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Infrastructure & Manufacturing 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 Facilities

1. Filtration Systems Manufacturing Unit

This unit is dedicated to the fabrication of complete filtration systems and pressure-rated assemblies for industrial, defence and infrastructure applications.

Production Process

• Raw material testing & inspection

• Welding procedure qualification

• Assembly of welded joints

• Weld joint and shell soundness verification

• Sand blasting / internal surface finishing

• Hydro testing

• Painting / surface finishing (as per metallurgy)

• Final inspection prior to dispatch

Machinery & Equipment

• Shearing machines

• Bending machines

• Power press

• Welding machines

• Lathe & milling machines

• Drilling machines

• Grinding & buffing units

• Sand blasting unit

• Painting booth

• Generator for uninterrupted power supply

Testing Facilities

• Raw material testing

• Hydrostatic testing

• Pneumatic testing

• Helium testing

• Nitrogen testing

• NDT (Non-Destructive Testing) / Radiography

• Surface roughness (Ra) measurement

2. Filter Elements Manufacturing Unit, R&D & Test Laboratory

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

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

• End caps and end gaskets manufacturing

• Assembly using welding, ultrasonic welding and epoxy bonding

• Visual inspection and performance testing

• Packing and dispatch

Machinery & Equipment

• Automatic shearing machines

• Automatic bending machines

• Welding machines (TIG, MIG, ARC, Ultrasonic, Gas)

• Lathe machines

• Pleating machines

  • Pleat width up to 2000 mm

  • Pleat depth 5–50 mm

• Ultrasonic fusing machines (longitudinal & circular joints)

• Electrical cutters for precision media height control

• Hot air ovens for filter paper curing

• Industrial hot plates for adhesive setting

• Aluminium foil forming machines

• Hot melt adhesive dispensers

• Air compressors with dryers

• Sewing machines & riveting tools

• Painting booth

• Generator for uninterrupted power supply

In-House Testing Capabilities

• Raw material testing

• Filter media pore size testing

• Multi-pass testing

• Bubble point testing

• Performance testing as per BS, IS, ASHRAE, ARAMCO, EN 779 standards

3. 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

• Heat exchangers

• Skids

• 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.

Advanced Manufacturing & Support Facilities

• 3D Printing Laboratory (rapid prototyping & development)

• Blade pleating machines

• Rolling machines

• Filter paper weaving facility

• Screen printing machines

• Hydraulic press brake & bending machines

• Spot welding machines

• Ultrasonic welding machines

• TIG welding machines

• MIG & ARC welding machines

• Paint booth

• Perforation machines

• Power press

• CNC engraving machines

• CNC laser cutting machines

• CNC laser welding machines

• CNC lathe machines

• CNC milling machines

Infrastructure That Enables Excellence

Our comprehensive infrastructure enables design-to-delivery execution, ensuring:

• Precision engineering

• Consistent quality

• Compliance with international standards

• Scalability for OEM and defence projects

• Reliable delivery for domestic and global markets.