In an earlier work [JMS 193 (2001) 69-841 computational fluid dynamics (CFD) simulations were used for flow visualization in spacer filled rectangular channels. This work reports results of CFD simulations on new designs of spacers in similar channels. These new spacer designs involve changing the convex surface of circular cross section of filaments in commercial spacers to concave surfaces with varying degree by adjusting the width to height ratios. It was shown that new spacers gave significant reduction in pressure drop across the channel when compared to corresponding original spacers. Based on CFD simulations it was also found that new spacers produced comparable strain rates to their corresponding original spacers. (C) 2004 Elsevier B.V. All rights reserved.