Category Archive: Dust Collectors

How Much Does a Dust Collector Cost?

Summary: Small dust collectors for applications up to 1,000 CFM airflow cost between $100 up to $5,000 USD.  Pre-fab dust collection systems such as a bin vent or cartridge type collector cost between $10,000 and $80,000 USD. Pre-fab units acommodate airflow volumes between 2,000 and 10,000 CFM. Custom baghouse dust collectors or multiple module bin vents and cartridge collectors range between $50,000 to $1 million USD and more.

Watch Video: How Much Does a Dust Collector Cost?

 How Much Does a Dust Collector Cost


Table of Contents

  • What is a dust collector?
  • Dust Collector Cost
  • What Goes into the Price of Your Dust Collector
  • Dust Collector Filter Media
  • Electrical Controls or Accessories
  • Summary
  • Dust Collection Resources

What is a Dust Collector?

Dry dust collection systems remove airborne dust that generate during manufacturing or industrial processing.  Examples include woodworking, bulk powder processing, or food production.  Dust collectors range from small portable units to extensive custom turnkey systems.

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Dust Collector Cost

Small Dust Collector Cost

A small dust collector that is able to handle up to 750 or 1,000 cubic feet per minute (CFM) of airflow can cost between $100 up to $5,000.  These small retail units are ideal for ventilating two to three pieces of equipment (i.e. saw, sander, planer) for a small woodworking or metalworking shop.  Small units must be set up extremely close to the collection point. This reduces static pressure and fan size.  You can find these units at an online retailer or home improvement store.

Large Dust Collector Cost

Larger dust collection systems are needed to ventilate large scale processing equipment. These industrial dust collectors are found in some of the following commercial applications:

  • School woodshops
  • Metalworking facilities
  • Sandblasting
  • Chemical processing
  • Food processing
  • Cement production
  • Energy production
  • Mining
  • Foundries, and many others.

Large dust collectors are designed to handle a much larger dust loads, meet higher airflow, or specific temperature requirements.  Pre-fabricated dust collection systems like a bin vent or cartridge dust collector can handle airflow volumes between 2,000 and 10,000 cubic feet per minute (CFM).  Depending on the size of the unit, filter media, and the fan size, units can range between $10,000 – $80,000 USD.

Custom Dust Collector Cost

Custom turnkey, dust collection systems that require complete engineering can range between $50,000 – $1 million USD or more. These systems can include one more pulse jet baghouses, multiple modular bin vents, or several cartridge collectors.

What Goes into the Price of your Dust Collector

The price of your dust collection system is also determined by several variables outlined below.

Dust LoadUSAF CleanFlo Collector

Dust load is the amount or volume of dust in your work environment that must be cleared within a given time period.

 

Applications with higher dust loads require more filter media to remove airborne dust particulate.  This means you’ll need a dust collector with a larger footprint. This can drive up the overall cost of your dust collection system.  Applications that generate less than one or two 55 gallon drums of dust per day are usually good candidates for a small cartridge collector or bin vent.

Type of Dust

The properties of your dust particulate play an important role in the following:

  • Size of your system
  • Number of filters
  • Type of filter media
  • Filter treatments your application will need.
  • Air to Cloth Ratio
  • Fan Size
  • Temperature
  • Material Handling and Conveying

To understand the characteristics of your dust particulate, you can ask yourself the following questions.

Product

What is being filtered?  Does your product contain moisture or oil?  Products with moisture content greater than 25% are not suited for a dry dust collection system. Products containing hydrocarbons, including oils, may require the application of a special treatment to get optimal filtration.

Chemistry

Does your airstream or dust contain chemicals that could damage filter media?  Are there also acids or alkaline in the airstream?  When certain compounds are combined during processing, a chemical reaction can occur. This may require additional media treatment or coating to protect the filter bags from accelerated wear.

Abrasion

How abrasive is the dust that’s being filtered?  Consider the hardness of the material along with the shape of the dust.  The velocity of your airflow can also make your dust more abrasive.  Highly abrasive dust may require your housing be fabricated in stainless steel, titanium or other costly materials that are able to withstand long term wear.

Particle Size

What is the size of the dust particulate are you collecting? Depending on your emissions requirements, your application may require a special membrane. This would apply if your particulate is very fine.

Is your dust combustible?

Combustible dust can be defined as any fine material that has the ability to catch fire and explode when mixed with the proper concentration of air.  Examples of combustible dust include:

    • Wood
    • Food products such as grain, sugar, flour, starch, metals
    • Rubber
    • Chemicals
    • Pesticides
    • Plastics, and more.

OSHA and NFPA have created guidelines to protect your plant and employees from the risks of a serious explosion.  Also, be sure to review your state and local regulations for proper identification and management of combustible dust.

Applications filtering combustible dust will also need an explosion venting strategy. Explosion vents or Brixton latches are two common strategies that help reduce this risk. You may also need explosion isolation valves in the dust collection line. This helps prevent a deflagration from travelling back to the equipment should an event occurs inside the dust collector.

Dust Collector Filter Media

The type of filter media you choose impacts your system startup and long term maintenance costs. Polyester filter media is an ideal for applications with temperatures below 250°.  Polyester is affordable, highly efficient and readily available.

 

Other common filter medias include Aramid (Nomex©), Fiberglass, PPS, P84 and Teflon.  You can add treatments to  filter media to enhance it’s efficiency and performance. Treatment for your filter is dependent on your dust characteristics.  In addition, treatments can drive up the cost of your filter bags but also extend it’s life, reduce changeout’s and drive down long term maintenance costs.

Cartridge Dust Collector

Air to Cloth Ratio

Air to cloth ratio, also known as air to media ratio, is a measurement of the amount of cubic feet per minute of air passing through one square foot of filter media.

 

You can calculate air to cloth ratio based on the size and type of dust particulate you are filtering. It’s an important element in the design and size of your dust collection system.

 

Generally, the lower your air to cloth ratio, the better your system is at removing dust from the work environment.  However, if your air to cloth ratio is too low it can place unnecessary strain on your dust collector.  Systems that operate at a higher air to cloth ratio have a smaller footprint, size, and price than dust collectors operating at a lower air to cloth ratio.

Fan Size

Your dust load, CFM requirements, and static pressure measurements will determine the size of the fan that will pull dust through the system and turn the air.  Your dust collector’s location is relative to the work environment being ventilated and also impacts the size of your fan.  Systems installed close to the work environment can reduce the length of ducting and static pressure. As a result, a smaller fan may be required. The cost of a fan can vary depending on each of these factors.

Temperature

Applications operating above 250 degrees Fahrenheit may require more expensive filter media. These applications would need their filter to withstand long term exposure to high temperatures.

Material Handling & Conveying

Once your dust particulate has moved through your dust collection system and lands in the hopper, you’ll need to determine how to properly remove the dust. This ensures it doesn’t return into the airstream and plug up your system.  Drums are the most economical option. They perform well when handling waste material with light inlet dust loading.  Light inlet dust loading applies if you generate, at most, a one or two 55 gallon drum of dust per day.

 

Applications with higher dust loading requirements or those filtering non waste product, need an advanced system to convey material. This helps prevent the drum from overfilling, which can cause dust to back up or return into the hopper.  This can also result in a processing issue that will impact your dust collector’s performance.  In these situations you may need to upgrade from a drum to a larger dumpster, rotary or dump valve.

Rotary Valves

Rotary valves seal the bottom of your collector. They help prevent outside air from entering the system while allowing material to be continuously emptied from the hopper.  The cost to add a rotary valve to your dust collection system can vary between $3,000 and $5,000 USD.  

Pneumatic Conveying

Larger applications may also require a vacuum pneumatic conveying system. Their purpose is to vacuum material from the dust collector discharge to a common point.  For example, an application with five baghouses may include a common vacuum conveying system. It would help pull discharge material from all five baghouses to one common dust collector discharge area.

Paints, Coatings 

Applications with high moisture levels or chemical resistance may require an upgrade to epoxy paint. It can be applied to the interior and exterior of the dust collector. This helps to reduce long term wear of the system. Facilities located near an ocean, lake, or those that process caustic chemicals would use epoxy paint.

Unit Insulation

Insulation may also be required if you’re airstream temperature is high and must remain above the dew point in gas form. This eliminates the risk of moisture and condensation. Airflows with high moisture content can cause performance issues with your filter bags. This can include plugging of the system and inefficient filtration. Applications requiring insulation include ventilation of exhaust air coming off boilers, burners during metal forming, and similar processes.

Electric Controls or Accessories

Most baghouses, cartridge collectors, and bin vents come standard with an electrical control panel. This powers your pulse cleaning system and your fan separately.  Most experts recommend to integrate your control panel into a starter panel. This powers your pulse cleaning and fan at the same time.

 

Installation of starter panels can be done at any desired location in your plant regardless of the distance to the dust collection system. Starter panels protect your system from surges or motor damage.  While the addition of a starter panel can add to the initial cost of your system, the ease and added safety it offers make up for startup costs.

Dust Collection Design Considerations 3

Is an OEM Dust Collector like Torit Right For Me?

We recently took a survey asking customers their attitude and preference towards OEM vs. aftermarket dust collection products. Here’s what we learned:

  • 15% of buyers prefer OEM dust collector parts and equipment exclusively
  • 85% of buyers like the option to purchase OEM or aftermarket dust collector parts and equipment
  • 65% of buyers who purchase aftermarket said they get the same performance as an OEM at a more affordable price and/or don’t care about having brand name components.
  • Another 50% prefer aftermarket products because they are more affordable
  • Of the 15% of buyers who only purchase OEM,  the most popular reason for choosing OEM is because they believe they can be trusted to perform long term (33%).

If budget is not a factor for you and you are willing to pay more for OEM then this may be the right solution for you.  However if you are looking to get the same long term performance from a dust collection system as an OEM and don’t want to pay a higher price for a brand name, then a U.S. Air Filtration system may be a fit.

Summary of Dust Collector Cost

Selecting and pricing out a dust collection system involves consideration of each variable above.  Understanding each of these variables is critical to ensuring your dust collector performs efficiently for many years to come while also creating a clean and safe work environment. Each dust collection application is unique so it is possible that applications with very similar product characteristics or volume may require a system that is different in price and size.

 

To ensure a successful solution, consult with a dust collection engineering and manufacturing company with extensive design and manufacturing experience.  An experienced dust collection engineering firm can help you engineer a system customized to your unique application requirements.

 

If you have any questions unique to your application, give us a call at 888-221-0312. You can also email [email protected]. In addition, below are some related videos and resources that may help.

Dust Collection Resources

Different Baghouse Styles: Advantages and Disadvantages

When it comes down to finding the right dust collection system, there are a few different baghouse styles to choose from. So how do you know which one is best for you?

Baghouse Styles

Before we dig into the differences between some of the baghouse styles, you need to consider your dust properties and air-to-cloth ratio.  Baghouses are ideally suited for large volume applications with airflow exceeding 1,000 CFM or when high temperature applications are above 375 degrees.  In these environments, a baghouse will handle and most efficiently filter your dust laden air. 

There are three main baghouses styles (e.g. shaker, reverse, and pulse-jet)  that are commonly used in most industrial processing and manufacturing applications.  Here’s a brief overview on the pros and cons of each to help guide you in identifying the right option for your work environment.

Pulse Jet Baghouse 

Pros:    Cons:
Constantly cleaned so there is minimal dust build up in the dust collector   Requires dry compressed air
Space Efficient   Cannot be used when there is humidity of high moisture content present
Requires fewer bags   Cannot handle high temperatures (unless you use special filter media
     

Reverse Air Baghouse 

Pros:  Cons:
Can handle high temperatures Needs to be cleaned often
Gentle cleaning which allows for longer bag life Residual dust build up is hard to remove
Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse Low air-to-cloth ratio
   

Shaker Baghouse 

Pros:     Cons:
Very simple to operate     Cannot handle high temperatures
Low initial investment cost     Not space efficient (takes up a large area)
Units are typically compartmentalized into sections which allows them to be cleaned without shutting off the entire baghouse     Energy and time sensitive 

Dust Collector Inspection and Service

James Hardie Dust Collection System

22 Point Inspection

A well maintained dust collector ensures your system is performing at peak efficiency. It’s also critical to minimizing unscheduled plant downtime and the wear and tear of your dust collector parts. As part of a regular preventative maintenance program, customers can also request a visit from bonded and insured technicians to perform either a dust collector inspection. An inspection typically includes an analysis of your dust collector and its most vital parts, a written report, and recommended corrective actions to solve any issues. An inspection may also include an exam of the following:

  1.  Overall status of dust collector(s)
  2. Compressed air system for leaks
  3. Regulator pressure
  4. Air Shut off valve is sealed and is properly working
  5. Solenoids firing properly
  6. Diaphragm Valves firing properly
  7.  Couplings are sealed
  8. Magnehelic is working properly
  9. Fan Vibration readings
  10. Bearing Temperatures
  11. And more

Dust Collector Service

Different from an inspection, a service on a dust collector system includes bonded and insured technicians performing a change out or corrective actions. This can include the following:

  1. Changing filters
  2.  Seal minor air leaks
  3. Repair or replace damaged solenoids, valves, or diaphragm kits
  4. Any other repairs or troubleshooting needed on a baghouse – for example, vibration issues with a system after a filter change

USAF Dust Collector Warehouse

Dust Collector Inspection and Service Questions

If you are looking for an inspection or service from a supplier, here are some of the most common questions asked before receiving a formal proposal and costs.

  1. What type of service or troubleshooting are you requesting?
  2. Where will the service take place?
  3. What type of dust are you filtering? Is it hazardous? Is special safety equipment required?
  4. Are there any current issues with your filters?
  5. Is there any special training or background checks needed before entering a facility?
  6. When would you like to have the service performed? What are the permitted service hours (evening or day work, weekends only, etc.)?

For more information on inspections or services for your dust collector, you can contact a USAF account manager at 888-221-0312 or also email [email protected] Also included below is a link to our comprehensive dust collector maintenance eBook that can be downloaded.

12 Days of Christmas Dust Collection Maintenance Tips

For a little Christmas Cheer we’ve pulled together some of our most popular dust collection maintenance resources here to the theme of the 12 Days of Dust-mas.  Enjoy!

Baghouse 3D Demo

Is your building all dusty? Time for a new system?  Check out a 3D Demo of our most popular baghouse units.

Broken Dust Collector Bags

Two broken bags?  Check out this video on how to detect a dust collector leak in your system.

 

Dust Collector Shipping

Learn more about how USAF ships your orders and what to do to expedite your lead times.

Four Cartridge Filters

Is it time for a changeout?  Here’s a brief instructional video on how to changeout your USAF cartridge filters.

5 broken valves

Do you have a leaky diaphragm valve?  Get some tips you can try to troubleshoot your broken valves.

6 Bags a Blinding

Is your differential pressure rising and dust escaping your dust collector?  It could be blinding bags.  Find out how to tell your bags are compromised and signs it’s time for a filter changeout.

7 Cages a Rusting

Learn all about cage construction for your filter bags here.

8 Gates a Sticking

Having trouble removing dust from your dust collector?  Has your dust load increased?  Check out some of the most common dust removal options available including rotary valves and pneumatic conveying.

9 Pleated Filters

Need help installing pleated filters?  Here’s a brief tutorial on how to install yours correctly.

10 Bags a Clogging

Do you have clogged bags?  Does your system utilize on-demand cleaning?  Find out how this can help you save time and energy.

11 New Workstations

Are you looking to expand plant operations in the new year?  Get information on how much a new baghouse, cartridge collector or bin vent costs and all the factors that go into the cost of a new dust collection system.

12 Bosses Yelling

Check out our USAF Cartridge Dust Collector 3D Demo and learn how a USAF system can help improve plant operations.

Dust Collection: How to Create a World Class Customer Experience

Dust Collection Customer Experience Summary:

• Industrial Dust Collection buyers place high importance on customer experience when making purchasing decisions
• Customer experience is defined by the interactions a buyer has with a company before, during and after a sale.
• There are five things industrial buyers value most in their purchasing experience: Product knowledge, Responsiveness, Service, Relationship, and Educational Resources

If you were to ask most people what’s most important to them when making a purchase historically it’s come down to three things – price, quality, and service. But as buyers have become more savvy and have less time to spend on purchasing, customers now place equal if not more importance on customer experience when making dust collection purchasing decisions. In fact, 86% of buyers are willing to pay more for a great customer experience. And a recent Walker study found that by the end of 2020, customer experience will overtake price and product as the key brand differentiator.

Customer experience is defined by the interactions a buyer has with a company before, during and after making a purchase.

What makes a good customer experience when purchasing dust collector parts

We recently sent a survey to our customers to understand what they currently value when making purchasing decisions and to learn where there may be gaps and opportunities for improvement.

By understanding our buyer’s perspective it helps us build an experience tailored to the different needs and wants of our customer.
We’ve organized our findings into five core components that customers valued most:

Top 5 Key Components to a Customer Service Experience

  1. Expertise and Product Knowledge
  2. Responsiveness
  3. Service
  4. Relationship
  5. Educational Resources and Tools

 

Dust Collection Purchasing Survey Graphic 1

Dust Collection Expertise and Product Knowledge

Expertise and product knowledge were voted as the most valued component in a dust collection customer service experience. Dust collection needs vary significantly even within the same industrial application. Today buyers value sales reps who function first as product experts who understand their specific dust collection challenges. Finding the right dust collection products that will optimize performance requires vast technical knowledge on a filters, valves, troubleshooting, dust collection engineering and more. When a sales rep delivers and establishes their expertise, this evokes trust and assurance to the customer that their buying journey and partnership will be successful.

“I had a very good conversation with internal sales, Mark. Sharing technical knowledge and information is always helpful!” – Customer Testimonial

Leveraging Technology to Improve Responsiveness

Responsiveness is critical to industrial dust collection customers in order to keep their system running at peak performance. A customer may need dust collector parts for an upcoming inspection, an unexpected explosion, or replacements for broken or underperforming parts. To help solve issues before they turn into more disruptive maintenance problems, it’s vital to get a response back to the customer promptly.

To improve response time, companies can leverage technology in innovative ways that cater to the customer.

For example, at USAF our sales reps can be reached through multiple channels including direct phone line, email, online quote request, online chat, email nurturing and marketing automation, or via the main line where a live person will answer and direct your call immediately. Investing in several channel options allows USAF to communicate with customers quickly, using their preferred communication method.

Further, as more of the buyers journey moves online, and as more buyers now prefer online communication over phone and face to face contact, particularly in response to COVID-19, companies need to adapt by investing in technology that will streamline the buyers journey by moving more customer interactions online. This could include any or all of the following solutions:

  • Chatbot Artificial Intelligence
  • Call Center
  • Marketing Automation & Email/SMS nurturing
  • Content marketing – Includes videos, blogs, eBooks, case studies

“The products I purchase are specialized and by me contacting Patty and her quick response back to me works for our relationship and I wouldn’t change it. She does a fabulous job!” – Customer Testimonial

 

Dust Collection Purchasing Survey Graphic 2

Service

Customers face so many choices when it comes to where they purchase dust collector parts. One key component to the dust collection customer experience is service. Great service isn’t about being short-sighted and merely searching for the next opportunity, instead it’s about prioritizing solving customer problems and focusing on long term wins.

Today’s industrial buyers expect a service experience that combines one on one human connection with the efficiency that technology brings. An example of this could include the following touchpoints that combine technology with personal outreach:

  • Regular phone call check ins by sales rep before, during and after a sale to help the customer identify the right product and confirm successful delivery.
  • Email nurturing that includes how to advice and relevant educational information on dust collection.
  • E-Commerce product catalog for direct online sales
  • Post-sale shipping and tracking notifications by email or text
  • Post-sale customer satisfaction survey by email

While technology has changed the way we do business in critical ways, particularly through e-commerce, the need for human connection will never go away. Companies who can master this hybrid model by finding the right balance of human vs. technology touchpoints will be the most successful in the future.

“I think you’re already doing a great job. Bonnie is always fast to respond to my emails (always within an hour, often within minutes). On top of that she calls me periodically just to check up. She is a true professional and you should consider her a major asset to your company. Without her being my sales person I cannot guarantee that I would be even purchasing from you, there are local guys that I could buy from but I keep coming back to USAF because the service is so good.” – Jake Z.

Relationship

The main goal of establishing a relationship between the customer and their sales rep is to create a consistent experience across all touchpoints in the dust collection journey. The sales rep is the direct connection from the company to the customer, and to ensure the process is as smooth and positive as possible the sales rep should be a customer’s first go-to contact for orders, questions, or issues.
Have you ever called a customer service line for a large retail or phone company? You often find yourself frustrated at being bounced around through several different departments before you even speak to the right person. A direct sales rep for a company keeps an eye on the customer’s entire journey to ensure their experience is positive and to also help mitigate any issues that may cause a bigger problem down the road.

“Bonnie was incredibly kind, helpful, and persistent (in a good way) with our last order” – Thomas J.

Educational Dust Collection Resources and Tools

Expertise, product knowledge, responsiveness, service, and a relationship are all important to the dust collection customer service experience. Providing additional educational resources and tools throughout the purchasing journey is crucial to building trust and long term partnerships. Examples of successful educational resources can include:

  • eBooks that provide in depth analysis on a key topic such as dust collection design
  • Regular blog posts that answer common questions customers ask
  • 3D animated product demo videos
  • Instructional maintenance videos – includes installation, assembly, how-to and troubleshooting advice
  • Engineering drawings of products
  • Detailed spec sheets
  • Project case studies

Here are the most popular dust collection resources USAF has complied over the years that are most valued by our customers.

Dust Collection Resources:

5 Ways a Dust Collection System Improves Plant Efficiency and Saves Money

Why you may need a new dust collection system for your application and how a new system can improve operations.

What is a Dust Collection System?

Dust collection systems are engineered and designed to filter airborne dust particles and debris that can cause damage to plant equipment, create a hazardous work environment, and negatively impact plant production.

Installation of a new dust collection system for your facility either by replacing an old unit or expanding your existing operation, can mean an improvement in plant maintenance, waste collection, an increase in product quality, and plant efficiency and production. A new dust collection project can be a long process. Let’s start by exploring the top 5 benefits of a dust collection system.

Baghouse

The Top 5 Benefits of a Dust Collection System

  1. Meet Compliance Regulations and Standards
  2. Boost Productivity
  3. Improve Product Quality
  4. Enhance Health and Safety Standards
  5. Preserve Quality of Equipment

Meeting Compliance Regulations and Standards

Many industrial industries in the U.S. must comply with strict air pollution control standards . These standards can be set by the Environmental Protection Agency (EPA), National Fire Protection Agency (NFPA), OSHA, or local governing entities such as the AQMD in California.

All agencies require industrial facilities to maintain and meet air quality standards to ensure a safe and clean environment for their plant, employees, and the surrounding community. To get started on what air permits may be needed for your specific application and location, check out our guide on dust collector air permits.

The risks of non-compliance are health and safety risks to employees, explosions, failed inspections, and fines from agencies such as the EPA. All companies, large or small, are susceptible to these risks. Cemex, one of the largest producers of cement in the U.S. was fined by the EPA for $1.4 million in 2011 for exposing people to sulfur dioxide and nitrogen oxide emissions. Cemex was also ordered to install pollution controls at its Ohio cement plant as part of the settlement.

Enhance Production

An accumulation of dust particles and debris on industrial equipment can interfere with overall plant performance. A dust collection system can collect these dust particles before they can interfere and compromise the health and performance of your manufacturing equipment. When your dust collection system is not performing well either due to extended wear and tear, or because your dust collector is undersized and overextended, your entire operation is at risk. Maintenance issues that go unchecked can result in an unexpected plant shut down that can close down operations for days, weeks or more. It may be difficult to know if your unit is undersized, overextended, or too old. In these cases, consult with a dust collection engineering firm and request an engineering study. By doing so you’ll get recommendations that can minimize the risk of inefficient and poorly working equipment as well as frequent and costly maintenance.

Improve Product Quality

For many manufacturing facilities, dust in the air can mean dust on their products. Dust can settle and accumulate on products during the manufacturing process. This has a negative impact on the quality and consistency of finished goods. A dust collector will reduce and effectively capture these dust particles, allowing for product quality to improve and maintain consistency.

Enhance Health and Safety Standards

Inhalation of hazardous dust affects human health and a dust collection system is vital to removing these hazards and to keep employees safe. Industries like woodworking, chemicals, iron casting, asphalt, etc. operate facilities that continuously emit hazardous contaminants, debris, gasses, and chemicals. If the hazardous dust particles and debris aren’t removed, employees inhale this polluted air and are at risk for both short-term and long-term health issues. A dust collection system can minimize this hazard. To get a better understanding of the long and short term health risks check out this guide on the health impact of dust collection systems.

Dust Collection Safety

Another serious risk for the company is the possibility of a fire or explosion due to an accumulation of combustible dust. There are only four conditions needed for an explosion to occur:

4 Conditions That Create an Explosion

  • Oxygen
  • Enclosed Space
  • Ignition Source
  • Combustible Dust at the Right Concentration Level

Do you work in an industry with combustible dust? Some of the industries that are susceptible are:

Agriculture (grain, flour, sugar, etc.)
• Wood
Metals (aluminum, zinc bronze, etc.)
• Rubber
Chemicals (coal, sulphur, etc.)
• Pharmaceuticals
• Pesticides
• Plastics
• And More

Learn how you can prevent a dust collector explosion with these resources we’ve gathered together here.

Preserve the Quality and Prolong the Life of Equipment

When dust particles and debris are created inside a manufacturing facility the contaminated dust settles onto other surfaces such as computer systems and manufacturing equipment. A buildup of dust can be harmful and result in malfunctioning equipment. This can also create unnecessary, frequent, and costly maintenance in order to keep harmful dust and debris from accumulating. With a dust collector system purifying and collecting dust particles, the chances of excessive dust build-up is minimized.

To find out if you may benefit from an engineering study at your facility, contact a US Air Filtration engineer today. If you’re looking for additional resources on dust collection systems and the buying journey, download our free Dust Collector Purchasing Guide that touches on key topics like dust properties, volume, air-to-cloth-ratio, dust collector styles, low maintenance design features, and more.

Video: How Much Does a Dust Collector Cost?

Dust Collection Lead Times and Shipping During the Holidays

Dust Collection Lead Times

There are many variables that impact dust collection lead times, particularly during a pandemic.  Whether you are returning to work, ramping up production, or are planning a change-out during  this holiday season, consider the following factors that can have an impact on your lead times.

  • Media Availability: Specialty or rare media is usually not in-stock and may need to be sourced or fabricated. Examples include media such as PPS, P84, PTFE on PTFE, Fiberglass, Basalt, and Aramid (depending on seasonal availability and media weight requested), etc.
  • Custom Features: Dust collector parts with features, dimensions, or accessories that are not common. This can include oval shaped cages, uncommon weights for filter media (e.g. Aramid 16 oz.), and more.
  • Production Schedule: Dust collector change-outs and maintenance are often seasonal depending on factors such as location and industry. Production schedules can get backed up when an influx of orders are received around the same time. For example, change-outs in the Northeast region of the U.S. are commonly scheduled in the spring or fall season. This is because a large percentage of customers want to avoid conducting change-outs in the extreme temperatures of summer and winter months.
  • Holidays: Holidays can impact everything from production to shipping. If you have a scheduled change-out during a long holiday weekend, it is best to cushion in additional time to receive and inspect your order.

If you are returning to work after a long hiatus, we have created a return to work dust collection start-up guide and a dust collector maintenance eBook that you can download below to help get your dust collection system started safely.

Return to Work Guide

Dust Collector Maintenance eBook

Dust Collection Shipping

Shipping will continue to change and evolve, especially during the holiday season. We want to help you get what you need, when you need it. We also want to be as transparent as possible and provide the most up to date changes regarding dust collection lead times and shipping. The standard procedures and guarantees that you may have been used to with shipping, may have been modified. Below are some of the top changes that directly affect a large portion of businesses.

UPS

  1. Changes to the UPS Service Guarantee: Effective March 26, 2020 and until further notice, the UPS Service Guarantee is suspended for all shipments from any origin to any destination. Commitment times for some services have also changed.
  2. Is UPS slowing down delivery service? The majority of UPS services continue with the same expected delivery timeframes customers have come to expect. While UPS has suspended their Service Guarantee, they are committed to providing timely and reliable service.

For more details and answers to some of your other questions, we highly recommend checking the UPS website for the latest changes and service alerts: UPS Notices and Service Alerts

Fedex

  1. Changes to Fedex Money Back Guarantee: Earlier this year and until further notice, FedEx suspended money-back guarantee for all FedEx Express, FedEx Ground, FedEx Freight and FedEx Office services.
  2. Do I need to sign for my package? Until further notice, Fedex has suspended Signature Required for most shipments.

For more details and answers to some of your other questions, we highly recommend checking the Fedex website for the latest changes and news: Fedex Notices and Alerts

Freight Carriers

This year multiple freight carriers have minimized their workforce or altered their protocols as businesses slowly ramp up production or remain closed in response to COVID-19. Many carriers adapted quickly and implemented safety measures for their remaining staff to maintain continuity of shipping services. As freight carriers navigate through ever-evolving changes and face the upcoming holiday season, you may experience a delay in general delivery times.

To get more detailed information about a specific carrier, please check their website directly for the latest updates or changes.

Warehouse Management

Should businesses’ and warehouses ramp up holiday hours, we want to help you avoid costly delays or complications. Implementing a comprehensive receiving process is one way to eliminate added time or delays to your dust collector start-up or change-out.

To get a comprehensive receiving check list, access and download our guide below.

Download My Free Receiving Check List

Once the receiving process is complete, and as soon as you are able to, you can access our filter bag check list below. The check list will help guide you through the process of verifying product count, fit, and what to do should you encounter any issues.

Download My Free Filter Bag Check List

Baghouse Dust Collector FAQ

Table of Contents

Baghouse dust collectors are highly efficient systems used in industrial applications that remove dirt, dust, and debris from the air.  Baghouses improve worker health and safety, protect the mechanics of industrial equipment, and maintain compliance with environmental and workplace safety regulations.

Proper baghouse system design, installation, and maintenance are critical for minimizing plant downtime and maximizing system efficiency and longevity. Important design considerations, such as the airflow and square footage required for your system, will depend on your facility’s workspace and dust collection needs. Once a system is designed and installed, performing regular maintenance is vital for keeping it operating as efficiently as possible. Here, we address some of the most commonly asked questions about these critical systems.

Why do you need to install a baghouse dust collector system?

The primary reason for installing a baghouse dust collector system is to improve air quality by removing potentially harmful airborne particles, gas fumes, and other contaminants generated during manufacturing processes. Depending on the industry and the types of debris being produced, installing a dust collection system may be required in order to comply with air emission guidelines or workplace safety standards. OSHA, for example, requires industrial plants to meet certain indoor air quality standards to prevent dust-related health issues. Before designing a baghouse dust collector system, it is important to research what types of safety and air quality regulations might be applicable to your facility.

Baghouse dust collection systems may also be installed to upgrade, improve, or enhance a facility’s existing dust control strategies. Regardless of your specific reasons for installation, it is important to implement a preventative maintenance program in order to prevent future problems and keep the system operating at optimal efficiency. General steps may include:

  • Making sure the system operates within acceptable levels by monitoring differential pressure, timing controls for pulse valves, compressed air pressure, etc.
  • Regularly emptying drums and hoppers to prevent dust build-up
  • Frequently inspecting valves, hoses, gaskets, filters, and other components and replacing them when necessary

What type of particulate are you looking to filter?

The type of dust being generated in your facility will influence the type of dust collector that should be used. Common types of industrial dust include:

  • Wood dust. Fine wood particles generated during woodworking processes can linger in the air, causing health issues for workers.
  • Pharmaceutical dust. The manufacturing of drugs, vitamins, and minerals generates fine powders that can be highly toxic if inhaled.
  • Food particulates. High levels of dust can be created during the processing of spices, flour, sugar, cornstarch, grains, and other dry food products.
  • Metalworking dust. Metalworking processes can create a harmful mixture of fumes and fine dust ranging from 0.01 micrometer to 1 millimeter in diameter.

Particle size will help you determine the number of filters required and the best type of filter media for your system. While standard filters are usually sufficient for collecting moderate-to-large particles, pleated filters may be necessary to effectively capture very fine particles and fumes. It is also important to select a filter with the appropriate air-to-cloth ratio as this will influence the system’s ability to adequately protect workers from dust and contaminants.

Low filtration efficiency will expose workers to more particles and can increase the risk of explosions. In some cases, coating the filters with a porous particulate layer, known as a precoating, can enhance filtration and improve baghouse system performance.

 

What size of baghouse dust collector system do you need?

Baghouses tend to be larger than other dust collector systems and are typically used for high-volume and high-temperature applications. These systems employ cylindrical fabric filter bags to capture and separate dust particles from the air. The three most common baghouse designs are:

  • Pulse jet. Pulse jet baghouses are self-cleaning filtration systems that use pulses of compressed air to clean the bags.  Cleaning occurs while the system is online.
  • Reverse air. Reverse air baghouses feature a compartmentalized design that allows for the cleaning of individual sections without shutting the entire system down.
  • Shaker baghouses clean bags by mechanically shaking the dust out of them. These are simple to operate and have a low initial investment cost. However, cleaning is performed while the system is offline.

With their versatile and universal design, baghouses can meet a wide variety of industrial dust collection requirements. Common applications range from food production, pharmaceutical manufacturing, woodworking, and metalworking to energy utilities, chemicals, mining, and more. For optimal performance, your baghouse dust collector should be sized and designed to accommodate your facility’s air purification requirements as well as any spatial restrictions. Design considerations should include:

  • Anticipated cost
  • Type of dust being produced and expected dust volume
  • Size of area needing ventilation
  • Collector system size and required flow volume
  • Filter material

Baghouse Filter Bag Media

One of the most important decisions when designing a baghouse system includes selecting the right filter media.  There are a wide range of filter medias available to accommodate a variety of dust characteristics.  Temperature, dust properties such as moisture and abrasion will determine which filter media will provide the best performance and efficiency at your operation.  Here is an overview of the most common filter medias available.

  • Polyester – Polyester’s maximum continuous operating temperature is 275 degrees Fahrenheit and has good overall qualities to resist abrasion and performs well with dry temperatures.
  • PPS – PPS, also otherwise known by the proprietary name Ryton© or Procon©, is a filter bag media that is commonly used in dust collection applications where excellent resistance to acids and alkaline is required.
  • P84 – The stability of P84 filter media is a benefit to a wide variety of applications lime kilns, smelting, incinerators, coal fired boilers, and glass and ceramic industries. It can be utilized in operating conditions of a maximum 500 degrees Fahrenheit and offers a good resistance to mineral acids.
  • PTFE/Teflon – Generally used for severe environments operating at high temperatures. Industries that use PTFE filter media range from cement, steel foundries, and energy.
  • Fiberglass – Fiberglass filter media has been a leading industry standard for air filtration and applications where high temperatures are prevalent.
  • Aramid – Aramid, also known as Nomex©, is widely used in high-temperature applications because of its excellent resistance to abrasion and ability to perform at maximum continuous operating temperatures of 400 degrees Fahrenheit. 

How much do baghouse dust collector systems cost?

Baghouses are custom designed for each unique application and often require advanced engineering to integrate the baghouse system into the overall plant operation. As such, baghouse units typically start at $50,000 to $1 million or more.

To get the best value from your dust collector, it is important to size the system appropriately during the design phase. This will ensure the system captures dust efficiently while reducing energy consumption.

How do you remove dust collected by the baghouse system?

Knowing how to properly dispose of dust once it enters the baghouse system’s hopper is essential for preventing airflow blockages, fire hazards, and other issues. The most common dust removal strategies are:

  • Enclosed box. Dust is funneled into an enclosed box under the hopper that is emptied once capacity is reached.
  • Drum/bag. Dust is collected into a detachable drum or bag, allowing for convenient disposal.
  • Rotary valve. Rotary valves allow materials to be manually or automatically moved from the collector to a disposal drum or bin.
  • Screw conveyor. In large baghouse systems, screw conveyors remove dust by transporting it from the collector to a disposal area.

Most baghouse systems employ rotary valves or screw conveyers for automatic removal of dust.

Baghouses have automated cleaning options with control panels that can be programmed to clean the bags anytime the differential pressure reaches an upper threshold. This enables an ongoing cycle of cleaning that occurs automatically during dust collector operation.

Filters, filter media, and other baghouse components should also be inspected at regular intervals and replaced when necessary. Routine inspections are an essential part of preventing future problems and maintaining optimal efficiency.

How do you enter a baghouse dust collection system for further cleaning?

When entering the baghouse system for cleaning or maintenance, the following measures should be implemented to ensure employee safety:

  • Secure the system by powering down and shutting off valves, blowers, compressed air, etc.
  • Communicate the details of the operation to all employees
  • Wear the appropriate personal protective equipment (PPE)
  • Have additional crew available to assist if needed
  • Thoroughly purge the system of combustible dust before performing any hot work (welding, grinding, etc.)
  • Establish an emergency plan for escape/retrieval

Baghouse Dust Collector Systems from U.S. Air Filtration

Baghouse dust collection systems provide a versatile and efficient solution for capturing particles that are released into the air during industrial activities. At U.S. Air Filtration, we design and manufacture baghouse dust collection systems to accommodate a range of operating conditions and filtration needs. Our solutions are expertly designed and constructed to optimize your facility’s productivity while minimizing maintenance and energy costs.

For assistance with selecting or designing a baghouse dust collection system, please check out our product democontact usrequest a quote, or visit our design services page today.

Rotary Valve FAQ’s

What is a Rotary Valve?

Rotary valves (also known as airlocks, rotary feeders, or airlock feeders) are used to transition material from one pressurized point, such as a dust collector, to another unpressurized point, such as a drum or bin. Rotary valves help seal a pressurized system against loss of air and pressure. Rotary valves also help ensure loss of product during processing is minimized.

Rotary Valve Applications

Typical dust collection applications for rotary airlocks are dust collection, pneumatic conveying, pollution control, mixing, feeding, weighing, drying, and blending. Some of the relevant industries for rotary airlocks include metalworking , cement, minerals, agriculture, wood, paper, rubber, textiles, grains, paint, pharmaceutical manufacturing, and many more.
Typical Products for a Dust Collector Rotary Valve

  • Baking Soda
  • Corn or Corn Meal
  • Cloth
  • Flour
  • Grains
  • Grits (Corn)
  • Minerals
  • Oats (Rolled or Whole)
  • Peanuts (Roasted)
  • Soybean Flakes (Raw or Spent)
  • Starch (Granulated or Powdered)
  • Talcum Powder
  • Paint
  • Tobacco (Ground)
  • Wheat
  • Woodworking or paper pulp
  • Yarn
  • And more

How to prevent a dust collector explosion

Rotary Valve Construction

The main parts of a rotary valve comprise of the following:

  • Housing
  • Vanes
  • Motor (Can come in various combinations for a multitude of applications and environments. For example; speeds, explosion/spark proof, chain driven vs. direct driven, and more.
  • Drive, reducer or gear box which takes speed and converts it into power

Round rotary valve

Rotary Valve Options

Depending on your industry, application, and environment there are a few rotary valve options that could work for your facility. Here are some of those options in further detail:

  • Temperature:
    • High Temperature: Can expand when exposure to high heat. The rotary valves vanes are also shortened to leave a gap between the vanes and housing.
    • Low Temperature: Should be used or low or regular temp
  • Vanes: Standard is 6 vanes but 8 vanes can be made available, but would be more time and cost consuming.
  • Size: Sizes can vary from 6, 8, 10, 12, 14 and larger depending on application
  • Shape – Square or Round
  • Duty: Heavy duty or regular duty
  • Material:
    • Cast Iron (standard)
    • 304 Stainless Steel (resistant to most chemicals)
    • 316 Stainless Steel (resistant to chemicals 304 stainless steel can’t handle)
    • Chrome Plated Cast Iron (harder than steel, best for abrasive material)
  • Tips:
    • Beveled Steel Tips (standard – beveled spins counter clockwise so as not to compact the material and bind the vanes)
    • Replaceable Steel Edge – (good for applications that vary in their process)
    • Urethane Tips (best for large particles that may wedge between the vanes)
  •  Rotor: Open or Closed

Cartridge Filter Media

Selecting the right filter media for your cartridge dust collector plays an important role in keeping your system running at peak performance. You want to ensure the filter media you choose is best for your unique application and specific needs. Choosing the incorrect cartridge filter media can negatively impact the life of your filter, escalate energy usage, and increase the risk of dust build-up resulting in a dangerous dust collector explosion.

Most Common Cartridge Filter Medias

For a majority of cartridge dust collector applications, about 90% can be handled with just one of these common types of filter media. There are other specialty media’s that can help with unique environmental conditions, but it is rare and can cost two to three times as much as Spunbond polyester filters.

80/20 Cartridge Filter Media

80/20 filter media is comprised of 80% cellulose and 20% polyester. It is one of the most common and lowest priced filter media available for basic applications. This mixed filter media will provide more strength than a 100% cellulose cartridge filter.

Industry UseTreatmentsBenefits
Blasting, Paint Booths, General Dust FiltrationFire retardant (FR): can be added to help keep flame from bursting; doesn’t increase temperature resistance, Anti-StaticLowest price, widely available commodity filter for basic applications

Nanofiber Cartridge Filter Media

Nanofiber comprises of a thin, synthetic web of fibers that is overlaid on top of a substrate, usually 80/20 but sometimes polyester. This works similar to a PTFE membrane on a filter bag; the web of fibers will act as a dust cake and capture a bulk of the dust particulate. One of the other features of Nanofiber is that in comparison to 80/20 filter media, nanofiber can withstand greater cleaning demands.

Industry UseAvailable TreatmentsBenefits
Plasma cutting, Metalworking, Castings, Smoke or very fine dustFire retardantBetter at handling superfine dust versus 80/20

Spunbond Polyester Cartridge Filter Media

Spunbond polyester performs well in applications with heat, or abrasive dusts. This option is ideal for applications that require a strong filter media with enhanced dust release.

Industry UseTreatmentsBenefits
Cement, Cardboard, Sandblasting, Abrasive BlastingFire retardant, PTFE, Hydro-Oleophobic, Anti-staticHigh burst strength, increased dimensional stability

Polyester Cartridge Filter Media

Polyester is rigid and contains additional pleats, making it more permeable and allowing an easier flow of air.

Industry UseTreatmentsBenefits
Cement, Cardboard, Sandblasting, Abrasive BlastingFire retardant, PTFE, Hydro-Oleophobic, Anti-staticHigh burst strength, increased dimensional stability

Cartridge Filter Resources

Do you have an upcoming cartridge filter project? To get you started, below is a complete checklist of dimensions and questions to help you get the right fit.

Find Your Cartridge Filter

Are you ready to find your cartridge filter? We have a variety of standard cartridge filters in stock with the option to view, request a quote, or order through our online catalog. If you need a quote you can simply submit your request by clicking the link below and we will provide a response in 24 hours.