Infrastructure

Manufacturing & Testing Capabilities.

State-of-the-art facilities supporting end-to-end Filtration Solutions

Genius Filters and Systems Private Limited is equipped with state-of-the-art manufacturing and testing infrastructure, designed to support every facet of our business—from research and development to precision manufacturing and quality assurance.

Our facilities are powered by modern equipment, operated under the continuous supervision of specially trained and qualified technicians, ensuring consistent performance, process control and adherence to international quality standards. The workforce is systematically structured and hierarchically organized to ensure operational efficiency, accountability and seamless execution across departments.

Production Process at Genius Filters

At Genius Filters and Systems Private Limited, our manufacturing process is built on engineering precision, stringent quality assurance and application-specific customization. Each production stage is executed in-house under controlled conditions to ensure high performance, reliability and compliance with international filtration standards.

At Genius Filters and Systems Pvt. Ltd., the production process begins with rigorous raw material testing and inspection, followed by the development of detailed Quality Assurance Plans (QAPs) and engineering drawings. Filter components and assemblies are precisely designed and fabricated, including panel filter frames and filter tubes, with electroplating applied to sheet metal components for enhanced corrosion resistance. Filter media is pleated and rolled as per specified performance requirements, while end caps and end gaskets are manufactured to ensure proper sealing and structural integrity. Final assembly is carried out using welding, ultrasonic welding and epoxy bonding techniques. Each product then undergoes thorough visual inspection and performance testing before secure packing and dispatch, ensuring consistent quality, reliability and compliance with international standards.

Component Manufacturing Unit

Component manufacturing forms the foundation of our filtration solutions. All critical parts are produced using advanced fabrication and machining technologies to ensure dimensional accuracy and structural integrity.

Process Overview: 

  • Incoming raw material inspection and certification verification

  • CNC laser cutting, CNC machining, bending, forming, and rolling operations

  • Fabrication of filter housings, frames, end caps, perforated sheets, panels, and structural components

  • Welding using TIG, MIG, ARC, and spot welding processes

  • Surface preparation, treatment, and coating based on metallurgy and application

  • Outcome: 

  • High-strength, corrosion-resistant components

  • Precision-fit parts ensuring leak-free assembly

  • Long-term durability under demanding operating conditions

Machinery & Equipment

  • Shearing machines and Bending machines

  • Power press and Welding machines

  • Lathe & milling machines

  • Drilling machines and Grinding & buffing units

  • Sand blasting unit and Painting booth

  • Generator for uninterrupted power supply

Production Process 

  • Raw material testing & inspection

  • Development of QAPs and engineering drawings

  • Design of filter components and assemblies

  • Fabrication of panel filter frames and filter tubes

  • Electroplating of sheet metal components

  • Pleating and rolling of filter media as per specifications

  • Visual inspection and performance testing  and Packing and dispatch

Filter Element / Assembly Manufacturing Unit

This unit forms the core of Genius Filters’ innovation and product development, supported by in-house R&D and advanced testing facilities.

Filter elements are the core of any filtration system. At Genius Filters, elements are manufactured using carefully selected filter media and controlled processes.

Key Operations:

  • Filter media selection and qualification, Pore size, permeability, and strength testing, Pleating, rolling, and forming of filter media, End caps and gasket manufacturing, Assembly using ultrasonic welding, TIG welding, or epoxy bonding

Genius Filters and Systems Pvt. Ltd. is equipped with a comprehensive range of advanced machinery and equipment to support high-precision filtration manufacturing. Our facilities include automatic shearing and bending machines, along with a wide spectrum of welding technologies such as TIG, MIG, ARC, ultrasonic and gas welding. Precision machining is supported by lathe machines and advanced pleating machines capable of handling pleat widths up to 2000 mm and pleat depths ranging from 5 to 50 mm. The infrastructure also features ultrasonic fusing machines for both longitudinal and circular joints, electrical cutters for precise media height control, hot air ovens for filter paper curing and industrial hot plates for adhesive setting. Additional capabilities include aluminium foil forming machines, hot melt adhesive dispensers, air compressors with dryers, sewing machines and riveting tools, supported by a painting booth and generator for uninterrupted power supply, ensuring consistent quality and continuous operations.

Production Process 

  • Raw material testing & inspection

  • Development of QAPs and engineering drawings

  • Design of filter components and assemblies

  • Fabrication of panel filter frames and filter tubes

  • Electroplating of sheet metal components

  • Pleating and rolling of filter media as per specifications

  • Visual inspection and performance testing  and Packing and dispatch

In this stage, filter elements are integrated into engineered filter housings and complete filtration systems, including custom-built and skid-mounted units.

Key Operations:

  • Assembly of filter elements into housings, Sealing, fastening, alignment, and torque verification, Integration of gauges, valves, and accessories, Final surface finishing, labeling, and identification

Outcome:
✔ Leak-proof, robust filtration assemblies
✔ Easy installation and maintenance

Heavy Engineering Workshop

The Heavy Engineering Workshop is designed for manufacturing large and complex fabricated products used in critical industrial and infrastructure applications. 

Capabilities Include

  • Pressure vessels and Heat exchangers, Skids and Dust collection housing systems, Air intake housing systems, Heavy-duty structural and fabricated assemblies

This workshop is equipped to handle high-capacity fabrication, precision welding and stringent quality requirements for heavy engineering projects.

Genius Filters and Systems Pvt. Ltd. is supported by advanced manufacturing and support facilities that enable precision engineering, rapid development and scalable production. Our infrastructure includes a 3D printing laboratory for rapid prototyping and product development, blade pleating and rolling machines, a dedicated filter paper weaving facility and screen printing machines. We are equipped with hydraulic press brake and bending machines, along with spot, ultrasonic, TIG, MIG and ARC welding systems to support complex fabrication requirements. Additional capabilities include a paint booth, perforation machines, power press, CNC engraving machines and advanced CNC laser cutting and laser welding systems. Precision machining is further strengthened by CNC lathe and CNC milling machines, ensuring high dimensional accuracy, repeatability and consistent quality across all manufacturing operations.

R&D - Filter Test Labs

Genius Filters and Systems Pvt. Ltd. is equipped with advanced in-house testing facilities to ensure the highest levels of quality, performance and reliability across all filtration products. Our testing capabilities include raw material testing to verify material integrity, filter media pore size testing to ensure uniformity and efficiency, multi-pass testing to evaluate filtration performance under continuous operating conditions and bubble point testing to confirm structural soundness and sealing integrity. Comprehensive performance testing is carried out in strict accordance with internationally recognized standards such as BS, IS, ASHRAE, ARAMCO and EN 779, ensuring every product meets stringent regulatory, safety and application-specific requirements before release.

The Filter Lab conducts comprehensive testing across the entire filtration lifecycle—from raw material validation to final product certification.

Testing Facilities

    • Raw material testing and Hydrostatic testing, Pneumatic testing, Helium testing, Nitrogen testing, NDT (Non-Destructive Testing) / Radiography, Surface roughness (Ra) measurement.

    • Inhouse Test Facilities

    • Raw Material and Media Testing

      • Verification of raw materials and filter media

      • Pore size distribution and permeability testing

      • Mechanical strength and integrity assessment

      • Peformance & Efficiency Testing

       

      • Bubble point testing to verify media integrity

      • Pressure drop and airflow measurement

      • Multi-pass testing to evaluate dust holding capacity and service life

      • Integrity & Strength Testing

        

      • Hydrostatic and pneumatic pressure testing for housings and assemblies

      📏 Dimensional & Visual Inspection

      • Dimensional verification against approved drawings

      • Visual inspection for workmanship, bonding and sealing quality

      Compliance with International Standards

      Testing and validation are performed in accordance with national and international standards, including:

      • IS (Indian Standards)

      • BS (British Standards)

      • ASHRAE

      • EN Standards

      • ARAMCO specifications

      • Customer-specific and application-specific requirements

      This ensures products are suitable for defence, industrial, automotive, cleanroom and critical process applications.

      Role in R&D & Custom Engineering

      The Filter Laboratory plays a key role in:

      • New product development and prototype validation, Custom filtration solution testing, Performance benchmarking and improvement, Failure analysis and root cause evaluation

      This integration between R&D, manufacturing, and testing enables faster development cycles and higher reliability.

      Quality Assurance Philosophy

      All laboratory activities are governed by our preventive quality philosophy, where defects are eliminated at the design and validation stage rather than corrected later. The lab operates under the company’s ISO 9001:2015 certified Quality Management System, ensuring traceability, repeatability and continuous improvement.

      Commitment to Reliability & Safety

      Through rigorous laboratory testing, Genius Filters and Systems Private Limited ensures that every filtration product delivered performs reliably under actual operating conditions, meeting the expectations of customers across defence, industrial, automotive, power and clean air sectors

      Filtration efficiency testing for air, gas, oil and liquid filters 

      Leak detection and sealing validation