In the filter and filter element design cycles, the last crucial step before going into production is the validation of the product and production process through testing, which is critical to ensure that the component and production process meet and satisfy the required high quality, safety and performance standards.

Once the simulations have been completed and we have good confidence in the results obtained, we move on to the validation phase.

In this phase, a series of tests previously defined in the Design Validation Plan (DVP) are used to verify the correctness of the initial hypotheses about the characteristics and performance of the filter, and to confirm that the manufacturing process is capable of producing parts that meet the performance requirements.

The UFI Group’s certified laboratories

The UFI Filters Group has three certified in-house laboratories, located in Italy, India and China.
In our laboratories, a global team of highly qualified experts use certified instruments and test benches to perform a wide range of tests with the utmost precision and accuracy.

Each laboratory is equipped with advanced technology capable of simulating the most extreme conditions to which our filters may be subjected.
Thanks to the combination of experience and state-of-the-art equipment, we are able to rigorously test components to ensure their durability and reliability.

Types of tests performed

Validation tests fall into two main categories:

• Structural tests
• Performance tests

Both types of tests are essential to ensure that the filter meets technical and safety requirements.

What are structural tests?

Structural tests are designed to assess the physical strength and durability of the filter under extreme conditions.

The principal structural tests performed in our laboratory include

• Burst test: Tests the filter’s ability to withstand internal pressure to the point of rupture.
• Pulse test: Simulates pressure cycles to test the filter’s resistance to repeated stress.
• Collapse pressure test: Tests the filter’s resistance to external collapse pressure.
• Vibration test: Simulates the vibrations to which filters are subjected during operation and tests the filter’s ability to withstand vibrations without compromising performance.
• Bubble point test: Tests filter tightness by checking for air leaks under pressure.
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What are performance tests?

Performance tests focus on the functioning of the filter, from its efficiency to its ability to maintain performance over time.

The main performance tests are

• DHC (dirt holding capacity) and element efficiency: Measures the filter’s ability to retain contaminants without compromising efficiency.
• Pressure drop test: Analyses the pressure drop across the filter to ensure fluid flow is not impeded.
• Accelerated aging test: Simulates the ageing of the filter to assess how its performance may change over time.
• Thermal cycling test: Tests the filter’s resistance to varying temperature, verifying its ability to operate in extreme environments.
• Corrosion test: This test exposes the component to a highly corrosive environment, using different fluids and varying temperature conditions.

The Design Validation Plan

The Design Validation Plan (DVP), prepared by the Product Engineer (PE), defines all the tests necessary to ensure that the filter meets the required performance and safety specifications.
Each test includes specific performance criteria that must be met before proceeding to production and includes a minimum number of filters to be tested to achieve a statistical level of confidence in the repeatability of the results.

The validation plan is formulated in accordance with internal regulations and guidelines as well as the specifications provided by the customer. After agreeing the test plan with the customer and obtaining their approval, we proceed with the execution of the tests. This phase is essential to ensure that each component meets the required quality and safety standards prior to series production.

The final results

The suite of results generated by the testing process is crucial for the subsequent production phase. Specifically, the final results include

• A design validated and approved by the customer that corresponds exactly to the filter that will go into production.
• Production costs defined on the basis of performance and product specifications.
• A guarantee of reliability, in terms of both safety and performance, for the products that will go into production.

If downstream changes are necessary, the validation process starts again from the beginning to ensure that the filter continues to meet the requirements after each change.

Each stage of the design cycle is constructed to maximize reliability, minimize time and limit the number of iterations during the process, in order to meet our customers’ needs for each application in the shortest possible time.

The test validation phase is a crucial part of the filter design cycle.
Thanks to our laboratories and a rigorous validation plan, we are able to offer products that not only meet safety and performance standards, but also perfectly match our customers’ specifications.
At the end of the design cycle, we have a quality guarantee that allows us to meet market and customer requirements by offering increasingly innovative and safe solutions.