The past few years have been a roller coaster for the global supply chain, with natural disasters and pandemics causing major disruptions for manufacturers. These challenges directly impact manufacturers’ ability to effectively run production and positively impact the supply chain downstream.
In this article and latest “Filtered: On the Air” podcast episode, our experts Tim Keeter and Brent Bassett discuss supply chain issues and its impact on the dust collection industry, while also providing tips on how to alleviate some of the issues that manufacturers face in today’s supply chain.
The Future of the Supply Chain Delays
No industry was immune to global supply chain delays that have been impacting manufacturers the last few years. While some sectors did bounce back quickly, others are still in the process of recovering. Looking ahead, most of us learned that predicting anything has gone completely out the window. It appears things have improved, there are shorter delays, and more products on the shelves. As a result, we’re seeing less supply chain issues impacting consumers. But it’s still hard to tell as there are places around the world that are still recovering. At U.S. Air Filtration, we like to hope for the best but prepare for the worst. One takeaway from the last few years is that we can all be better prepared.
Industry Purchasing Trends
There are customers who have storage space, which has allowed them to update their purchasing process to include a back-up set of filters. More commonly, we see customers who try to order a month or two sooner than they normally would. But that may not always work out because some parts can have multiple delays. While an order may originally have a lead time of two months, there could be an additional delay for another month. One example would be for cartridge filters which consist of multiple parts. All it takes is one of those crucial parts of a cartridge filter to have a delay, and as a result the entire filter is delayed. In this scenario, planning ahead doesn’t always guarantee you’re going to receive your items on time.
How To Reduce Supply Chain Delays
Maintenance Plan:
Having a solid preventative maintenance plan is key. If you’re organized with your change outs, and know when they’re going to happen then you can order your things well in advance. One thing that U.S. Air Filtration can do for our longtime customers is help them realize their normal buying patterns. Oftentimes people just don’t know what those patterns may be. But if a customer has been ordering from U.S. Air Filtration for a number of years, we can look at those frequencies whether it’s every 12 months, or every 9 months which allows us to suggest a time to order with a little bit of a cushion.
In summary, a maintenance plan reduces the supply chain challenge because it allows a manufacturer to develop a predictable pattern, and understand the intricacies of their production. Some plants absolutely cannot run when filters clog, which means all production may stop if there is no cushion when ordering dust collector wearables. If you’re one of those clients that is going to shut down without your filters running at peak performance then you need to be able to plan ahead.
Warning Signs
Some of the warning signs to look out for include a rising or high differential pressure. If your differential pressure is rising, your filters are getting clogged. If you know how often this happens, then maybe your filters typically last a year. This shows that your normal production schedule is pretty consistent and you could just order a few filters at a time. Knowing when that happens is key. But a lot of facilities will have a tough time because their production may change. They may run 24/7 for a couple of months on a big project and then slow down for a couple of months. So it’s a little less predictable for some people.
Spare Parts
Due to the lack of predictability within manufacturing in general, some facilities opt to purchase a back-up set of dust collection parts. While some manufacturers are safe from unscheduled downtime with the availability of back-up dust collection parts, there are still a lot of companies out there that just aren’t equipped to store them. Another factor could be budget and timing.
Having a spare set of filters is always something the U.S. Air Filtration recommends, but we understand that there are challenges that come with this besides the storage issue. Here’s a few considerations with having to store dust collector filters
Limited space
Temperature swings
Moisture
Contaminants or pests
There are a lot of considerations to make when you’re thinking about storing,100 filters versus 1000 filters. But, at US air filtration we have come up with a solution on how to solve these issues.
STOCK ‘N GO Program Solution
At U.S. Air Filtration we have developed the STOCK ‘N GO program to address most issues that companies are challenged with when stocking extra parts. How it works is, U.S. Air Filtration will fabricate filters ahead of time for customers and store them in our warehouse. This way when a customer is ready for them, we can ship them out just within a day or two of being notified. This takes away the stress and the headache from the ordering process and lead times, resulting in a streamlined purchasing process.
Summary
In summary, supply chain issues can have a significant impact within the industrial air filtration industry resulting in delayed lead times passed down to manufacturers. Implementing a maintenance program and having a set-up back of dust collection parts are our top tips to alleviate the challenges that manufacturers face in today’s supply chain environment.
At US Air Filtration, we understand the importance of reducing supply chain delays. We are here to help ensure that your dust collection systems are working at optimal levels, so you can focus on growing your business and meeting the needs of your customers. If you would like more information about the STOCK ‘N GO program, visit us here. You can also reach out at 888-221-0312 or email [email protected]
To download a free PDF version of this Dust Collector Filter Bags Guide simply click this link here.
Choosing the right filter bags for your dust collection system is critical to ensuring long term, reliable performance of your collector and the safety of your employees. Our guide will help you understand your facility’s unique dust properties and provide an overview of various filter media, construction, and treatment options available.
We’ve organized our dust collector filter bags guide into these key topics:
Top Factors to Consider for Dust Collector Filter Bags
Understanding Your Dust Properties
Dust Testing
Common Filter Media
Filter Bag Finishes
Filter Bag Construction
Air-to-Cloth Ratio
Additional Resources
Understanding Dust Properties
Choosing the right filter media for your dust collection system is critical to achieving peak performance while reducing system wear, plant downtime, and extending filter life. The first step is to consider the properties of your dust particulate and review the following:
Product – What you are filtering? Does your product contain a moisture or oil? Products with moisture content greater than 25% are not suited for a dry dust collection system (baghouse, cartridge collector or bin vent). Products containing hydrocarbons, including oils, may require the application of special treatment to your filter media for optimal
Temperature – What is your typical operating temperature? Max temp? Media temperature ranges for dry dust collection can typically be sorted into three categories listed below:
< 275°F – Polyester filter media performs very well for ambient airflow temperatures in this range.
Between 275°F and 400°F – Aramid filter media is the optimal choice for temperatures in this
Between 400°F – 500°F – Fiberglass filter media is the most economical option for high-temperature applications; however depending on the type of dust, another filter media may be a better
Once you understand the temperature of your work environment, you can narrow down your filter media options and in many cases, apply a special treatment to the media to further improve performance. Treatment application can be an efficient way to minimize costs before considering a more expensive filter media.
Chemistry
Does the airstream or dust contain chemicals that could damage the filter media? Are their acids or alkalines in the airstream? Often when certain compounds are combined during processing, a chemical reaction can occur, which may require a specific media treatment or coating on your filter bags to protect the bags from accelerated wear.
Abrasion
How abrasive is the dust being filtered? Consider the hardness of the material that’s being filtered along with the shape of the dust. The velocity of your airflow can also make your dust more abrasive. If you are designing a new dust collection system, it’s important to engineer the ductwork, fan size, and unit placement to ensure the airstream is not entering your dust collector too quickly or too slowly.
Particle Size
What size dust particulate are you collecting? Depending on your emissions requirements, your application may require a special membrane. This will 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. To protect your plant and your employees from the risks of a serious explosion, carefully consider OSHA and NFPA guidelines and be sure to review your state and local regulations for proper identification and management of combustible dust.
OSHA Standards
Implement and maintain OSHA’s set of standards regarding combustible dust. When you adhere to OSHA’s set of standards, you are creating a safe work environment, avoiding property and economic loss from an explosion, and avoiding regulatory fines.
NFPA Guidelines
Make sure you are meeting codes outlined by the NFPA (NationalFire Protection Agency) . The NFPA publishes a list of guidelines that will help you minimize injury or death from combustible dust. The following regulatory codes are related to the most combustible types of dust (e.g., sugar, wood , fine aluminum):
664, Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities
484, Standard for Combustible Metals
61, Standard for the Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities
Dust Testing
Dust testing may also be performed to assess the properties of your particulate and ensure proper filter selection and performance. This option may be ideal for new facilities and large applications . If you have an existing plant and many of your filter bags have failed prematurely with no consistent pattern, and there are no signs of workmanship error, it may be necessary to perform laboratory testing to find out if changes in the airstream could be compromising the bags.
Common Filter Media
Polyester
Polyester media is an economical option with excellent filtration properties and is widely available. This makes polyester the most common filter media used across many industry applications. Polyester has an operating temperature limit of 275°F and comes in both needled felt and woven medias. Both needled felt and woven polyester can be treated with several finishes and membranes to increase the efficiency and filter bag performance in varying operating conditions.
Aramid
Aramid, also known as Nomex, is used in applications with high temperatures and has excellent filtration and abrasion properties. The operating temperature limit for aramid is 400F which makes it a great choice for applications such as asphalt batch plants, furnaces, and dryers. Both needled felt and woven aramid can be treated with several finishes and membranes to increase the efficiency and filter bag performance in varying operating conditions.
Fiberglass
Fiberglass is often used in baghouses with temperatures ranging up to 500°F. Since fiberglass media is typically woven, the efficiency of a plain fiberglass media is lower than most felts. However there are several different membranes and finishes that can be added to fiberglass to increase filter efficiency and performance in harsh baghouse conditions. These finishes and membranes make fiberglass a versatile media for applications with high temperatures. You’ll see Fiberglass media used in industries such as energy, cement/ concrete/aggregates, and agriculture. Different membranes, coatings and finishes can be added to fiberglass media to increase performance in certain applications. This makes fiberglass a versatile media for applications with high temperatures.
P84
P84 media has a high temperature rating of up to 500°F. This filter media handles acids better than fiberglass and also results in less abrasion to the filters due to filter media flex.
Teflon (PTFE)
Teflon (PTFE) is one of the highest performing filter medias available for a wide range of applications and is also the most expensive. It bears well against chemical and acid resistance, high temperatures, and moist heat. Teflon membrane can also be applied as a treatment on other filter medias to further extend filter life and reduce system wear.
For more information on other media types in the dust collector industry (e.g. PPS, Acrylic, and Polypropylene) access our Fabric Characteristics Chart below.
Filter media fabrics can be made from both natural and synthetic fibers, although synthetic fibers are more common today. As we have seen in the previous section, different fibers provide each media with different performance characteristics. Most medias today are pre-shrunk and include some type of finish to improve media performance. Finishes for felt and woven bags can be different as we will see below.
Napping
This process is the scraping of the filter surface across metal points or burrs on a revolving cylinder. Napping raises the surface fibers, creating a “fuzz”, that provides a large number of sites for particle collection by interception and diffusion. Fabrics used for collecting sticky or oily dusts are sometimes napped so they can provide better collection and an easier cleaning process.
Coating
Coatings , or resin treating , involves immersing the filter material in a resin which can add certain characteristics to the filter media. For example, fiberglass threads can be coated with Teflon to prevent abrasion during bag cleaning and silicon graphite to aid in acid resistance.
Filter Bag Construction
The construction of your filter bags is dependent on your baghouse style, application, and other requirements specific to your facility. Below is a brief summary of how each type of baghouse works.
The three main baghouse styles available include:
Pulse jet
Reverse air
Shaker
In each baghouse style there are a variety of filter top and bottom configurations that can be used. Some top and bottom configurations are meant for a specific baghouse style, and other configurations can be used across multiple baghouse styles.
Pulse Jet
Pulse jet baghouses collect dust on the outside of the filter and clean filters from the inside out with a jet or pulse of clean air. Dirty air enters the baghouse and is forced to pass through the filter bags to exit the baghouse. As air pass through the bags, dust is filtered out and collects on the outside surface of the filter bags. This buildup of dust on the outside of the filters is known as a “filter cake.” The filter cake aids in filtration by trapping smaller particles as the dirty air passes through the filter cake and bag. Pulse jet baghouses offer a wide range of filter media, making it an excellent fit for most applications.
Reverse-Air or Shaker
In a baghouse using reverse air or shaker cleaning systems, the particulate is collected on the inside surface of the bag. The dust-laden gas enters the dirty side (inlet) of the collector and flows up through the bag. The particulate is filtered by the dustcake and the fabric, and clean air exits through the outside of the bag. Shaker and reverse air bag top and bottom designs vary by cleaning system and original equipment manufacturer.
Reverse air and shaker style baghouse both collect dust on the inside of the filter bag. Reverse air baghouses reverse the flow of air through the baghouse in order to clean the filter bags while shaker style baghouses clean the filter bags by moving them back and forth in a shaking motion. The buildup of a filter cake is important with these style collectors as it greatly aids in filter efficiency.
Both pulse jet and reverse air/shaker style baghouse come in a number of different bag constructions and understanding the requirements of your specific baghouse is important to ensure proper filter bag fit.
Air-to-Cloth Ratio
Dust collector air-to-cloth ratio is a critical measure to ensure your collector is performing efficiently.
Air-to-cloth ratio, also known as air to media ratio, is a measurement of the number of cubic feet per minute of air passing through one square foot of filter media.
Generally, a lower air-to-cloth ratio, the more effective your system is at removing dust from the work environment. When determining an appropriate air-to-cloth ratio, there are several factors to consider, including application, type of dust, moisture levels, inlet loading, etc. If the air-to-cloth ratio is higher than recommended, some common issues can arise, including increased differential pressure, frequent filter changeouts, and varying or reduced suction at pickup points. These issues are a result of not having enough filter media to handle the air flow and dust load effectively. As the dust cake builds on the filters, the airflow is restricted and slows, resulting in a decrease in air velocity and suction. From there it becomes a domino effect: air quality decreases, filters clog quicker requiring more changeouts, pulse valves see increased wear, and facility production may be impacted.
Why is the right Air-to-Cloth ratio important?
Ensures dust collector is running efficiently
Minimizes operating costs
Maximizes filter life
To meet air quality goals and requirements
What are the negative effects of an improper Air-to-Cloth ratio?
Increases maintenance which can impact production
Reduced air velocity resulting in poor ventilation at pickup points
Download the chart below for a summary of recommended Air-to-Cloth ratio for a variety of industrial applications.
Dust Collector Filter Bags Additional Resources
Filter Bag Media Quiz
Finding the right filter bag can be overwhelming, confusing and time consuming. There are so many options and it’s hard to know which will work best for your application. Or if there is a better option out there that will get you better performance.
To get you to the right solution, take this interactive filter media quiz. You’ll immediately receive:
Recommendations on the best filter media options for your unique application.
Filter media characteristics chart with media specs and pricing.
No obligation price quote for your filter media within 24 hours.
Selecting the right dust collector filter bags will keep your employees and your operation safe and at peak performance. We hope this information is a helpful resource for you. For tips and troubleshooting guides, check out our article on dust collector maintenance.
If you have specific questions about your application and filtration needs, call today at 888-221-0312 or email us at [email protected]One of our dust collection specialists can assist you with your dust control challenges. If you have an upcoming dust collection project and need assistance, read Dust Collector Purchasing Guide or contact one of our equipment specialists at the number above.
When calculating the life expectancy of your filters, there are multiple environmental factors that come in to play. Filters can last anywhere from a few weeks up to 5 years or more, but it really varies. The top factors that can influence filter life are:
Standard dust collection systems are designed for dry dust environments. If you have over 20 percent of moisture or oils in your process (e.g., working with fertilizers or concrete) you may need to consider a different type of filtration system. If you continue to operate with uncontrolled moisture, the physical properties of your dust may change due to the increase in water content. Certain types of dust can then become sticky or heavy which would cause your dust cake to build quickly, affect the ability of dust to fall off during cleaning and thereby creating a scenario where your filter bags fail prematurely. An excess of moisture can also cause excessive dust build-up in your duct work, rotary valve, and inside the dust collector’s walls. Common industries that deal with moisture are:
Industries with Moisture
Chemicals
Pharmaceuticals
Cement
Abrasive Dust
When considering how abrasive your dust can be, consider the hardness of the material being filtered along with the shape. If material is abrasive, a filter bag media with the ability to resist the additional wear and tear is generally recommended. Different types of filter media more resistant to abrasive dust are:
The velocity of your airflow can also make your dust more abrasive. Highly abrasive dust may require your housing to be fabricated in stainless steel, titanium or other costly materials that are able to withstand long term wear.
Filter Bag Fit & Installation
Filter Bag Fit
To help give your filter bags better life expectancy, make certain to have the proper bag to cage fit. Filter bags with the correct flex allows the precise amount of momentum to happen when the filters hit the cage. Filter bags with insufficient flex are too rigid and can prevent dust build-up from properly falling off during the cleaning process. The general recommendation is to have between 1/4″ to no more than 3/8″ pinch on your filter bag on each side of the cage. Filter bag media with sensitive bag to cage fit are:
Sensitive Bag to Cage Fit
Fiberglass
PPS
If you have filter bags with the following medias, also consider oversizing your filters due shrinkage that can occur in temperatures above 450 Degrees F.
Proper installation of filter bags allows for optimal dust handling and cleaning efficiency. When it comes to filter bag installation, common errors to watch out for are:
Top Load –The groove between the double beaded snap band should be set into the cell plate. For a video tutorial on the proper way to install this type of filter bag, visit this guide here.
Bottom Load – Raw top bags should be folded over the cage with enough material to allow for proper and tight clamp placement.
Undersized Dust Collector for CFM
A couple of the biggest problems we see people run into with an inappropriately sized dust collector are:
Consistently clogged filters
Reduced filter life
Higher maintenance costs
To avoid the dangers of an undersized dust collector, consider both CFM and Air to Cloth Ratio. For example, if you have an air to cloth ratio that is too high, the dust you are trying to collect embeds into the filters too fast for your system to efficiently pulse. You end up with rapid build-up of dust, which ends up clogging your filters and making your dust collector work even harder than it should be.
Conclusion
Prevention is the best method for avoiding filter bags failing prematurely and total dust management. Achieving longer filter bag life means the design of your dust collection system should be correct for your specific application from the very beginning.
At U.S. Air Filtration our specialists are available to help with the design of your dust collection system. Or if your filter bags fail continuously, we can help guide you to the right solutions. For assistance now, contact us at 888-221-0312 or email [email protected].
If your plant is operating from ambient to 275 degrees Fahrenheit, there are a few low temp filter media bag options you can choose to use in your dust collection system. To guide you to the right one, we’ve gathered information on the three commonly used medias in low temperature dust collection applications. The following filter medias are generally for dry dust applications with very little moisture and no issue heats or acids.
Polyester
Polyester is one of the most economical low temp filter bag medias used in the dust collection industry because of its reliable performance in a broad range of applications and availability. This media is used in industries including food manufacturing, woodworking, metalworking, building products, and energy. Polyester is one option if you are continuously operating between ambient – 275 degrees Fahrenheit, and have less than 10% moisture.
Polyester Filter Bag Media
Characteristic
Rating
Relative Cost
$
Max Continuous Operating Temperature
275 Degrees F.
Abrasion
Excellent
Energy Absorption
Excellent
Filtration Properties
Excellent
Moist Heat
Poor
Alkaline
Fair
Mineral Acids
Fair
Oxygen (15%+)
Excellent
Pros
Cons
Low cost and widely available filter media.
Does not perform well with moist heat.
Applications
Food Manufacturing
Woodworking
Metalworking
Polypropylene
Polypropylene is another relatively low-cost, low temp filter bag media. The big difference between polyester and polypropylene is that polypropylene can withstand some moisture. If your continuous operating temperatures are between ambient – 170 degrees Fahrenheit, and you have more than 10% moisture in your application, then Polypropylene could be the right fit for your baghouse.
Polypropylene Filter Bag Media
Characteristic
Rating
Relative Cost
$
Max Continuous Operating Temperature
170 Degrees F.
Abrasion
Excellent
Energy Absorption
Good
Filtration Properties
Good
Moist Heat
Excellent
Alkaline
Excellent
Mineral Acids
Excellent
Oxygen (15%+)
Excellent
Acrylic
Another option for applications with more than 10% moisture is Acrylic. This is similar to polypropylene but more expensive. Acrylic can handle moisture better than polyester and has a higher temperature rating. If you need to run between 200-265 degrees Fahrenheit, but you have moisture, you could use acrylic.
Acrylic Filter Bag Media
Characteristic
Rating
Relative Cost
$$
Max Continuous Operating Temperature
265 Degrees F.
Abrasion
Good
Energy Absorption
Good
Filtration Properties
Good
Moist Heat
Excellent
Alkaline
Fair
Mineral Acids
Good
Oxygen (15%+)
Excellent
Assistance with Low Temp Filter Bag Media
If you have a unique application we can help get some answers to your questions. Reach a dedicated account manager at 888-221-0312 or email [email protected]
Are you looking for high temperature media options? Then check out our guide here.
Shaker baghouses collect dust similar to reverse air baghouses. Dust collects on the inside surface of the shaker filter bags, and then clean air exits through the top of the bag. The main difference is how the bags cleaned.
How to Clean Shaker Filter Bags
Shaker baghouses are engineered so that filters are hung and tensioned from the top of the unit, and at the bottom they are attached to a tube sheet. Mechanically shaking the filter bags is what cleans them. Shaker baghouses only clean while the system is off-line. Shaker baghouse operation is simple and can be seen in applications where no compressed air is available.
Construction of Shaker Filter Bags
Fabric filter bags used in shaker baghouses are typically constructed with woven or light weight media options like polyester sateen, shaker felt, beane knit, and more. Treatments are dependent on a plant’s application and dust characteristics. The most common top and bottom configurations for shaker baghouses are below.
Most Common Top & Bottom Construction for a Shaker Baghouse
Top Load Baghouse: Grommet Top, Loop Top, Strap Top Bottom Load Baghouse: Corded Cuff Bottom, Double Beaded Snap Band
If you would like to get a free media recommendation, check out our filter bag media quiz here. There is also a fabric characteristics sheet that you can download below. It takes a closer look at the most common filter bag medias used in the dust collection industry.
Looking to start with the basics? Watch this “Guide to Filter Media” video to learn more about the most common medias used in the industrial dust collection industry.
Are ready to get a set of filters? Check out our online product catalog below. You can also request a quote within 24 hours, call at 888-221-0132, or simply email [email protected]
Filter bag configurations can vary from one dust collector to another. Baghouse filter top and bottom configurations will be dependent on the type of baghouse dust collector you have. The most common types of baghouses are pulse-jet and plenum pulse, reverse air, and shaker.
Pulse-Jet and Plenum Pulse Baghouse
Pulse-jet and Plenum Pulse baghouses collect dust on the outside of the filter. Dust-laden gas floods the dust collector, and clean air exits through the inside of the bag while dust particles collect on the outside filter surface. A pulse-jet is one of the most common styles of baghouses will see across a variety of industries and applications. The most common types of filter top and bottom configurations in this style of baghouse are:
Top Load Baghouse Filter: Double Beaded Snap Band Top, Disc Bottom Bottom Load Baghouse Filter: Raw Top, Disc Bottom
Reverse Air Baghouse
In reverse air baghouses dust will collect on the inside surface of the filter. Air enters the dirty side (inlet) of the baghouse and flows upwards through the bag. The bag filters and collects the dust on the inside, then clean air exits through the top of the bag. Reverse air baghouses are typically seen in large air handling applications like energy.
Top Configuration: Compression Band with Cap & Hook Bottom Configuration: Compression Band, Corded, Double Beaded Snap Band
Shaker Baghouse
The way shaker baghouses collect dust is similar to reverse air baghouses. Dust is collected on the inside of surface of the filter. Dust particulate is filtered and collected on the inside of the filter, then clean air exits through the top of the bag. The difference in this system is in how the bags are cleaned. Filter bags are hung and tensioned from the top of the unit, and at the bottom they are attached to a tube sheet. As the name suggests, you clean the bags by mechanically shaking them. Shaker baghouses are generally simple, and can be seen in applications where there is no compressed air available.
Top Configuration: Grommet Top, Loop Top, Strap Top Bottom Configuration: Corded Cuff Bottom, Double Beaded Snap Band
Filter bag construction and dimensions vary between industries, applications, dust collector types and manufacturers. Here are some of the filter bag top and bottom configurations you may come across.
Are you ready to find your filter? If you are looking for a quote, click on the link below to submit your information. We’ll get a quote back to you within 24 hours.
Do you want to get twice the life out of your filter bags and reduce costly change-outs?
What if your dust collection system captured more dust?
Would you like to get 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.
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.
Adding PTFE to a Filter Bag
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.
How PTFE Membrane Works
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.
Benefits of PTFE Membrane
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.
Additional Advantages of PTFE Membrane
Another advantage of PTFE membrane bags is that they clean easier because of their slick surface. This means less bag pulsing. Which also 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. It provides 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.
Pulse-jet filter bags are used to remove dust particulate and contaminants from the air in warehouses, plants, factories, foundries, and more. Pulse-jet is one of the most common styles of baghouses you will see across a variety of industries and applications. With this style of baghouse, dust collects on the outside of the filter as clean air exits through the inside of the bag.
How Pulse-Jet Filter Bags are Cleaned
To clean pulse-jet baghouse filters, a blast of compressed air is injected through a blowpipe over each row of bags via a venturi. In a pulse-jet baghouse one row of bags can be cleaned while the remaining rows continue to collect dust particulate. This is known as on-line cleaning.
Construction of Pulse-Jet Filter Bags
Pulse-Jet baghouses are engineered to hold either bottom or top load filter bags and cages. Fabric filter bags used in pulse-jet and plenum pulse baghouses come in a variety of medias and treatments. The type of filter media and treatment that’s best will be dependent on a plant’s application and dust characteristics. To get a free filter recommendation, check out our filter bag media quiz here. You can also download our fabric characteristics sheet to get a closer look at the most common filter bag medias used in the dust collection industry.
Most Common Top & Bottom Construction for a Pulse-Jet Baghouse
Top Load Baghouse: Double Beaded Snap Band Top, Disc Bottom Bottom Load Baghouse: Raw Top, Disc Bottom
If you are ready to get a set of filters you can check out our online product catalog, request a quote within 24 hours, call at 888-221-0132, or simply email [email protected]
Is your application operating at a high temperature over 275 degrees Fahrenheit? If so, there are many dust collector filter bag options to choose from. Outlined below is your guide to high temperature dust collector filter bags. We’ve broken down characteristics and properties of the top five most common filter media options.
Aramid filter media is commonly used in asphalt plants and rock plants where there is high heat but are no chemical issues. You can typically distinguish an Aramid filter bag by its color. It is usually yellow and can have brown speckles which is caused by singeing.
Aramid (Nomex) Filter Bag Media
Characteristics
Rating
Relative Cost
$$$
Max Continuous Operating Temperature
400 Degrees F.
Abrasion
Good
Energy Absorpsion
Good
Filtration Properties
Excellent
Moist Heat
Good
Alkaline
Good
Mineral Acids
Fair
Oxygen (15%+)
Excellent
Pros
Cons
Provides great resistance to highly abrasive dust applications.
Mineral oxides can cause deterioration or partial decomposition over time.
Applications
Cement
Cupolas
High Temp Dryers
Fiberglass
Fiberglass filter media has been the leading industry standard for dust collection applications where high temperatures above 500 degrees Fahrenheit are present. Fiberglass filter media is composed of a dense structure of fine fiberglass filaments. You’ll see Fiberglass used in industries such as energy, chemicals, and minerals.
It is cost efficient when compared to similar high heat filter medias and is the most common choice for situations where heat is above 400 degrees Fahrenheit. Fiberglass can have a lot of variation in color, and depending on the application, can have different types of treatment (i.e. silicon, carbon).
Fiberglass Filter Bag Media
Characteristic
Rating
Relative Cost
$$$$
Max Continuous Operating Temperature
500 Degrees F.
Abrasion
Fair
Energy Absorption
Fair
Filtration Properties
Fair
Moist Heat
Excellent
Alkaline
Fair
Mineral Acids
Poor
Oxygen (15%+)
Excellent
Pros
Cons
Performs excellent in high temperature applications up to 500 Degrees Fahrenheit.
Sensitive bag to cage fit. Has poor flex abrasion qualities and would require a cage with 20 vertical wires for minimum support.
P84 (polymide) dust collector filter media is used in operating conditions of a maximum 500 degrees Fahrenheit. P84 performs well under dry high heat temperatures and can even withstand some elevated levels of moisture. P84 has a slightly better resistance to acids than PPS. This is a proprietary fabric that is imported from Germany to all manufacturers. For these reasons, P84 is one of the more expensive filter medias used in pulse jet baghouse dust collectors. P84 filter can be seen in used in waste to energy, power, lime kilns, smelting, glass and ceramic, and cement applications.
P84 Filter Bag Media
Characteristic
Rating
Relative Cost
$$$$$$
Max Continuous Operating Temperature
500 Degrees F.
Abrasion
Fair
Energy Absorption
Good
Filtration Properties
Excellent
Moist Heat
Good
Alkaline
Fair
Mineral Acids
Good
Oxygen (15%+)
Excellent
Pros
Cons
Excellent stability in applications with high dry heat temperatures, mineral acids, and alkaline.
Must oversize bag for shrinkage that can occur in temperatures above 450 Degrees F.
Teflon delivers superior dust cake release and high filtration efficiency in high heat applications that demand high resistance to acids and moist heat.
Must oversize bag for shrinkage that can occur in temperatures above 450 Degrees F.
Applications
Steel Foundries
Coal Fired Power Plants
Carbon Black Plants
Do you need more information after reading this guide to high temperature dust collector filter bags? If you need help, one of our account managers can help find the right fit for you. Contact us at 888-221-0312, email [email protected] or request a consultation here.
Today we are exploring the differences between Polyester vs Polypropylene filter bags. Polyester is one of the most widely used filter bag medias in the dust collection industry because of its reliable performance in a broad range of applications, relatively low cost, and availability. Many industries including food manufacturing, woodworking, metalworking, building products, and energy have used polyester filter bags to achieve peak dust collection performance. If you continuously operate between temperatures of ambient – 275 degrees Fahrenheit and you have less than 10% moisture in your application, then polyester may be the right fit for your application.
Polypropylene is also another relatively low-cost filter bag media. The main difference between polyester and polypropylene is how well polypropylene can withstand moisture. If your continuous operating temperatures are between ambient – 170 degrees Fahrenheit, and you have more than 10% moisture in your application, then Polypropylene could be the right fit for your baghouse.
To find out which media is the right fit for your specific application you can take our filter bag media quiz that will provide an instant recommendation based on your application.
Polyester vs Polypropylene Filter Bag Treatments and Finishes
Depending on your specific needs an additional filter bag treatment or finish could be lengthen the life of your filter bags.
Polyester Filter Bag Finishes & Treatments
PTFE Membrane – Can double the life of a standard filter bag, reduce wear and tear, reduce maintenance costs, reduce energy costs, and more.
Hydro-oleophobic coating – Aids in filtration and adds resistance to water and oils.
Acrylic – Can help improve cake release and filtration efficiency in certain applications.
Anti-static – Helps ground the filter bag.
Singed – Removes straggly fibers which provides a uniform surface area and improved dust cake release.
Glazed – Improved mechanical stability since fibers are fused to the body of the filter medium.
Calendered – Flattens and smooths the filter medium. This can increase surface life, dimensional stability, and provides a more uniform fabric surface.
If you’re looking for additional filter bag resources such as construction, air-to-cloth ratio or dust properties you can download our filter bag eBook below. You can also access our filter bag characteristics chart below.
Ready to find your filter and need a quote within 24 hours? Simply follow the link below and we’ll help with your filter bag request.
