Material & Application Consultation
- Fiber selection based on temperature & chemical resistance
- Matching felt type to industry needs (cement, asphalt, power, metallurgy)
- Sample supply for performance validation
Industrial Needle-Punched Felt
Omela Industrial Needle-Punched Felt
1. What Is Needle-Punched Felt?
Needle-punched felt is a non-woven industrial filtration media made by mechanically interlocking fibers into a dense three-dimensional structure. The unique depth-filtration mechanism enables superior dust-loading capacity, stable differential pressure, and reliable performance in pulse-jet and reverse-air baghouses.
- 3D fiber matrix enabling multi-layer particle capture
- High dust-holding capacity → longer bag life
- Stable permeability even under high dust loading
- Customisable treatments (singeing, calendering, PTFE impregnation, PTFE membrane).
- Suitable for fine dust, variable temperature, and corrosive flue gas
A properly designed needle-punched felt bag delivers:
- Consistent low differential pressure, enabling stable airflow and reduced fan energy consumption.
- High particle capture efficiency, supporting compliance with strict emission regulations.
- Long-term mechanical durability, minimizing tears, abrasion failures, and premature change-outs.
- Reliable performance in demanding environments, including high dust-loading, temperature fluctuations, and corrosive flue gas.
40%
Reduced Total Operating Cost (TOC)
Better stability, longer lifetime, and fewer cleaning cycles combine to lower maintenance cost, compressed-air usage, and downtime.
2. Types of Needle Punched Felt Filter Fabric
High temperature needle-punched felt
Aramid(Nomex) Needle-Punched Felt
Nomex Needle-Punched Felt is a meta-aramid (Nomex®) fiber filter media engineered for high-temperature
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P84 Needle-Punched Felt
P84 Needle-Punched Felt is a polyimide (PI) fiber filtration media engineered for high-temperature
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Fiberglass Needle-Punched Felt
Fiberglass Needle Felt is a high-temperature, chemically inert, and dimensionally stable non-woven
View DetailsMiddle temperature needle-punched felt
PTFE Needle-Punched Felt
PTFE Needle-Punched Felt is a 100% pure PTFE (Teflon®) filtration media designed for high-temperature
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PPS Needle-Punched Felt
PPS Needle-Punched Felt is a high-performance filtration media engineered for high-temperature
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FMS Needle-Punched Felt
FMS Needle-Punched Felt is a high-temperature composite-fiber filtration material engineered
View DetailsNormal temperature needle-punched felt
Acrylic Needle-Punched Felt
Acrylic needle-punched felt is a non-woven filter media made from 100% homopolymer acrylic fibers
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Polyester Needle-Punched Felt
Polyester needle-punched felt is a filter media made from 100% high-quality polyester short fibers
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Polypropylene Needle-Punched Felt
Polypropylene (PP) needle-punched felt is a lightweight, hydrophobic, chemically inert non-woven filter media
View Details3. Needle-Punched Felt Performance Comparison Table
| Material | Working Temperature | Instant Temperature | Abrasion Resistance | Hydrolysis Resistance | Acid Resistance | Alkali Resistance | Oxidation Resistance | Relative Cost |
|---|---|---|---|---|---|---|---|---|
| Polypropylene Needle Felt | 90°C | 110°C | Good | Excellent | Excellent | Excellent | Middle | $ |
| Polyester Needle Felt | 130°C | 150°C | Excellent | Poor | Middle | Fair | Good | $ |
| Acrylic Needle Felt | 120°C | 130°C | Middle | Good | Good | Middle | Good | $$ |
| PPS Needle Felt | 180°C | 200°C | Good | Excellent | Excellent | Excellent | Fair | $$$ |
| Aramid Needle Felt | 204°C | 220°C | Good | Middle | Middle | Good | Middle | $$$ |
| Fiberglass Needle Felt | 250°C | 280°C | Fair | Good | Middle | Fair | Good | $$$ |
| P84 Needle Felt | 240°C | 260°C | Good | Middle | Middle | Middle | Good | $$$$ |
| PTFE Needle Felt | 250°C | 280°C | Good | Excellent | Excellent | Excellent | Excellent | $$$$ |
Needle Punched
APPLICATIONS
Needle-punched felt is widely used across medium and heavy industries requiring stable particulate control, high filtration efficiency, and reliable baghouse performance.
Cement kilns & clinker coolers
Needle-punched felt performs reliably under high dust loading and temperature fluctuations, ensuring stable pressure drop and long service life in kiln and clinker cooler baghouses.
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Carbon Black Dust Filtration
The carbon black industry produces one of the most challenging dust environments in industrial filtration due to the extremely fine particulate nature.
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Coal-fired power plants
Needle-punched felt provides reliable filtration in high-temperature, corrosive flue gas environments, maintaining low emissions and long bag life in coal-fired boiler baghouses.
Read MoreDelivering Stable Baghouse Performance Through Expertise in Needle-Punched Felt
95%
Filtration Efficiency
Typical filtration efficiency achieved with needle-punched felt media based on PPS, Aramid, Fiberglass and PTFE fibres in well-designed baghouses.
50%
Pressure Drop
Lower average pressure drop when upgrading from basic or woven media to optimized needle-punched felt and correctly engineered air-to-cloth ratios.
Needle-Punched Felt Step-by-Step Process
4. Needle-Punched Felt Manufacturing
Manufacturing high-quality needle-punched felt for industrial filter bags demands precise fibre control, consistent needling density, and strict in-process quality checks at every station. The goal is a stable, uniform felt with predictable permeability and mechanical strength in real baghouse conditions.
From fibre opening and carding, through cross-lapping, needle punching, heat setting, and surface finishing, Omela follows a standardized workflow to guarantee durability, filtration performance, and dimensional stability. Each roll of felt is produced on advanced lines, then converted into filter bags with accurate cutting, stitching, and sealing—ensuring tight fit on cages, reliable operation, and long service life.
① Bale Opening
Opening compressed fiber bales and loosening fiber tufts to ensure a stable, uniform feed into the needle-punched felt production line.
② Pre-Opening
Further separating individual fibers and removing coarse impurities to improve fiber cleanliness and prepare for accurate blending.
③ Blending
Precisely mixing different fiber types and deniers according to the media recipe to achieve consistent basis weight, permeability, and temperature resistance.
④ Fine Opening
Using precision opening units to fully individualise fibers and achieve excellent dispersion before forming the web.
⑤ Carding
Aligning and combing fibers into a uniform single-layer web, controlling thickness, evenness, and fiber orientation for stable mechanical properties.
⑥ Web Forming
Continuously laying the carded web onto a conveyor to build the target basis weight and create a stable substrate for crosslapping and needle punching.
⑦ Crosslapping
Stacking multiple web layers at controlled angles to enhance strength in both machine and cross directions and improve felt uniformity.
⑧ Needle Felting
Using barbed needles to repeatedly punch through the fiber web, mechanically entangling fibers into a dense three-dimensional needle-punched felt structure.
⑨ Rolling & Inspection
Inspecting thickness, weight, surface quality, and defects on-line, then winding the felt into rolls for downstream thermal and surface treatments.
⑩ Heat Setting
Stabilising the felt under controlled temperature and tension to reduce residual shrinkage and lock in dimensional stability for high-temperature service.
⑪ Surface Singeing & Calendering
Optimising the surface by gas singeing and/or calendering to remove loose fibers, smooth the face, and improve dust release and filtration efficiency.
⑫ PTFE Membrane Lamination
Laminating a microporous PTFE membrane or other functional layer onto the felt to create surface-filtration media with ultra-low emissions and fast pulse cleaning.
5. Needle-Punched Felt Selection Guide
01
Fiber Properties
The performance of needle-punched felt depends heavily on the selected fiber. Key factors: temperature resistance, abrasion resistance, hydrolysis stability, chemical resistance, and oxidation resistance .
02
Media Structure & Weight
Different applications require specific felt densities and structural designs. Higher weights typically offer better durability and lower emissions, while lighter felts provide higher permeability for low-pressure systems.
03
Surface & Finishing Options
Surface treatments enhance filtration efficiency and service life.Typical finishes include: singeing, calendering, heat-setting, anti-static treatment, oil & water repellent, PTFE impregnation, PTFE membrane.
04
Mechanical Strength & Dimensional Stability
A well- engineered felt must maintain integrity under pulse-jet cleaning and high dust loading.Critical factors: tensile strength, elongation, heat shrinkage, and internal bonding strength developed during needle-punching.
05
Operating Environment Compatibility
Choose felt according to process conditions: temperature peaks, moisture level, acid/alkali concentration, corrosive flue gas, and dust abrasiveness. Matching the right felt significantly reduces pressure drop, downtime, and operating cost.
Needle-Punched Felt Engineering & Lifecycle Support
Custom Media Engineering
- Customized basis weight, thickness, permeability
- Surface treatments (singeing, calendaring, coating)
- PTFE membrane lamination for ultra-low emissions
Precision Production & Quality Control
- Automated blending, carding, cross-lapping, needling
- Heat setting to stabilize fiber structure
- Strict lab testing (permeability, tensile strength, shrinkage)
OEM Media Supply & Converting Support
- Roll-goods supply for filter bag manufacturers
- Technical guidance on cutting and bag fabrication
- Cooperation with global OEM & ODM partners
Performance Optimization
- Permeability adjustment for airflow performance
- Surface finish optimization for lower emissions
- Media structure tuning for longer service life
Technical Support & Troubleshooting
- Root-cause analysis of media failures
- Recommendations for upgrading felt performance
- Continuous customer support for critical applications
LET’S WORK TOGETHER
Why Choose Omela Filtration?
Choosing the right filtration supplier affects everything from system stability to maintenance downtime. At Omela Filtration, we combine reliable materials, controlled production, and years of industry experience to support dust and liquid filtration needs across different plants and applications.
We use consistent-grade filter media, sewing thread and metals sourced from qualified suppliers. Each batch is checked for weight, thickness, air permeability and tensile strength to keep performance steady across shipments.
Our facility is equipped with modern sewing lines, hot-welding machines and automated inspection tools. This keeps production efficient and helps us meet tight delivery schedules, even on custom orders.
Our engineers and technicians have long experience with dust collectors, liquid systems and industry-specific conditions. They help you match materials to temperature, chemistry and air-to-cloth ratios to avoid unnecessary failures.
From sampling to documentation and shipping, our team responds quickly and keeps information clear. Customers in cement, asphalt, power and water-treatment plants rely on our service to resolve problems without delay.
From the first technical discussion to installation and long-term maintenance, our team stays involved at every stage. We analyze your operating conditions, adjust product designs when needed, and ensure the final filtration setup works reliably in real plant environments. After delivery, our service team continues to provide guidance and troubleshooting support, helping you keep your system stable and downtime low.
Frequest Asked Questions
Needle-punched felt is made from randomly oriented fibers mechanically bonded by needling, offering:
- Higher dust-holding capacity
- Lower initial pressure drop
- Better depth filtration
Woven fabrics are structured, smoother, and used more in liquid filtration or specific industrial processes. Needle-punched felt is the standard for dust collector bags.
| Operating Temperature Range | Recommended Needle-Punched Felt Material |
|---|---|
| Below 120°C | Polyester (PE) / Polypropylene (PP) |
| Up to 150°C | High-Grade Polyester |
| 150–180°C | Acrylic (PAN) / PPS (Ryton) |
| 180–220°C | Aramid (Nomex) |
| 220–260°C | P84 Needle Felt |
| Above 260°C | PTFE Needle Felt |
Choose PTFE-membrane felt when:
- Ultra-low emission is required
- Dust is extremely fine
- High dust-loading or sticky dust is present
- You want faster pulse-cleaning and lower pressure drop
P84 or PPS with PTFE membrane is commonly used in cement, waste-to-energy, and chemical plants.
Higher needling density results in:
- Stronger mechanical strength
- More stable pore structure
- Better filtration efficiency
- Slightly higher pressure drop
Lower needling density gives:
- Higher permeability
- Lower initial pressure drop
- Reduced durability
We customize the felt structure to match your dust characteristics and air-to-cloth ratio.
Yes — all fibers have a thermal shrinkage range. Typical shrinkage at working temperature:
- Polyester: 1–2%
- PPS: <=1%
- Aramid: 1–2%
- P84: <=1%
- PTFE: <=0.5%
We supply complete specifications including:
- Fiber composition
- Weight (g/m²)
- Thickness
- Air permeability
- Tensile strength
- Working & peak temperature
- Finishing method
- Chemical resistance chart
OEM/ODM customization is available.
Yes. We customize:
- Permeability
- Basis weight
- Thickness
- Surface treatment
- Membrane coating
- Cut size for different bag lengths and diameters
We also support OEM roll-goods supply for bag manufacturers.
Yes — small sample rolls, sheets, or trial bags can be provided for onsite testing before mass production.
- Confirm operating conditions
- Select fiber type and finishing
- Approve technical data sheet
- Produce sample (optional)
- Mass production
- Inspection reports
- Roll-goods or bag shipment
Trusted Needle-Punched Felt Partner
Worldwide
With 20+ years of filtration know-how and hundreds of projects in cement, power, steel and asphalt, we engineer needle-punched felt media that deliver stable differential pressure, low emissions and reliable baghouse performance.