Cardboard Frame ZIG-ZAG Filter (Metal-Free)
Cardboard Frame ZIG-ZAG Filter (Metal-Free) is a disposable panel filter manufactured without a metal support mesh. Its synthetic fiber filter media is arranged in a ZIG-ZAG configuration, while the pleats are supported by hot-melt adhesive lines.
High Filtration Area Without Metal Support
The pleats in the filter media are supported by hot-melt adhesive lines instead of metal wire or expanded metal. This construction helps the filter media maintain its shape under airflow while eliminating the need for metal components within the media support structure.
The ISO Coarse 65% filter is used in air handling units, ventilation equipment and HVAC systems to capture coarse dust, protect coils and reduce the dust load on subsequent filtration stages.
Metal-Free Construction
No metal wire or expanded metal mesh is used to support the filter media.
ISO Coarse 65%
Used as a prefilter for capturing coarse dust and large particles in ventilation systems.
Hot-Melt Supported
Pleats are separated and supported by hot-melt adhesive lines that improve structural stability.
Up to 3,400 m³/h
Nominal airflow up to 3,400 m³/h under reference conditions for standard 592 × 592 mm models.
What Is a Cardboard Frame ZIG-ZAG Filter (Metal-Free)?
The metal-free cardboard frame ZIG-ZAG filter is a panel-type air filter manufactured by folding synthetic fiber filter media into multiple pleats and supporting these pleats with hot-melt adhesive lines.
The metal support mesh commonly used in conventional ZIG-ZAG filters is not present in this product. Structural integrity is provided by the cardboard frame, synthetic filter media and adhesive support lines that stabilize the pleats.
The increased filter surface can contribute to high dust-holding capacity and longer replacement intervals under suitable operating conditions. Actual service life depends on ambient dust load, airflow, relative humidity and operating time.
Operating Principle
Air Inlet
Air containing coarse dust and particles reaches the wide face area of the filter.
Distribution Across the Pleats
The airflow spreads across the ZIG-ZAG filter surface arranged with hot-melt support lines.
Particle Capture
Coarse particles are captured on the synthetic fibers, reducing the dust load in the air.
Filtered Air
Prefiltered air is directed toward the coils or the next filtration stage.
Metal-Free Filter Construction
Cardboard Frame
The external supporting structure makes the filter lightweight, economical and easy to replace.
Synthetic Fiber Media
Large-surface filter material designed to capture coarse dust and large particles.
Hot-Melt Separators
Maintain pleat spacing, reduce pleat collapse and help preserve the filter shape.
Mesh-Free Design
No expanded-metal support mesh is required on the upstream or downstream face of the filter media.
Technical Specifications
| Technical Parameter | Value | Technical Parameter | Value |
|---|---|---|---|
| Filter Standard | ISO 16890 | Recommended Final Pressure Drop | Initial ΔP + 50 Pa or initial ΔP × 3, whichever is lower |
| Filter Class | ISO Coarse 65% | Former EN 779 Class | G4 |
| Filter Media | Synthetic fiber | Maximum Operating Temperature | 80°C |
| Frame Type | Cardboard | Standard Depths | 48 and 96 mm |
| Pleat Support | Hot-melt adhesive lines | Metal Support Mesh | None |
| Usage Type | Disposable | Standard Capacity Definition | High-filtration-area construction |
Product Coding System
| Filter Type | Filter Class | Frame Type | Capacity | Dimensions |
|---|---|---|---|---|
| GZ: ZIG-ZAG filter | G4: Former EN 779 class | C: Cardboard frame | H: High filtration area | Width × Height × Depth Example: 592 × 592 × 48 mm |
GZ-G4-C-H-592-592-48
GZ = ZIG-ZAG filter
G4 = Former EN 779 classification
C = Cardboard frame
H = High filtration area
592-592-48 = Width, height and depth
Standard Models and Performance Values
The following values are reference performance data for standard metal-free cardboard frame ZIG-ZAG filter sizes.
| Filter Model | EN 779 Withdrawn |
ISO 16890 | Dimensions W × H × D |
Filtration Area m² |
Nominal Airflow m³/h |
Initial Pressure Drop Pa |
|---|---|---|---|---|---|---|
| GZ-G4-C-H-287-287-48 | G4 | Coarse 65% | 287 × 287 × 48 | 0.3 | 850 | 80 |
| GZ-G4-C-H-287-592-48 | G4 | Coarse 65% | 287 × 592 × 48 | 0.6 | 1,700 | 80 |
| GZ-G4-C-H-592-592-48 | G4 | Coarse 65% | 592 × 592 × 48 | 1.2 | 3,400 | 80 |
| GZ-G4-C-H-287-287-96 | G4 | Coarse 65% | 287 × 287 × 96 | 0.6 | 850 | 55 |
| GZ-G4-C-H-287-592-96 | G4 | Coarse 65% | 287 × 592 × 96 | 1.2 | 1,700 | 55 |
| GZ-G4-C-H-592-592-96 | G4 | Coarse 65% | 592 × 592 × 96 | 2.4 | 3,400 | 55 |
Custom sizes can be manufactured according to filter housing and project requirements.
Differential-pressure tolerance should be evaluated according to whichever value is greater: ±10% + 5 Pa or 10 Pa + 5 Pa.
48 mm and 96 mm Depth Comparison
48 mm Depth
Provides a compact solution for equipment with limited filter housing depth. The initial pressure drop for standard models is approximately 80 Pa.
96 mm Depth
Provides a larger filtration area. At the same nominal airflow, the reference initial pressure drop is approximately 55 Pa.
Metal-Supported vs. Metal-Free ZIG-ZAG Filter Comparison
| Comparison Criterion | Metal-Free Filter | Metal-Supported Filter |
|---|---|---|
| Filter Media Support | Hot-melt adhesive lines | Expanded metal or wire mesh |
| Metal Component | Not present in the filter support structure | Present in the media support element |
| Filtration Area | Large area due to high pleat density | Varies according to model and pleat structure |
| Waste Separation | May reduce the need for metal separation | Metal support can be separated separately |
| Usage Type | Disposable | Generally disposable |
Application Areas
Product Advantages
Pressure Drop and Energy Efficiency
Filter pressure drop forms part of the total system resistance that the ventilation fan must overcome. Lower pressure drop can contribute to limiting fan energy consumption when the overall system is properly designed.
In the reference product table, models with a depth of 96 mm have an initial pressure drop of 55 Pa, while 48 mm models have an initial pressure drop of 80 Pa.
Actual energy consumption depends on filter loading, fan efficiency, airflow, system operating time, duct pressure loss and the automation control scenario.
Filter Selection Criteria
Maintenance and Filter Replacement
The Cardboard Frame ZIG-ZAG Filter (Metal-Free) is designed as a disposable filter. Washing the filter media or applying compressed air for reuse is not recommended.
Replacement time should be determined by evaluating differential-pressure measurements, contamination on the filter surface, reductions in airflow and system operating conditions together.
When installing a new filter, the product should fit completely into the filter housing, peripheral leakage should be prevented and any airflow-direction marking should be followed.
Technical Performance Note
The airflow, filtration-area and initial-pressure-drop values in the tables are provided for standard dimensions and reference test conditions.
Actual pressure drop, dust-holding capacity and service life may vary depending on airflow, face velocity, ambient dust load, relative humidity, filter installation and process conditions.
G4 is the former classification under the withdrawn EN 779 standard. Current product selection should be based on the ISO 16890 performance class.
The term metal-free indicates that no metal mesh is used to support the filter media. Product packaging, installation accessories and other system components in the filter housing are outside this definition.
Metal-Free ZIG-ZAG Filter Selection
Filter selection should be based on equipment housing dimensions, airflow, filter depth, pressure drop, filtration area and ambient conditions.
Contact Airtes for the selection and supply of standard or custom-size Cardboard Frame ZIG-ZAG Filters (Metal-Free).
