Filters, more precisely, fluid filters, are used to separate solid particles from a gas or liquid flow. The core of this statement already gives a first idea of how widespread the different applications for filters are.
Motor vehicles need oil, fuel, and air filters. Activated carbon filters and respirators are widely used in different industries and crafts to clean the air or protect people from hazardous substances.
Kirkco engineered a resin encapsulation architecture to stabilize pleated filter media and ensure consistent sealing under high-flow conditions.
Filter OEMs required repeatable encapsulation quality, reduced scrap, and scalable automation readiness.
Controlled dispensing of PU or epoxy resins to fully wet and seal pleated media.
Gear-pump metering with static mixing and precise flow regulation.
Recipe-based control with validation of bead volume and placement.
Designed to scale from semi-automated stations to fully automated lines.
Kirkco supports filtration encapsulation systems under NDA.
Kirkco engineered a fully automated two-component adhesive encapsulation architecture to support high-volume production of precision filter assemblies. The system replaced manual encapsulation with a robot-integrated dosing cell, enabling consistent quality, reduced unit costs, and scalable production capacity.
A newly introduced filter design experienced rapid market adoption, driving a sharp increase in production volume. Manual encapsulation methods were no longer sufficient to maintain delivery readiness, process consistency, or cost control. Automation was required to stabilize quality while reducing labor dependency.
The application demanded precise volumetric dosing of a specialty adhesive used to bond filter media to housings. Narrow tolerances, short cycle times, and repeatable shot accuracy were critical to ensure long-term filter durability and performance.
The solution consists of a robot-integrated automation cell paired with a modular, servo-driven two-component dosing system. The metering units are configured for shot-based operation and mounted close to the application point to minimize hose length and improve response time.
A closed-loop control architecture governs the dosing process, delivering highly repeatable shot volumes across all cycles. The modular design allows flexible configuration of mixing ratios and supports processing of abrasive or demanding adhesive chemistries.
Extensive pilot trials were conducted to validate material behavior, dosing parameters, and cycle performance prior to production release. Following successful testing, the system was delivered as a turnkey solution, including commissioning and operator training.
After commissioning, the automated encapsulation process enabled high-output production with maximum process reliability. Material consumption was reduced through precise dosing, manual handling was minimized, and overall unit costs decreased measurably.
The modular architecture was intentionally designed to support future throughput increases and system expansion, ensuring long-term alignment with evolving production demands.
Kirkco delivered a precision resin dispensing architecture to encapsulate and stabilize pleated filter elements for industrial air and gas filtration systems.
Secure pleated media with consistent resin distribution.
Two‑component PU or epoxy processed in bulk.
Gear‑pump metering with static mixing and solvent‑free changeover.
Improved process security and higher automation readiness.
Have a process challenge that cannot be solved with off-the-shelf equipment?
Dispense & Regulate
1K & 2K Systems
