Pall Corporation | Package Water Initiative (PWI) — Next Generation Process Filter (NGPF)
As the UX Research and Design lead on Pall’s Next Generation Process Filter (NGPF) within the Package Water Initiative, I applied human-centered design methods to improve a mission-critical filtration component used across diverse industries, including food and wine production, biopharmaceuticals, petrochemical processing, and ultra-pure semiconductor manufacturing. The project was initiated by a technical constraint—the addition of new filtration media required a reduced inlet diameter, which exposed usability and safety limitations in the existing cartridge handle.
My role focused on understanding and improving the full product lifecycle experience. I documented workflows and task flows across installation, removal, transport, and disposal, mapping all user interaction points to identify broader UX opportunities beyond the handle itself. I created user personas and organizational hierarchies to align cross-functional teams around real operator needs, and conducted time-on-task and task success analyses to better understand pre- and post-installation behaviors that influenced usability.
Based on these insights, I developed 3D concepts and printed prototypes, which were evaluated through usability and user preference testing with representative users under simulated conditions. Testing measured grip strength, applied force, push/pull/twist actions, and transport scenarios across multiple orientations. Findings informed clear characteristics for success, resulting in a redesigned handle that improved grip security, reduced physical strain, and supported safer handling—while remaining fully compatible with existing manufacturing and assembly processes. The final solution also incorporated Pall branding and product identification considerations, ensuring alignment across engineering, manufacturing, and marketing touchpoints.
current & prototype Filter cross sections & grip pattern - illustrating project starting point.
Work and Taskflows illustrating User patterns, Interaction Points, and Areas of Opportunity within the product lifecycle. Mapping out all interaction points allowed for exploration into additional areas of opportunity to IMPROVE the ENTIRE product UX.
creation of User Personas and Organizational Hierarchy - educating other team members and putting a “personal face” on the product. These personas allowed focus to be centered on removal/installation/ and disposal tasks of greatest opportunity for improvement.
TaskFlow Description and Time on Task Analysis - detailed description of steps needed to perform a SUCCESSFUL filter change out. These studies allowed for further understanding of pre and post tasks that Affect interaction with the filter product.
3D Concepts and Printed prototypes - based on investigations and research findings, 3D concepts were created to be evaluated in user testing under simulated conditions.
Usability and User Preference Testing - REPRESENTATIVE personnel were recruited to PERFORM a series of simulated tasks while measuring force and grip strength. Push/Pull/Twist - Vertical/Horizontal and Transportation tasks were measured.
Areas of Acceptance Scale and Testing Data Sheet
Characteristics for Success derived from User Testing ANALYSIS
Proposed 3D Printed Next Generation Process Filter handle. BENEFITS include: INTEGRATION into EXISTING MANUFACTURING processes, improved form factor ENABLING better grip strength, secure transportation and lifting, and enabling twist and anti-slip measures. Marketing with Pall branding, and Product identifier placement areas.
