The long term costs of baghouse ownership you need to consider. Plus our top tips on the steps you can take to reduce them.
Costs of Baghouse Ownership
Industrial dust collection systems are vital to maintaining efficient plant production and ideal working conditions. Dust collection systems designed to filter airborne dust and debris can range from small bin vents to complex and customized turnkey baghouse systems. There are several factors that play a role when choosing the right dust collection system for your facility. These factors, along with assessing up-front and long term costs of baghouse ownership will help guide you to the dust collector that can handle your filtration needs, while offering long-term cost-saving features.
In a new dust collection project you have two types of costs; up-front and long-term. Up-front costs play a major role, but equally important are long-term operational costs which can add up significantly over time.
Upfront Costs of Baghouse Ownership
- Cost of engineering and design
- Shipping costs
- Baghouse system and parts
Long Term Costs of Baghouse Ownership
Stack testing: The frequency and requirements for stack testing will be determined by your state or local air pollution office. For example, if you are located in California you would refer to the AQMD office for the rules and regulations your facility needs to meet.
Energy Usage: This includes the energy costs to run the dust collector itself and all of its components. The dust collector component to consume the largest amount of power from a baghouse would be the fan, and fans can consume up 95% of the baghouse energy. Other costs include the compressed air being used to clean filters.
Cost Saving Tip: On-Demand cleaning improves dust collector performance while reducing energy consumption and labor costs. Learn more about on-demand cleaning for Pulse-Jet technology in this article here.
Replacement Parts: The 5 most commonly replaced parts on a dust collector are filters, pulse valves, timer boards, solenoids, and diaphragm kits. Beyond the replacement parts on the dust collector itself, you will also want to consider the replacement costs for the dust collector’s accessories. This may include:
- Fan: With proper maintenance of the fan’s belts and bearing, a fan can typically last as long as the baghouse itself. For free access to a fan maintenance guide, head over to our PDF here.
- Screw Conveyors: Being on the dirty side of a dust collection system, a screw conveyor receives a lot of wear and tear. This is the reason why a screw conveyor may wear out before the lifespan of a baghouse ends.
- Duct Work: Abrasive atmosphere or dust can contribute to the erosion of ductwork.
Cost Saving Tip: Understanding the signs of a worn out dust collector part can help you identify any issues before they become larger problems. Learn more about the common warning signs in our video here.
Shipping: These are costs associated with shipping replacement parts.
Cost Saving Tip: Eliminate price increases and delayed lead times with automatic parts delivery that you have full control over. Get answers to the most frequently asked questions about parts delivery here.
On-Going Maintenance: One of the tips to maximizing the life of a dust collection system is implementing a preventative maintenance plan. Depending on your system, preventative maintenance checks can be weekly, monthly, semi-annual and annual. For access to a comprehensive dust collector maintenance guide with free PDF download, visit our article here.
Beyond preventative maintenance, there is a 22-point inspection which can ensure your system is running at its peak performance. To get more information on a 22-point inspection and what it includes, check out this article here.
Waste Disposal: Costs associated with removing and disposing of dust and debris.
Labor for Change-Out’s: There are multiple factors that drive the cost of labor for a change-out. Some of these include travel, number of filters being replaced, the environment of the dust collector, and more. When you choose to outsource this service to experts, it may include:
- Changing filters
- Seal minor air leaks
- Repair or replace damaged solenoids, valves, or diaphragm kits
- Any other repairs or troubleshooting needed on a baghouse – for example, vibration issues with a system after a filter change
If you are looking for more information on dust collection services and the commonly asked questions needed to determine cost, get full insight with this guide.
Highest Long Term Costs of Baghouse Ownership
Replacing dust collector parts like the filter cartridges, filter bags, the delivery cost for those replacement parts, the labor costs to switch out or maintain those parts, and maintaining inventory will be some of the highest long-term costs you incur. Filter replacements will be your highest maintenance item moving forward because, depending on your application, the lifespan of a filter can be anywhere from 1 year to 5 years.
Lifespan of a Baghouse
A properly maintenanced dust collection system in a non-abrasive environment can typically last around 20 years. On the other hand, the lifespan of a dust collection system in an abrasive environment is only between 5-10 years. An example of an abrasive environment can include a dust collector sitting outside of a plant, near the beach. In this scenario, you may start to see rust on the housing within 5 years.
How to Extend the Life of a Baghouse
We understand that getting the most out of your dust collection system is important. Below we are sharing our top tips that can help extend the life of your baghouse.
- Eliminate or reduce the unscheduled shutdowns by maintaining inventory levels.
- Your compressed air source should be dry and oil free, otherwise it can interfere with your pulse bounce
- Use the right air-to-cloth ratio
Benefits that Extend the Life of a U.S. Air Filtration Dust Collection System
To help further maximize the lifespan of a dust collection system U.S. Air Filtration offers the following benefits.
- U.S. Air Filtration primes the inside walls of your dust collection system to add a layer of protection
- Additional epoxy paint options can be added if required (additional cost varies depending on system size, paint, etc.). For example, a cement barge loading or transferring cement that may require a marine grade epoxy on their dust collection system.
- U.S. Air Filtration fabricates our dust collection systems in 10 or 12 gauge, while other suppliers may provide a thinner 14 gauge to cut costs
- Where applicable, heavier duty equipment may be provided as an option to lengthen the accessory’s lifespan. For example, a 5HP drive for a 20 foot screw conveyor instead of the typical 2 HP.
Dust Collection Cost-Cutting Steps to Avoid
If purchasing decisions are made solely based on the cost of equipment and not quality or application, you could end up spending less up front, but increasingly more over time. Some of the shortcuts to avoid on the front end are:
- Improper Air-to Cloth Ratio: Air-to-cloth ratios may cut up-front costs but they also cut you short on static pressure. For example, baghouses with a 10:1 air-to-cloth ratio will give you inconsistent suction at your pick-up points, resulting in clogged filters and more frequent change outs. Ultimately you’re going to be paying more in the long run than you would have if a proper air-to-cloth ratio was considered. To get a better understanding of the importance of air-to cloth-ratio or how to calculate it, access our latest video here.
- Cheap Baghouse Material: Avoid suppliers that fabricate their systems with the bare minimum materials and construction.
At U.S. Air Filtration we do not have a cookie cutter approach. Every dust collection project is specific to the customer. Therefore, we recommend working with an engineer to customize a dust collection system that will meet the unique characteristics and needs of your facility. This is the best approach to getting the long-term performance you need out of a dust collector.