The Filter Factory, Inc. is located in central California. Just a few steps off the beaten path. We enjoy 10,000 square feet of floor space plus we have two mezzanines adding another 7,000 square feet of light and heavy storage. We have separated our production areas into low efficiency panel assemblies and pleated filter assemblies. Having our pleaters near our assembly in a controlled environment, allows us to pay close attention to quality. Having our test lab close by keeps us on track, with air flow and efficiency. Having our production equipment and assembly all in one place helps us to maintain quality control over the entire manufacturing process. It is rare to find a filter company with this much sophisticated equipment, although here we are. We are a filter manufacturer, not an assembly house, and definitely not a distributor.
Speaking of machines, we have a wide array of band saws, notchers, shears, roll formers, presses, and corrugators within our machine shop. We also have four metal expanders. These make it possible for us to make the majority of the components for our filters from the most basic of materials (i.e. sheet metal, aluminum or steel coil), and therefore save on material costs. We have two machines that allow us to offer a wider variety of filter media types with significantly shorter lead times and more cost effective prices. Our Chandler Pleater can pleat cellulose or screen medias up to 48” wide from .625” to 2.5”. Our newest addition, a Solent pleater can pleat from .75” up to 6.0” of the high efficiency glass media used in HEPA filters.
Although it is nice to be able to say we have machines and the ability to make filters and media, we also realized quality control is a concern with all customers regardless of who their customers are. In efforts to guarantee quality, we have established our quality control system and have acquired two air flow tunnels and three laser particle counters (two on loan from Particle Measuring Systems). We also have a designated QC Lab, where this equipment is used under a controlled environment. Calibration is done and recorded annually for all inspection equipment (for those of you interested in paperwork).
Something that is not necessarily “new,” is our computer records; they go all the way back to the beginning of The Filter Factory. A new twist on this is that we also have the full ALFCO database and what there is of the Air Filtration Products database (both closed in 2004). Because of this in many cases we can not only tell you what your company ordered ten years ago, but we can also pull the layout and therefore duplicate it, while keeping with the current quality standards. Or if you need something like before, but slightly different, we do have the capability to help in the design of the filter so that it is the same, but better.