TCO Comparison Between Sintered PE and SS316L Filters for pH 5 Water at 60°C

Industrial water treatment rarely comes without challenges. When the feedwater has a slightly acidic character (pH ~5) and elevated temperature (~60 °C), choosing the right filtration medium becomes a balancing act between cost and reliability.

Two widely used options are:

• Sintered Polyethylene (PE) filters: lightweight, cost-effective, and chemically resistant in mild conditions.

• Sintered Stainless Steel 316L (SS316L) filters: premium-grade filters with exceptional mechanical and chemical durability.

But which option is truly more cost-effective when analyzed over a full operating horizon? This article presents a 10-year Total Cost of Ownership (TCO) comparison, highlighting not just purchase price but also maintenance, replacement frequency, and hidden operational risks.

1. Assumptions for the Comparison

To ensure a fair evaluation, the following assumptions are applied:

• Application: Continuous filtration of slightly acidic water (pH 5) at 60 °C

• Operating Pressure: 3 bar (43.5 psi)

• Contaminant Load: Moderate (100 mg/L solids)

• Downtime Costs: Excluded (though downtime favors SS316L due to fewer interruptions)

• Lifespan Consideration: 10 years

2. Sintered PE Filters – Cost and Performance

Initial Costs

• Filter Cartridge (10", 10 µm rated): $50

• Housing (Polypropylene, standard): $200

• Total Initial Investment: $250

Operational Limits

• Temperature: Rated up to 80 °C (60 °C is within range but near the limit).

• pH Compatibility: Stable at pH 5, though acidic water accelerates material fatigue.

• Pressure: Safe at ≤5 bar (3 bar is acceptable).

Maintenance & Replacement

• Expected Lifespan: 1–2 years (average 18 months) before degradation or flow decline.

• Replacement Frequency (10 years): ~6 cycles.

• Cleaning Feasibility: Limited. PE risks swelling or pore deformation under repeated chemical/thermal cleaning.

10-Year TCO for Sintered PE

Performance Note: PE filters are adequate for this environment but risk unexpected failures if exposed to thermal spikes or more aggressive acidity.

3. Sintered SS316L Filters – Cost and Performance

Initial Costs

• Filter Cartridge (10", 10 µm rated): $300

• Housing (Stainless Steel): $500

• Total Initial Investment: $800

Operational Strengths

• Temperature: Rated to 900 °C (60 °C is negligible).

• pH Compatibility: pH 5 is safe—SS316L is resistant to acidic water and chlorides.

• Pressure: Withstands >150 bar (3 bar is trivial).

Maintenance & Replacement

• Expected Lifespan: 10+ years (matches horizon of study).

• Replacement Frequency: None within 10 years.

• Cleaning: Backflush or CIP (every 6 months), low-cost and effective.

10-Year TCO for SS316L

Performance Note: SS316L is over-engineered for this mild application but provides unmatched reliability and minimal risk of failure.

4. Side-by-Side TCO Comparison

5. Key Insights

• Upfront vs Long-Term:
  PE is cheaper upfront, while SS316L demands higher initial investment.

• Reliability:
  PE risks premature failure near its operational limits (60 °C, pH 5). SS316L handles the environment effortlessly.

• Maintenance:
  PE requires 6 replacements, adding labor and material costs. SS316L requires only cleaning, reducing waste and interruptions.

• System Downtime (Not Included):
  Every PE replacement means shutdowns and revalidation, which could significantly increase real TCO. SS316L cleaning can often be done in-situ, avoiding costly downtime.

6. Recommendations

Choose Sintered PE If:

• Upfront budget is limited.

• The process is non-critical (downtime is tolerable).

• The system operates strictly within PE’s safe limits (≤80 °C, ≤5 bar).

Choose Sintered SS316L If:

• Reliability and uptime are critical.

• You anticipate future process changes (lower pH, higher temperature/pressure).

• You operate in compliance-driven industries (food, pharma, energy) where validation and certification matter.

DALON’s Role in TCO-Optimized Filtration

At DALON, we provide both cost-effective PE filters and premium SS316L sintered filters, helping clients choose the right balance of upfront vs lifetime cost.

• PE Solutions: Ideal for non-critical, low-pressure water treatment.

• SS316L Solutions: Designed for harsh, regulated, and high-stakes environments.

• Validation Services: Bubble-point testing, flow rate charts, and lifetime performance data.

👉 Explore DALON’s range of sintered PE and SS filters here.

Conclusion

The 10-year TCO comparison shows that sintered PE filters ($850) are less expensive than SS316L filters ($1,500) for filtering pH 5 water at 60 °C. However, this cost gap narrows quickly if downtime, compliance, or reliability are factored in.

• PE = lower upfront cost, higher operational risk.

• SS316L = higher upfront cost, long-term reliability.

For budget-sensitive, non-critical systems, PE is sufficient. But for mission-critical or compliance-heavy operations, SS316L is the clear winner in terms of lifecycle performance and risk management.

FAQ

1. What is TCO in filtration?
TCO (Total Cost of Ownership) includes not just purchase price but also maintenance, replacement, labor, and operational risks over the filter’s lifecycle.

2. Why does SS316L have a higher TCO despite no replacements?
Because of higher upfront housing + cleaning labor. However, SS316L offers greater reliability and lower downtime costs, which are not reflected in this baseline model.

3. Can PE filters reliably operate at 60 °C and pH 5?
Yes, but with accelerated aging. Expect replacement every 1–2 years.

4. How long do SS316L filters last?
Often 10+ years with regular cleaning, making them ideal for long-term installations.

5. Are SS316L filters always better?
Not always. For low-risk, budget-limited systems, PE is more economical. SS316L is best when uptime and compliance matter.

6. How often should SS316L filters be cleaned?
Typically every 6 months using backflushing or CIP (clean-in-place).

7. Does DALON provide both options?
Yes, DALON manufactures sintered PE filters (5–100 µm) and sintered SS filters (0.5–150 µm), both customizable to client needs.