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Pleating a nonwoven involves folding the material in a zigzag pattern to create a series of parallel ridges or folds. This process is commonly used in the production of air filters, face masks, and other products that require a high surface area for filtration or absorption. The pleats increase the material’s surface area, allowing for greater efficiency in capturing particles or liquids. Pleating can be done manually or using specialized machinery, depending on the desired outcome and production requirements. Nonwoven materials are ideal for pleating due to their flexibility, durability, and ability to maintain their shape after folding.

At Superior Felt & Filtration, we take pride in offering a wide range of product options to cater to your specific needs. Our pleating capabilities allow for flexibility in terms of pleating configuration, dimensions, and delivery formats.

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Superior has the capability to pleat any number of pleats per inch, depending on the material being processed. The pleat density can be adjusted to achieve the desired performance characteristics for your applications. Thinner materials allow for higher pleat counts per inch, maximizing surface area and enhancing filtration efficiency. To determine the optimal pleating configuration and line speed for various synthetic pleatable materials, we conduct rigorous testing and analysis.

Pleatable Materials

  • Pleat-able Meltblown Composites (Air and Liquid)
  • Pleat-able Technostat® (Tribo-charged Needle-punch)
  • Bico (Bi-component) Fibers
  • Needle punch Synthetic
  • Pleat-able Membrane Composites
  • Nylon (Trupor)
  • PTFE (Both air and Liquid)
  • PES (Liquid)
  • Microglass (Short Term)
  • Pleat-able Spunbonds (PET, PP, Nylon, etc.)
  • Pleat-able Needle-punch
  • Pleat-able Nettings and Mesh (Non-Metallic)

Blade Pleating Capabilities

  • Max Width: 40 inches
  • Optional Layers: 3
  • Inline Slitting: 7 Blades (>3.0” inches wide)
  • Max Pleat Count:  250 PPM
  • Pleat Height:  0.250” – 6.0”

Mini-Pleat Capabilities

Mini-Pleating systems add stability and rigidity to the pleated filter material. 

  • Optional Layers: 1
  • Max Width: 39 inches
  • Inline Slitting: 15 Blades (>2.0” inches wide)
  • Pleat Count:  150-300 PPM
  • Pleat Height:  0.375” – 4.0”

Mini-Pleat Advantages

  • Allows tighter pleating (higher surface area)
  • Ease of potting (gluing)
  • Uniform pleat amplitude
  • Ability to cut complex shapes
  • Formed canister filters allow for smaller geometry