HEPA filter production
HEPA and ULPA filters are used in cleanrooms, the pharmaceutical and medical industries, microelectronics, and laboratory environments. The key requirement for such filters is absolute tightness around the entire perimeter. Even minor deviations in gasket geometry can reduce the filtration class and compromise the entire technological process.
The first stage involves bonding the filter to its housing. Our two-component MAE TECH MINI adhesive machines ensure perfect mixing and precise dosing of 2K adhesives, both in manual and automatic modes, using 6-axis robots.
At the second stage, MAE TECH offers solutions for automatic gasket application on HEPA filter frames and housings using linear automation systems from the MAE TECH MAC series. The FIPFG (Foam-in-Place Gasket) technology forms a seamless sealing contour directly on the product, ensuring geometric precision, repeatability, and full compliance with cleanroom standards.
Our systems work with polyurethane foams, MS polymers, and other materials that ensure durability, chemical resistance, and stability under changing temperature and humidity conditions. For improved adhesion, surface pretreatment options are available — such as plasma activation or primer application. Servo-driven dosing units guarantee ±1–2% accuracy and a consistent bead profile along the entire contour.
Implementing automation reduces the defect rate to below 1%, increases production efficiency, and ensures full repeatability of each filter batch. MAE TECH solutions can be easily integrated into existing production lines and scaled for different filter sizes — from compact laboratory units to large industrial filters.
MAE TECH also offers fully automated production lines that enable:
loading onto the conveyor,
filter bonding,
polyurethane foam gasket application,
unloading the finished product from the conveyor and placing it on a storage rack for testing or packaging.
The maximum capacity of these lines is 60 filters per hour.
The gasket ensures maximum sealing performance, eliminating any risk of air leakage and guaranteeing the full efficiency of HEPA filtration.
Our 2K MAE TECH MINI machines enable perfect bonding of filters to housings made of:
- galvanized steel
- aluminum
- plastics
- MDF
Technological challenges
Technology comparison table
Criterion | MAE TECH Machines for Applying Gaskets / Polyurethane Foam in HEPA Filter Production | Manual Application of Gaskets / Foam |
| Dosing accuracy | Precise and uniform application of the gasket, control of width, quantity, and profile shape | Depends on operator, risk of uneven application and material loss |
| Sealing and filtration class | Seamless contour ensuring high sealing performance, eliminating air leaks (HEPA H13/H14 requirements) | Uneven sealing, higher risk of leakage and reduced filtration class |
| Quality repeatability | Identical gasket profile and density in each batch, compliance with clean-room standards | No repeatability, strong dependence on worker experience |
| Productivity | High speed, process automation, reduced cycle times | Limited speed, more time and manual labor |
| Waste and defect reduction | Minimizes defects, reduces human errors, lowers rework costs | Higher risk of errors and waste |
| Aesthetics and product appearance | Smooth, clean gasket contour, modern filter appearance | Possible drips, less aesthetic look and visual differences |
| Work safety | Limited staff contact with chemicals | Greater contact with adhesives/sealants, increased risks |
| Material savings | Optimal use of polyurethane foam and gaskets, no cutting waste | Excess material and waste during manual application |
| Ecology and clean-room standards | Compliance with ISO / GMP requirements, reduced emissions of VOCs and waste | Higher emissions, more difficult to meet clean-room standards |
| Labor cost | Higher initial cost but lower labor and material losses | Lower initial cost but higher operating costs and losses |
| Setup and changeover time | Quick reconfiguration between different filter types and sizes (machine memory) | Time-consuming manual preparation, fitting, and tool cleaning |
