Client: Fernox
Industry: Construction

EPP Thermal Covers fully encapsulate inline filters to keep system heat loss to a minimum.


The introduction of a thermal cover for a system filter is part of a broader initiative within the UK home building industry as developers recognise the importance of maintaining energy efficiency and reducing fuel wastage in domestic heating systems. Consumers are increasingly ranking the energy rating of a house as an important factor in the decision-making process when buying a home.

EPP is widely used in the HVAC industry as it is known to offer:

  • A strong and durable enclosure
  • Reduced heat loss
  • Greater heating system efficiency
  • Protection from internal components and hot surfaces

The challenge

Fernox, a global manufacturer of chemical water treatment and engineered filtration products, approached Foam Products to discuss an opportunity to design and manufacture thermal covers for two of its inline system filters:

  • The nickel plated, brass TF1 Omega Filter
  • The composite plastic TF1 Total Filter

Fernox requirements included strength, durability, protection and improvements in the performance of current systems.

Our approach

Foam Products developed a solution for each filter, both designs consisted of two parts (a male and female) that would push together to fully encapsulate the premium system filters. Various locator points were included on the moulded parts to ensure the correct alignment when fitted around the system filters.

The locator points on the original design were modified to provide a resistance fit to hold the two parts firmly together without the need for additional fixtures or fittings. The use of medium density Expanded Polypropylene (EPP) offered the water filters excellent protection and thermal insulation to reduce heat transfer.

The presentation to Fernox included a series of 3D CAD drawings and once approved, the drawings were sent to one of the in-house Computer Numeric Control (CNC) milling machines where EPP prototypes were produced. The EPP samples were then tested for fit and function prior to final tooling.

The results

The customised EPP thermal covers supplied to Fernox are designed to last the life of the filters. They will insulate and protect the system filter year–after-year without losing their integrity or performance.

Additionally, after the approval of the new EPP parts, Fernox approached Foam Products to help source an outer corrugated printed carton packaging for both models of the filter covers. Foam Products worked with colleagues at DS Smith Packaging in Wellingborough, UK to produce the corrugated carton packaging.

As an added advantage, both the EPP covers and the corrugated outer carton supplied by DS Smith are fully recyclable at the end of their useful life.

About Fernox

Fernox is a leading, global manufacturer of chemical water treatment and engineered filtration products. Headquartered in Woking, UK and with offices throughout Europe, the US and China, Fernox has been a pioneer of innovative and effective chemical water treatment and filter technology. Established in 1964 the company manufactures chemicals and filters that help to optimise energy efficiency in heating systems, reduce boiler breakdown and extend the life of a heating system. The latest addition to its award -winning filter range is the Fernox TF1 Omega Filter. Its ground-breaking, well- engineered design makes installation quicker and easier and servicing the heating system faster and more convenient. The filter combines magnetic and hydronic particle separation to remove both magnetic and non-magnetic contamination to sub-micron level offering greater protection for the system.

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