Benefits of PTFE Membrane

Are you spending too much time and money on costly change-outs?

If you’d like to save yourself from the headaches that come with change-outs, then PTFE may be the answer to your problem. Our brief video guide will provide some information on how PTFE membrane works and its benefits when its added to your filter media.

Hi this is Bob from US Air Filtration.

Would you like to get twice the life out of your filter bags and reduce those costly change-outs?

Would you like your dust collection system to capture more dust?

Would you like to get more consistent airflow or suction through your dust collection system while reducing wear and tear and reducing maintenance costs?

If the answer to any of these questions is yes. then PTFE membrane filter bags may be the answer.

For you to understand how PTFE membrane bags can accomplish these things let’s first look at how a standard filter bag works.

On a standard bag dust builds up on the outside of the bag and creates what is known as the filter cake. The filter cake actually does the filtering while the bag fabric acts only as a support for the cake. When the bags are pulsed most of the filter cake releases and the build-up of dust begins again.

Over time however some of the dust gets embedded deep into the bag fibers. Eventually the bags will completely plug and need to be replaced.

Conversely when PTFE is added to the bag it acts as the filter cake. Commonly known as Teflon. PTFE is used in many different applications from cookware to outerwear and more. When a PTFE membrane is laminated to a filter bag media it can enhance the performance of both the filter bag and the dust collection system.

Let’s take a closer look at how a PTFE membrane works. If we zoom in on the PTFE membrane we can see that it is actually made out of tiny microscopic holes like Swiss cheese. The holes are large enough to allow air molecules and vapors to pass through but small enough to inhibit even the smallest dust particles from getting through.

Because the membrane keeps the dust on the surface of the bag particles never get embedded in the bag fibers and the bags will not fail from plugging up. Typically PTFE membrane bags wear out before they plug up.

Usually lasting twice as long as standard bag. With twice the lifespan costly change outs and plant shutdowns are cut in half reducing maintenance costs and increasing plant production.

Since the bags are not gradually plugging up over time, PTFE bags give the additional benefit of providing more consistent airflow or suction from your dust collection system.

Because of the small pore size, PTFE membrane bags are up to eight times more efficient than a standard filter bag. This means it can cut out dust collector emissions by up to 800 percent.

Another advantage of PTFE membrane bags is that they clean easier because of their slick surface. This means less bag pulsing which means less wear and tear on the bags as well as the diaphragms and solenoid valves. It also means the system uses less compressed air resulting in reduced energy costs.

It can also improve performance when higher moisture levels or sticky dust are present.

PTFE membrane can be added to any bag media and can replace standard

bags and almost all applications. While there is a cost to add the membrane, the extra cost easily pays for itself by providing longer life, reduced maintenance cost, reduced wear and tear, and lower emissions.

To find out if PTFE membrane filter bags are right for you call and talk to one of our experts today.

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Guide to Cartridge Media

 

 

Guide to Cartridge Media

When it comes down to choosing the right filter media, it may not be as tough as you think. 

Do you know the characteristics of the dust you will be filtering?  If you do, then you’re a step ahead of the game.  There are three common medias for filter cartridges and they can cover a wide variety of applications. If you know your dust characteristics then watch our short video guide that provides a brief introduction and understanding into cartridge media, and which one may be best for your application.

Video Transcript:


Hi this is Bob from US Air Filtration and today we’re going to talk about cartridge filter media’s.

While there’s a lot of different media’s out there, most applications, probably over 90% of them, can be handled with one of three common medias. We’re gonna take a look at those today.

I have here a couple of standard filters. This one is made from a media called 80/20. 80/20 gets its name from being 80% cellulose and 20% polyester which is mixed in to give it some strength. But it looks and feels a lot like paper and the paper is folded into pleats and packed into this cartridge.

This is what a swatch of the media looks like before it’s been put into the cartridge.

This filter is a great general use filter for blasting or paint boosts and just general dust filtration.

The next filter I want to show you is one made with a media called nanofiber. Now you look at these two filters they look almost identical. Actually when you look at the media, the media looks identical, and that’s because nanofiber is made by taking the same 80/20 substrate and putting a microscopic web of fibers over the paper.

So when you look at them next to each other they look identical, but the Nanofiber is much better at handling the superfine dust particulate.

So when you have plasma cutting or smoke or really fine dust, nanofiber is going to be the better choice for you because those little fibers capture the dust and keep them from plugging up the filter.

You can use nanofiber as a general use filter as well. Some people say it lasts longer than the standard 80/20 because of that layer of nanofiber on the top of it.

The third filter I want to show you (or filter media) is this one which is made from spunbond polyester.

You’ll notice that the pleats are not as packed in this filter and that’s because this media is a little more permeable. This is a very tough rigid plastic feeling filter media.

This is what the spunbond polyester looks like a close.

This is filter is one you that you want to use when you’re trying to avoid damage to the filter because you’ve got tough dust.

So this is used often in cement industries, cardboard, abrasive blasting, sandblasting or anything else where strength is required. Spunbond polyester is the filter media of choice.

You can also add a PTFE membrane to spunbond polyester that you can’t to these other filters. So when you have a real sticky dust, putting the membrane on spunbond polyester may also be an option for you.

There are also other specialty media’s to help take care of unique environmental conditions. To find out which filter media is right for you call and talk to one of our experts.

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Benefits of On Demand Cleaning

Are you running your dust collector at it’s peak efficiency?

A preventative maintenance plan is one way to make sure that your filters are clean, and that both your airflow and pick up velocities are at its maximum efficiency. So how do you know when to clean your filters? One of the easiest ways to avoid the guess work is by using “On Demand Cleaning”. Take a look at our brief video guide below that shows how on-demand cleaning can lower your long term maintenance and energy costs.  When you purchase your next dust collector this feature should come as a standard component.

Video Transcript:

Hi this is Bob from US Air Filtration. Differential pressure is a great tool that you can use to make sure your dust collector is operating properly.

Today we’re going to talk about what differential pressure is how it works and how you can use it to better maintain your dust collector.

Differential pressure commonly called DP measures the difference in pressure between the clean and dirty sides of the collector. As dust builds up on the filters it creates more resistance for the air trying to pass through. This creates unequal pressure on each side of the filter. The dirtier the filters become the more unequal the pressure gets resulting in the higher DP reading.

To illustrate this concept let me compare it to something we’re all familiar with; drinking from a straw.

If I drink this soda through a regular soda straw, I can get a fair amount of liquid with not much effort. However if I try to drink soda through a small little coffee straw, it takes a lot more effort and I get a lot less volume through the straw.

The same thing is happening in your dust collector as the filters get dirty the holes that allow air to pass through get smaller and smaller causing the differential pressure to rise.

Once your dust collector’s cleaning cycle has taken effect then the dust is released and it opens up those pores and allows air to flow through and your differential pressure will drop.

Differential pressure is measured by a gauge with the fancy name called a manometer. This gauge is usually part of the dust collectors control panel.

Air tubes from the clean and dirty sides of the collector are brought into the control panel and connected to the port’s on the gauge.

The gauge can either be analog or digital in either case the gauges typically report the DP in a measurement called inches of water or sometimes called water column.

Since every dust collection system is different, DP readings are relative and should be compared to the collectors baseline levels.

A collector with brand new filters usually sees a DP reading of one to two inches. As filters age and become more en-trained with dust the differential pressure levels rise over time. Near the end of the filters life, the DP will be around six inches and stay there even after the cleaning cycle has run.

Running a collector consistently above six is not recommended since it will likely cause a noticeable drop in plant suction and lead to faster dust en-trainment and shorter filter life.

Sudden changes in DP can indicate problems in the collector. When the differential pressure becomes suddenly low it means there is no resistance to the filter because of the presence of holes or poor seals.

DP that suddenly becomes high means the filters are plugged which could be due to problems in the cleaning cycle. Usually a bad diaphragm or solenoid valve is the culprit.

For more information on differential pressure or to have one of our representatives help you understand what differential pressure is telling you on your collector give us a call today.

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What type of Dust Collector is right for my application?

Learn the differences between the three most common dust collection systems – baghouses, cartridge collectors and bin vents.

Abstract view of a cement plant

Your dust collector is a critical component in your facility, so here are a few questions you should consider when investing in a new dust collector.-What type of dust are you filtering?


-What CFM or volume are you looking for?
-Are there any size or restrictions for the space the dust collector needs to be in?
-Do you have AQMD or any local emissions requirements you need to meet?
-What is the temperature of my environment like? Cold? Hot?

After you consider these questions, the next step is looking into what type of dust collector will provide you with the most optimal performance.

Baghouse

Baghouses are typically the largest of the three types of dust collectors. They are best suited for high volume and high temperature applications. You would consider this if you were dust loading more than one 55 gallon a drum per day. The most common applications we see are:

-Wood

-Automotive

-Mining

-Foundries

Cartridge Collector

Cartridge Collectors are compact and very modular in its design. These are best suited for applications where your dust loading volume is low (collecting less than one 55 gallon drum per day), if you have a small footprint to work with, or if you want to easily expand in the future. The most common applications we see are:

-Steel Fabrication

-Bulk Powder Processing

-Welding

-Paint Booth

Bin Vent

Bin vents are usually used in applications where you are moving product from one location to another. Like a cartridge collector, bin vents are also compact, modular, and designed for easy change-outs. They are designed to efficiently vent silos and tanks while keeping the product inside the silo. So most often you will see them being utilized in these applications:

-Cement

-Agriculture

-Tank loading

-Conveyor Belt

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