ABSTRACT This paper presents a novel optimization algorithm for designing single-tuned filters in industrial power systems to reduce harmonic distortion. Single-tuned filters are cost-efficient, simple, and easy to maintain. We formulate the filter design as an optimization problem, minimizing costs while incorporating harmonic limits and system constraints. Our solution algorithm simulates tree growth, proliferation, and death based on the forest algorithm to generate optimal solutions. This enables both local and global searches for fast convergence and feasible designs. Unlike traditional approaches, we account for variations in filter components and system parameters caused by factors like manufacturing tolerances, operating temperature, and frequency variations. Our study contributes by designing adaptive filters that match practical systems. We validate our method against previous publications and other techniques like simulated annealing and teaching-learning-based optimization. Simulation results demonstrate the effectiveness of our approach in minimizing costs, satisfying operation constraints, and accounting for component variations in this complex problem.