating pressure difference

• New HEPA and ULPA filter technology tailored to the highest requirements of the pharmaceutical and microelectronics industries

At the ICCCS Symposium in Zurich, AAF officially introduced its new proprietary NELIOR Filtration Technology. HEPA and ULPA filters from AAF with NELIOR Filtration Technology offer significant added value for applications with the particularly high demands of the pharmaceutical and microelectronics industries — areas where air quality directly influences process performance, product quality, and ultimately human health. The potential benefits generated by air filtration solutions with NELIOR Filtration Technology are demonstrated by the newly developed AAF Life Cycle Valuation Program.

About NELIOR Filtration Technology

NELIOR Filtration Technology is based on patented membrane air filter media, developed by AAF engineers and manufactured at one of AAF’s production facilities. It features a special composition and mechanical strength, resulting in unique performance characteristics in HEPA and ULPA filtration, unmatched by other currently available air filtration media on the market.

The NELIOR membrane air filter medium consists of a highly homogeneous fiber layer, with fiber diameters around 100 nanometers. This ensures up to 50% lower operating pressure difference while maintaining the highest collection efficiency compared to conventional high-performance filter media. Furthermore, a recent study conducted by the renowned ÖP Textile Testing Laboratory in Germany confirmed the superior mechanical strength of the NELIOR membrane air filter medium. The test cycle included various comparison tests on tensile strength, burst pressure, and abrasion resistance of both media types. Notably, traditional media lose strength after folding, whereas NELIOR membrane air filter media remain intact. The investigation also showed high resistance to damage from mishandling and improper installation. In daily practice, this means a significantly reduced risk of filter failure, and contamination of ambient air through fiber shedding is eliminated. For risk management in highly sensitive cleanrooms, these results offer a new perspective. Due to their high mechanical strength, HEPA and ULPA filters with NELIOR Filtration Technology provide a clear improvement — reliable process conditions and reduced reinstallation and failure costs. As such, they are a vital link in the entire value chain.
The superior composition and mechanical strength are complemented by a chemically inert and hydrophobic media structure, creating a unique combination of advantages for the most sensitive process areas. AAF’s HEPA and ULPA filters with NELIOR Filtration Technology offer an absolute advantage through consistent air quality, improved process performance, environmental benefits, and favorable overall operating costs.

Georg Schuermann, Vice President Sales & Marketing for AAF Europe: "With our new NELIOR Filtration Technology, we present the next generation of air filtration for industries that rely on strict control of air purity conditions. Industries where even the slightest contamination can make the difference between success and failure. Through extensive communication and visits to our customers across Europe, we have gained valuable first-hand insights into our new HEPA and ULPA filters with NELIOR membrane air filter media. Feedback after presenting our technology at the ICCCS Symposium 2012 shows that the new AAF technology makes a difference when it comes to providing the market with a unique solution for ongoing challenges in quality and process management.”

HEPA / ULPA application solutions

Each individual process application has its own challenges; it is always essential to ensure that the necessary conditions for air cleanliness are met to maintain process quality at the highest constant level. This means that requirements for air filtration vary depending on the application. Therefore, AAF has developed new HEPA and ULPA filters with NELIOR Filtration Technology that meet even the strictest demands across various industries. Specifically, the NELIOR Filtration Technology has led to the development of the VITCAcel filter series for the pharmaceutical industry, while the AAF engineering team has further advanced the MEGAcel product line for microelectronics.

The pharmaceutical industry requires absolutely sterile conditions for the production of active pharmaceutical ingredients or for aseptic manufacturing of parenteral medicines. Adverse effects on medical products must be prevented, and GMP requirements must be met. A reliable and high-performance, end-stage air filter is therefore crucial. The new VITCAcel HEPA / ULPA filter series with NELIOR Filtration Technology demonstrates superior air filtration performance in pharmaceutical applications, meeting the highest standards through high particle separation efficiency, superior mechanical strength, and extremely low operating resistance. VITCAcel is available in filter classes H14 and H16 according to EN1822:2009, for applications in ISO 5 / GMP Grade A cleanrooms and adjacent areas. The air filter features an anodized aluminum frame and, as standard, a stainless steel handle guard to prevent corrosion. The NELIOR membrane media packs are available in 35 mm and 50 mm depths, with the 50 mm media packs reaching an initial operational resistance of 50 Pa in filter class H14. A double tear-off label is provided to support Good Documentation Practices (GDP). VITCAcel is packaged in a double-layer heat-sealed plastic film to eliminate contamination risks during entry into classified environments.

Additionally, AAF introduces the MEGAcel ULPA filter for the microelectronics industry. With the increasing miniaturization, manufacturing processes have become significantly more complex. Reliable contamination control is critical for optimizing process yields and meeting environmental standards. AAF’s new mini-pleat MEGAcel filters with NELIOR Filtration Technology ensure high-quality microelectronic applications and compliant solutions. Integrated circuits with sizes around 5 nm are securely protected from airborne contaminants entering the cleanroom. Unlike ULPA filters with traditional media, the MEGAcel with NELIOR membrane medium is boron- and phosphate-free and fully resistant to hazardous chemical compounds; the filter medium remains intact, and outgassing risks are eliminated. MEGAcel filters are available in filter class U16 according to EN1822:2009, for use in controlled environments up to ISO 1, including highly sensitive semiconductor mini-environments. The filter is supplied with an anodized aluminum frame, and the NELIOR membrane media packs are available in 35 mm and 50 mm depths. The 50 mm media pack achieves a very low initial resistance of 60 Pa. A double tear-off label is included to support traceability requirements. The MEGAcel is packaged with a double-layer heat-sealed plastic film to eliminate contamination risks.

NELIOR Life Cycle Valuation Program

The choice of air filter not only significantly influences energy consumption in buildings and production facilities but also plays a crucial role in optimizing conditions for the safe production of sensitive products. While most current life-cycle cost calculations focus solely on energy savings, AAF also recognizes the potential cost effects in scenarios where clean process conditions fail.

Generally, the purchase price of an air filter accounts for only a small part of the total life cycle costs of air filtration, especially when considering the full spectrum of variables, such as the risk of process interruption. In some cases, it might be sufficient to wait until the first scheduled downtime cycle for inspection and filter replacement. However, considering all possible negative impacts on critical applications where contamination must be prevented at all times, this is often not an option. Investment decisions should therefore not be based solely on the initial cost of an air filter. AAF’s calculations always include a comprehensive analysis of potential cost risks arising from a malfunctioning air filtration system during operation.

The new and distinctive AAF Life Cycle Valuation (LCV) concept takes both factors into account: energy savings and downtime risk costs. It demonstrates the potential benefits achievable with air filters featuring NELIOR Filtration Technology. It calculates environmental and total operating cost savings based on risk management with application-specific data. The results are summarized in an automatically generated customer report. To request a Life Cycle Valuation and understand the benefits that air filters with NELIOR Filtration Technology can offer, AAF can be contacted directly or via the new NELIOR website.