About Andy Biancotti

Andy has been working in the maintenance field for over a decade, continuing to learn the secrets of preventive maintenance in the ever growing field of dust collection. Editor and marketing manager.

Entries by Andy Biancotti

NEW FREE WEBINAR: Boosting ROI with Smart Sensors & Industrial IoT

If you work in operations, engineering, facilities management, plant management, EHS, or purchasing, you are familiar with the constant pressure to keep production running smoothly while controlling costs. Unplanned downtime, wasted energy, and manual inspections drain resources and put safety at risk. This webinar will show you how IoT sensors and predictive monitoring can change that equation, helping you cut costs, prevent failures before they happen, and clearly demonstrate ROI. It’s a must-attend webinar!

What to Expect from the Webinar

This webinar will show you how integrating IoT sensors into your dust collection system can slash maintenance costs, extend equipment life, and eliminate manual guesswork. Our expert speakers will guide you through the power of predictive monitoring, with practical examples from real-world facilities.

Program

🔹 Welcome & Overview
🔹 What is IoT, and how does it apply to your facility?
Webinar Special Guest – Eric Schummer, CEO of Senzary

🔹 IoT Technology Explained In Depth – Interview with Eric Schummer
- ➡️ What are the building blocks of an IoT platform?
- ➡️ How data gets collected, transmitted, and visualized? What are the basic steps for implementing IoT tools?
- ➡️ What are some IoT sensor types relevant to dust collection and other industrial equipment?
- ➡️ How do IoT platforms interface with existing enterprise systems?
- ➡️ Review ROI cases for common facility types, and case studies.
🔹 How Can I Implement This Technology In My Facility?
🔹 Conclusion & Q&A

Why Should You Attend?

✅ Gain Practical Knowledge: You’ll learn exactly how sensors like particulate, pressure, airflow, and rotary monitoring devices can be integrated into your dust collection system to reduce unplanned downtime and avoid costly failures.
✅ Optimize Maintenance and Energy Use: Traditional “fix it when it breaks” or over-cleaning approaches waste time and money. This webinar will show you how predictive maintenance saves energy, avoids over-cleaning, and extends the life of your filters and fans.
✅ See the ROI Clearly: We’ll walk through real cost comparisons, labor vs. sensors, unplanned outages vs. predictive monitoring, so you can see how facilities are saving thousands each year.
✅ Learn from Industry Experts: With Baghouse.com and Senzary teaming up, you’ll hear directly from leaders who understand dust collection challenges and how IoT can solve them.

How to Connect

Attending the webinar is easy! Simply register using the link below. Once registered, you’ll get a confirmation email with all the details to log in. Don’t miss it:

📅 Date: Wednesday, October 8th, 2025

⏰ Time: 1:00 PM (EST)

📍 Platform: Zoom

🔗 Registration Link: Click here.

The session will be interactive, with a live Q&A at the end, so be sure to come prepared with any questions you may have about dust collection systems and projects.

Questions & Answers Section

During this section, our experts answered some of the live questions our attendees sent.

✅ What types of sensors work best for dust collection?
✅ Where should sensors be installed in a baghouse?
✅ How does predictive monitoring actually reduce downtime?
✅ Can IoT technology be retrofitted into older systems?
✅ How does sensor data integrate with plant operations?
✅ What is the cost-benefit of sensors vs. manual inspections?
✅ How can IoT improve safety and compliance with EHS standards?

Sign up now and take the first step toward smarter, safer, and more cost-effective dust collection.

We can’t wait to see you there!

September 23, 2025/by Andy Biancotti

Baghouse.com News

Federal Agency Says Fatal Fremont Explosion Was Preventable

A federal agency says the deadly July explosion at a Fremont, Nebraska, industrial plant was “a terrible tragedy” that never should have happened.

On Wednesday, the U.S. Chemical Safety and Hazard Investigation Board (CSB) released new information about the July 29 blast and fire at Horizon Biofuels. The accident killed worker Dylan Danielson, 32, and his two daughters, ages 8 and 12.

CSB Chairperson Steve Owens called it “a completely avoidable hazard,” saying early evidence shows it was likely a combustible wood-dust explosion—a well-known risk in wood-processing facilities.

Investigation Still Limited

The CSB investigates serious chemical accidents but does not set regulations. Its work at Horizon has been delayed because the site is too dangerous to enter.

“The facility remains unsafe, with a risk of collapse,” the agency said. Officials have advised keeping a safe distance until the building is stabilized.

What Happened That Day

Shortly before noon, witnesses saw a sudden release of dust or smoke from a tower. Flames appeared, followed by a powerful blast that tore through the structure.

Danielson was working inside. He survived the initial explosion but was trapped. He managed to speak by phone with the plant manager, who was off-site, and with his wife.

Neighbors heard him calling for help and tried to reach him, but unsafe conditions forced them back. Emergency crews arrived, evacuated the area, and could not enter until the next day, when they recovered the three victims.

Dust-Control System At the Plant

The CSB said its investigation will focus on the operations and conditions at the Horizon Biofuels facility, as well as dust-control systems, industry guidance for safe dust operation and regulatory oversight. A combustible dust explosion can occur when certain conditions align at a facility, including dust accumulation, dispersion and ignition within a confined space, potentially triggering a powerful secondary explosion, like the one that occurred at the Horizon Biofuels facility.

The CSB has examined many such disasters. A 2006 study reviewed 281 dust explosions, causing 119 deaths and 718 injuries across industries.

Past Safety Issues

Records from the Occupational Safety and Health Administration (OSHA) show Horizon Biofuels was cited in 2012 for four serious violations and fined $6,000.

The Nebraska State Fire Marshal’s Office, leading the state investigation, also called the incident an “accidental dust explosion” in its preliminary report.

You Can Prevent It

Combustible dust incidents are preventable with proper design, inspection, and maintenance. Baghouse.com helps industrial facilities diagnose hazards, install combustible dust prevention equipment, and identify measures to prevent explosions… protecting both your workers and equipment.

September 19, 2025/by Andy Biancotti

Dust Collector Maintenance, Operation & Optimization, Dust Collector Troubleshooting

How to Protect Your Filter Bags During Startup (And Why It Really Matters)

New bags take in, that’s why it’s essential to protect them during startup

Starting up a new set of filter bags in your baghouse might seem like a routine step, but it’s actually one of the most critical moments in determining how long those bags will last. Many operators don’t realize that what happens in the first 24 to 48 hours can make or break the long-term performance of the filters.

Here’s the issue: brand-new filter bags are clean and porous. That means air and dust can move through them very easily. If you send the full process flow through them right away, high-velocity dust particles can slam into the bare filter media, embedding deep into the fibers. This leads to premature blinding, where airflow is restricted, the pressure drop rises, and bag life is drastically shortened.

To understand this better, let’s talk numbers. A brand-new bag may have a permeability of 25 to 60 CFM/ft². That’s how easily air flows through it. A seasoned bag with a healthy dust cake may be down to 5 to 10 CFM/ft². A bag that’s blinded? Less than 2. That’s a massive drop. The takeaway: new bags take in a lot more air and dust—if you’re not careful. That’s why it’s essential to protect them during startup.

What’s The Right Way to Start Up a New Baghouse Compartment?

The short version: precoat, restrict, and go easy on the cleaning.

Precoat powder comes in 50-lb bags.

Start by applying a precoat—a compatible fine powder like limestone dust or commercial precoat products. This coats the clean bags with a thin layer of dust that acts like a buffer. It protects the fabric from direct contact with abrasive or sticky dust, and helps absorb moisture or acids that might form when the system is heating up.

Think of this step like preparing a fishing net: imagine you’re about to toss a net into a lake full of small fish. If you send it in empty, the fish will slip right through the holes. But if you first catch a few big fish and they block the holes, they form a barrier—so that even the smaller fish can’t pass through anymore. That’s exactly what a precoat does. The coarse particles land first, fill in the open pores of the fabric, and create a protective layer. When finer, stickier particles arrive later with the process dust, they’re less likely to get embedded in the media because the “big fish” have already blocked their path.

Next, limit the airflow. For reverse gas or shaker baghouses, you can do this by closing inlet or outlet dampers down to about 20% or by slowing down the fan. For pulse jet systems, you can also reduce fan speed or limit compressed air. Remember, the goal is to keep flow near the design air-to-cloth ratio, not wide open. Just enough to ventilate the system.

Finally, reduce or disable the cleaning cycle for the first 8 to 12 hours—or even longer if possible. That dust cake needs time to build. In reverse air systems, stop the reverse gas or shaking. In pulse jets, lower the compressed air pressure going to the pulse header. If you start blasting the bags too early, you’ll strip away the precoat and delay cake formation.

A Few Extra Tips

Turn on the hopper heaters before startup to preheat the compartments to avoid condensation

🔹 If your baghouse has hopper heaters, use them before startup to preheat the compartments. This helps you avoid hitting the dew point and forming condensation.
🔹 Be especially cautious with high-moisture or acidic processes—the precoat is even more important here.
🔹 Always document how the startup was handled. If you notice premature failures later on, it’s helpful to trace things back to how the bags were introduced into service.

The Payoff of a Proper Startup Routine

Taking care of your bags during startup is one of the smartest things you can do to extend their life and avoid expensive issues down the road. A little extra attention now can save you thousands of dollars in early bag replacements, lost production time, and increased energy costs.

Don’t let brand-new filters fail early. Precoat them, limit the airflow and give the filters time to settle in.

Need help with your startup procedure or choosing the right precoat material? Reach out—we’re always here to help!

August 20, 2025/by Andy Biancotti

News

“Our Track Record Says It All” —Interview With David Dal Santo

Interview With David Dal Santo, our Director of Operations

Director of Operations at Baghouse.com, David DalSanto

With decades of experience finding solutions to our customers’ often complex dust collection needs, Baghouse.com has acquired extensive experience overcoming obstacles foreseen and unforeseen.

Read what our Director of Operations, David DalSanto, who has been with the company since its inception nearly four decades ago, has to say about some of the most exceptional projects Baghouse.com has completed.

— "What former projects of Baghouse.com are you the most proud of having been a part of?"

David – “John Deere – Central Foundry – Waterloo, IA – A violent explosion in the furnace did extensive damage to the structure, including the housing, tubesheet and roof structures. We brought in a very large crew and worked around the clock, “improvising and adapting” as the repairs progressed. We sourced many of the needed repair parts, but also fabricated the main parts and structures we needed on site. We had the entire Baghouse system back on line in only nine days.”

— "What were some of the most challenging projects that you have tackled?"

Original condition unit with envelope filters and shaker mechanism

David – “Goodyear Tire & Rubber Co. – Topeka, KS – Old ‘Envelope” style Dust Collectors by W.W. Sly & Pangborn were a “maintenance headache” for the plant. We did multiple Pulse-Jet conversions to the existing Dust Collectors. By removing the inner workings and roof structures, we made room to install modern Clean Air Plenums. We modified the ductwork and installed High Efficiency Cylindrical filter bags and cages to take advantage of the Pulse-Jet cleaning system.”

— "What were the specific problems that you had to face?"

David – “Most units were in the center of a large building, an area that could not be serviced by conventional cranes.”

Follow Up Question — "How did you overcome those problems?"

As we couldnt use traditonal cranes, the collectors had to be installed using Helicopter lifts

David – “New equipment had to be installed using Helicopter lifts. As a licensed pilot/aircraft owner myself, I know well just how dangerous these aerial maneuvers are, and the great skill, and expertise that are needed to execute these operations safely. Despite all of the challenges we faced to get this Baghouse back up and running, downtime for each conversion was only 3 to 4 days each. Again remarkable considering the circumstances.”

— "What do you feel are some of the greatest dangers you know of regarding safety on the job site, and how do you handle them?"

David – “Several dangers present themselves regularly in our line of work. #1 – Harmful gasses leaking into the work area. #2 – Unsafe structures/hazard of falling objects. #3 – Fire hazards during welding/cutting operations. We work with our foremen, safety personnel and plant representatives to identify all of these dangers specific to each job before we begin. We then brief our people accordingly, enabling them to keep a close watch for these hazards and avoid them.”

Identifying all the dangers specific to each job before we begin is one of the most important routines of our team

“The greatest danger we encounter however is; unsafe materials hoisting practices by plant or outside contractor personnel. Because of my personal experience as a Structural IronWorker and Heavy Machinery Mover, I know full well the immense danger to life that this process poses. I have seen first hand the tragedy that results when people who are not qualified to carry out this task, or simply have a disregard for lifting/hoisting safety measures.”

“As such, we prefer to do our own lifting/hoisting. All of which is directly led by a duly trained foreman, with extensive training and experience conducting these lifts safely and properly.”

— "What are some of the biggest mistakes you notice other companies make when servicing a Dust Collector?"

Some of the biggest mistakes we notice other companies make when servicing a Dust Collector is to tension the structural filter bags incorrectly.

David – “#1 – Incorrect handling/installation practices on specialty filters such as Fiberglass and PTFE Membrane media. #2. Incorrect tensioning procedures on structural filter bags. #3 – Incorrect start up settings/procedures and Incorrect operations procedures.”

“In many cases we are called to fix another company’s mistakes. We often find that a rushed operation, or an overall lack of technical expertise & attention to detail on account of the contractor has caused many problems. These shortcomings later on, needed to be corrected by Baghouse.com during subsequent maintenance visits.”

— "What would you say makes Baghouse.com different from your competitors?"

David – “We care about our customers and we do everything possible to help get their operation running as efficiently as possible or get them back up and running quickly after problems do arise.”

“We have a long history of successfully responding to emergency breakdown situations in which we were able to get the customer back into operation quickly with minimal downtime and lost productivity. This is no easy task, and you will be hard-pressed to find another company capable of duplicating our successes in this area.”

“We also have initiated many Regular Maintenance Programs, Environmental Emissions & Energy Audits, that to this day continue saving our customers money through avoiding violations and unplanned downtime, and increasing efficiency.”

“At the end of the day, we don’t just fix problems – we fix them fast, efficiently, and with a little bit of creativity…It’s not always glamorous, but hey, someone has to get the Baghouse back up and running!

We’ve seen it all, done it all, and if we don’t know the answer right away, we’ll find it. We are always ready for the next challenge.”

July 29, 2025/by Andy Biancotti

Dust Collection 101, Dust Collector Maintenance, Operation & Optimization

Precoating: A Simple Step To Boost Performance In Filters

Why Consume Expensive Downtime To Precoat Your Dust Collector’s New Filters?

One good reason: Dust and fine particles 0.5 microns or smaller can leak right through a new bag or cartridge filter’s pores, working their way deep into the media to the point of clogging the filter and slowing or stopping airflow through your collector.

So if your dust particles are smaller than 10 microns, taking the time to precoat your new filters’ surface with a dry precoating material is the smart thing to do.

Precoat powder is a fine, inert material—typically made of substances like cellulose or diatomaceous earth—used in dust collection systems to protect and enhance filter performance. It is applied as an initial layer on new filter bags or cartridges before the system begins collecting process dust.

Common pre-coat materials include:

Expanded Perlite

Expanded Perlite: Absorbs sticky residues and hydrocarbons while providing a porous barrier.

Diatomaceous Earth

Diatomaceous Earth: Known for its fine particle capture and moisture-absorbing properties.

Calcium Carbonate

Calcium Carbonate: Neutralizes acidic contaminants and provides an effective protective layer.

Benefit: Longer Filter Life

When your dust stream contains a significant percentage of submicron particles, precoating can reduce or prevent the premature failure of your new filter media. Precoating material will build up an initial dust cake on the filter, preventing dust particles from flowing into and clogging the media.

Typical service life for bag filters without precoating is 1 to 3 years and for cartridge filters is 3 to 12 months. Depending on the application, precoating can extend the filter’s life substantially providing enormous cost savings in replacement filters and changeout labor.

Precoating material will build up an initial dust cake on the filter, preventing dust particles from flowing into and clogging the media.

Precoating new filters provides other benefits, too. By keeping particles on the filter surface, precoating improves the initial filtering efficiency at startup. Precoated filters are easier to clean and provide better dust cake release for applications with process air that contains moisture, hydrocarbons, or both. Precoating materials, which don’t burn, can be applied to filters made of fire-retardant media to help reduce explosion risks in spark-producing processes, such as milling.

So, as a review, the main benefits can be summed up as follows:

✅ Sets up consistent porous dust cakes throughout all the filters.

✅ Absorbs moisture and oils that can shorten bag life.

✅ Safe to handle, lightweight powder remains on the filter bags.

Pore Opening Size and Particle Size

Now that we have analyzed the benefits, there are two additional factors you should know when deciding to precoat your filters:

🔶 The pore openings in bag filter media are usually larger than in cartridge filter media, so precoating is required more commonly for bag filters than for cartridge filters. For example, the pore openings in a 16-ounce polyester bag filter are 19.675 microns, significantly larger than the 10.253-micron pore openings in a comparable 80-20 polyester blend (80 percent cellulose, 20 percent polyester) cartridge filter.

🔶 The smaller your dust particles are, the more important it is to consider precoating your filters. And depending on the kind of size analysis used for determining your dust’s size distribution, the particles may be smaller than you think.

The true filtering surface is not the bag itself, but the dust layer or filter cake. When adding a precoating material, you make sure that even the smallest particles are captured by the filter.

Instructions For Precoating Your Filters

The method for precoating new bag or cartridge filters is relatively simple and doesn’t require any special equipment. After installing the new filters in your dust collector, you simply run the collector fan at a low volume to draw precoating material into the collector and onto the filters. For a baghouse or large cartridge collector, this process typically takes 3 to 4 hours; for a small cartridge collector, it can take just 30 to 60 minutes.

The method for precoating new bag or cartridge filters is relatively simple and doesn’t require any special equipment.

Step by step

Whether you’re precoating bag or cartridge filters, the procedure is the same. After installing your new filters in your baghouse or cartridge collector, follow these steps:

For Collectors With A Full Set Of New Bags:

With the fan running, the cleaning mechanism off, and the process off, inject Baghouse.com precoat powder into the system.
With the cleaning mechanism remaining off, bring the process online.
Operate under normal conditions and allow differential pressure to reach 4” to 5” w.c.
Monitor differential pressure across the collector. It may be possible to reduce the frequency and/or duration of cleaning and maintain adequate differential pressure. This may extend filter bag life.

Some hoppers have an inlet above the discharge. Although many people are tempted to inject the precoat powder through this inlet, it is a very low location, there is not enough air volume to maintain the velocity needed to carry powder to the top section of the filter bags

For Bag Recovery And Spot Changing Online Cleaning Collectors (Pulse-Jet Only):

Turn off the fan and run the system through the cleaning cycle two or three times to purge the excess particulate. Turn off the cleaning system after purging the collector and leave it off through step 5.
With the process off, restart the fan and inject Baghouse.com precoat powder into the system.
With the cleaning mechanism remaining off, bring the process back online.
Operate under normal conditions and allow differential pressure to reach 4” to 5” w.c.
Turn the cleaning system on. Monitor differential pressure across the collector. It may be possible to reduce the frequency and/or duration of cleaning and maintain adequate differential pressure. For better cleaning on pulse-jet applications, stagger the row pulsing to prevent re-entrainment of particulate onto the bags.

Off-Line Cleaning Collectors (Reverse Air, Shaker, And Pulse-Jet)

Individually isolate the inlet and outlet of the compartments that will receive the injection and manually run through the cleaning cycle two or three time.

Turn off the cleaning mechanism in each compartment and leave it off until step 6.
The outlet of the compartment should be opened on negative systems. On positive systems, both the inlet and the outlet to the compartment should be opened.
Inject Baghouse.com precoat powder into your system.
With the cleaning mechanism still locked out, the isolated compartment should be returned to service. The pressure drop should be allowed to build up to the normal operating differential pressure before the cleaning mechanism is reactivated.
Turn the cleaning system on. Due to increased airflow and decreased differential pressure, it may be possible to reduce the frequency and/or duration of cleaning. This may extend filter bag life.

NOTE: DO NOT SHUT OFF THE COLLECTOR FAN FOR A MINIMUM OF 8 HOURS AFTER THE PRECOAT POWDER INJECTION!
The precoat powder may dislodge and fall into the collection hopper if the fan is shut off.

Calculating and Applying Precoat Powder

Precoat powder comes in 50-lb bags.

A good rule of thumb is to use one pound of pre-coat for every 20 square feet of baghouse filter media. Operate the system at 50% of the design airflow to the baghouse. This results in an inlet duct velocity of approximately 2000 FPM. Avoid dropping the velocity below this threshold.

The material should not be “dumped” into a system. Use a pre-coat feed rate of 1/3 pound per minute per 1000 CFM of reduced airflow. For instance, for a 25,000 CFM reduced airflow system, the feed rate would be 7.5 lbs./minute.

Calculations for Application

Bag Diameter (inches) x 3.1416 = Circumference

Circumference (inches) x length (inches) = Inches² Per Bag

Inches² / 144 = Feet² Per Bag

Feet² x Total Number of Bags = Total Feet²

Total Feet² x .042 lbs = Precoating agent (pounds) Required

Inspecting and Verifying Precoat Coverage

After applying the pre-coat, isolate each filter compartment and inspect the filter bags to confirm they’ve developed a uniform coating

After applying the pre-coat, isolate each filter compartment and inspect the filter bags to confirm they’ve developed a uniform coating—ideally about 1/16 inch thick. It’s also important to check the dust collector hopper to ensure there hasn’t been excessive pre-coat material dropout, which could indicate uneven distribution or overfeeding.

Once the inspection is complete and coverage is confirmed, gradually increase the airflow to the system’s design-rated volume. At this point, you can reactivate the dust discharge equipment, such as the airlock. However, hold off on restarting the filter bag cleaning system until the differential pressure across the bags reaches 3 to 4 inches. This delay allows the pre-coat to settle and form a stable dust cake on the filter media before the first pulse cleaning cycle begins.

Conditioning Feed Of Precoat Powder

After the initial injection, Baghouse.com precoat powder can be added on a continuing basis as a conditioning feed to improve overall long-term collection efficiency and absorb damaging moisture. This provides improved porosity of the dust cakes, resulting in better airflow while reducing bag blinding and depth penetration that can shorten filter bag life.

Although every case is site-specific, the following formula applies for conditioning feed:

Conditioning Feed = 10% of Precoat Powder Initial Control Layer Per Day

The extended life, improved efficiency, and energy savings when precoating your media filters is always a very cost effective solution.

Do you have any additional questions regarding the precoating powder use for your specific application?

July 15, 2025/by Andy Biancotti

Baghouse Design, Dust Collection 101

Our Free Baghouse Design Calculators Are Live!

We’re excited to announce something that’s been a long time coming—a full set of free online calculators designed to make dust collection system design and troubleshooting way easier.

If you’ve ever had to stop what you’re doing to run a quick air-to-cloth calculation, estimate how much precoating powder you need, or figure out what duct diameter to order… this is for you. These calculators were built for people like you: engineers, operators, maintenance personnel, and even purchasing staff… to quickly get answers without digging through spreadsheets or flipping through manuals.

Here’s what we’ve launched:

✧ Air-to-Cloth Ratio Calculator – See if your system is sized right or running outside the ideal range. Great for both design and troubleshooting.
✧ Interstitial Velocity Calculator – Quickly check if the air between the bags is flowing fast enough to keep dust suspended and prevent dropout.
✧ Can Velocity Calculator – Measure the vertical airflow between the baghouse housing and filters.
✧ Total Filter Cloth Area Calculator – Determine how much filter media your system needs to support your airflow volume efficiently.
✧ Leak Testing Powder Calculator – Get an accurate estimate of how much fluorescent leak test powder you’ll need for a given baghouse.
✧ Precoating Powder Calculator – Find out how much precoating agent to apply before startup to protect your filter bags from blinding.
✧ Air Velocity Calculator – Helps ensure you’re maintaining the right conveying velocity in your ductwork to avoid dust dropout or wear in your ducts.
✧ Duct Sizing Calculator – The goal is to select a duct size that allows for proper dust conveyance without excessive friction loss or particle dropout.

These tools are already proving useful in day-to-day work, from initial design to routine maintenance, even quoting and system retrofits. The goal is to take the guesswork out of some of the most common calculations we all deal with in the field.

Of course, these are reference tools, not one-size-fits-all answers. Real-world systems can be messy—airflow changes, system resistance fluctuates, dust loads vary, and what looks good on paper might not work in practice. That’s why we always recommend reaching out to an expert (like us at Baghouse.com) to review your results before making big decisions.

But if you need quick numbers, you’re in the right place.

Try the calculators out today and see how much time (and stress) they can save you.

At Baghouse.com, we believe that knowledge is power, especially when it comes to investing in equipment as critical (and expensive) as a dust collection system. That’s why we’re making these calculators available for free. Our goal is to help people make informed decisions by understanding the numbers behind the quotes they receive.

Whether you’re an engineer comparing different system designs, a plant manager reviewing proposals, or a purchasing agent trying to get the best value, these tools give you the ability to ask better questions and spot red flags. In an industry where it’s all too easy to get sold a one-size-fits-all system out of a catalog, we want to empower you to choose the solution that’s right for your application—one that performs reliably for years to come.

June 19, 2025/by Andy Biancotti

Baghouse Design, Cement and Construction Materials, Dust Collector Maintenance

Asphalt Production & Dust Collectors Design and Maintenance (Part 3)

As we have seen in the previous two articles, when you’re running a hot mix asphalt plant, your dust collector isn’t just another piece of equipment—it’s the beating heart of your dust control system. But for many plant operators and maintenance teams, baghouses are still a bit of a mystery. What makes them work well? Why do they suddenly clog up or burn through filters? And how can you keep yours running for years, not just months?

Why Asphalt Plants Need Dust Control

Regulations are only getting stricter. Hot mix plants must meet tight emissions limits for dust, for sulfur dioxide, and other volatile compounds.

Hot mix asphalt plants are regulated under both federal and local environmental laws, particularly for air emissions. These plants must use effective dust collection and pollution control systems to meet standards for:

♦️ Particulate Matter (PM): Baghouses (fabric filters) or scrubbers must capture fine dust generated in drying, mixing, and conveying.
♦️ Volatile Organic Compounds (VOCs) and Hydrocarbons: Released during asphalt heating and mixing. Controlled through burner tuning, proper operating temps, and vapor capture systems.
♦️ Sulfur Dioxide (SO₂), Nitrogen Oxides (NOx), and Carbon Monoxide (CO): Emissions from combustion systems, regulated especially when using fuel oil, coal, or RAP (Reclaimed Asphalt Pavement).
♦️ Opacity Limits: Visible emissions (smoke/dust) from the stack must remain below specific opacity percentages (often 20% or lower).

Design Requirements

🔹 Design: Since many asphalt plants are portable, dust collection systems must also be rugged and easy to transport. The compactness of the design and ease of maintenance are all key considerations.

🔹 Filter Media: Asphalt production involves high temperatures. The baghouse installed on the dryer end of the system must be able to handle continuous operating temperatures up to 375°F (190°C) — and sometimes even higher during spikes.

For this reason, aramid filter media (commonly known by the trade name Nomex®) is the go-to choice. It’s a heat-resistant material that performs well under the high-temperature, high-dust conditions of asphalt operations.

To improve performance in space-constrained systems, pleated filter elements made with aramid media are gaining popularity. These offer increased surface area in the same or smaller footprint, which helps overcome the limitations of older, compact baghouse designs. However, pleated filters come with some temperature limitations and should be used where appropriate.

If you choose membrane-coated bags to cut down emissions, be warned—hydrocarbon contamination from the mix or burner can blind those bags fast.

Knockout boxes or cyclones reduce dust loading on the bags and help stabilize pressure drop, which makes the whole system easier to maintain and run.

🔹 Dust Cake and Precleaners: A good cyclone can pull out 80–90% of large aggregate dust before it ever hits the bags. This helps build a healthy dust cake and cuts wear on the filters. We also sometimes install knockout boxes or cyclones when space or volume demands. These reduce dust loading on the bags and help stabilize pressure drop, which makes the whole system easier to maintain and run.

🔹 Fan Sizing and Air-to-Cloth Ratio: Too many asphalt plants are still running baghouses with poor air-to-cloth ratios—sometimes 5:1 or more—which leads to overloaded filters and early failure. Can velocity and fan performance need to be dialed in carefully to avoid high differential pressure (DP) and re-entrainment. We recommend staying between 3.5–4.5:1 for most applications.

🔹 Cleaning System: It’s almost always pulse-jet cleaning in the asphalt world. Most systems run at 60–70 psi, which is usually enough. Cranking it up to 90–100 psi often just shreds bags faster without actually solving the problem.

Your cleaning should be on-demand with a magnehelic or photohelic set to trigger between 3–5 inches W.C. Don’t space out cleaning pulses too far apart—if you wait too long between row cleanings, air takes the easiest path and some bags end up doing all the work.

Conveyor belts are used to move a large amount of material between different parts of the asphalt plant

🔹 Discharge System: Reusing the dust you collect (as we talked about in the previous articles) makes the whole operation more profitable. To handle the bulk material collected, you need one of the following options:

✧ Rotary Airlocks, especially for coarse or abrasive dust.
✧ Slide gates are cheap and simple, but they’re prone to leaking and jamming.
✧ Conveying Systems: Screw conveyors are standard, but some plants are now implementing conveyor belts or even pneumatic systems for faster, cleaner transfers.

Asphalt-Specific Challenges

One big challenge in asphalt baghouses is hydrocarbon vapors. These can migrate into the baghouse, coat the bags, and lead to blinding—especially if you’re using membrane filters. It’s a common issue when burners aren’t tuned properly or during heavy recycling (RAP) operations. Make sure your burner system is dialed in and your bags are suited for the environment.

Condensation is also a frequent challenge in this industry.

When hot gases hit cold metal (or filter bags), moisture condenses. This turns dust into a kind of mud that eats through metal and fabric alike—especially when sulfur in the fuel creates an acid flash.

That’s why preheating the baghouse is critical. We recommend:

✧ 20+ minutes at 350°F during startup.
✧ Make sure the tubesheet, bags, and ductwork are all above the dew point—especially in cold or wet conditions.
✧ Even during midstream restarts, don’t rotate the drum until preheat is complete.

Nomex can handle up to 400°F continuously (spikes to 450°F), but you want to avoid running too cold. The sweet spot is usually around 250°F. Running cold causes condensation, but overheating can destroy the bags. Train your operators to monitor temperature and pressure closely to prevent problems before they start.

What Should An Asphalt Plant Baghouse Inspection Sheet Include?

A good inspection checklist can help you spot issues early, keep your production up, and avoid costly downtime. Here are the key things to keep on your baghouse inspection sheet:

1. Is it the right size?
A baghouse that’s too small will choke your production. One that’s too big can make it tough to hit the right temps. The sweet spot? Around 200 CFM per ton of asphalt mix, assuming about 5% moisture content. So, if you’re running a 400-ton-per-hour plant, you’ll need something around 80,000 CFM.

2. Any leaks?
Make sure everything from the drum seals to the ductwork is airtight. Think of your dust collector like a big vacuum—if there’s a hole in the hose, it won’t suck up anything properly.

3. How are your filter bags holding up?
Worn-out bags lead to high pressure drops, poor cleaning, and lower production. Keep them in good shape by checking temperatures, tuning the burner right, and making sure everything stays in the recommended range. Bags aren’t cheap, so taking care of them will save you serious money—and make your system more attractive if you ever decide to sell it.

Other things to check regularly:

🔹 Total number of bags and their individual ID numbers
🔹 Bag damage (tears, holes, or thinning material)
🔹 When bags were installed, cleaned, or replaced
🔹 Airflow readings (CFM) and velocity (FPM)
🔹 Are airflow and pressure drop within normal range?
🔹 Check airlocks and dampers for proper function
🔹 Log pressure drops across the baghouse and individual compartments
🔹 Investigate weird pressure readings
🔹 Exhaust gas temperatures
🔹 Humidity levels inside the baghouse
🔹 Size and type of dust being collected
🔹 Any signs of system leaks

Invest Some Now or Invest a Lot Later!

Smart plant managers know that a little upfront investment in dust collection pays off big down the line.

Spend on quality filter bags rated for your operating temps, install a proper precleaner like a cyclone to reduce dust loading, and make sure your cleaning system uses demand-based controls. Don’t skimp on preheat systems either—they prevent condensation and extend bag life. Even setting up a solid inspection and maintenance schedule with trained personnel can prevent costly shutdowns.

The key takeaway from this series of three articles is that having the right equipment, the right process, and the right support makes the difference in how efficient (and profitable) your plant is.

Would like to go over some of the information in the previous two articles? Here are the links!

Would like some help designing or upgrading the dust collection system of your asphalt plant?

June 10, 2025/by Andy Biancotti

Baghouse Design, Cement and Construction Materials

Asphalt Production & Baghouse Fines (Part 2)

In the first part of this series, we looked at how an asphalt plant works and why it needs a dust collection system. Now, in part two, we’ll go a step further and talk about baghouse fines (BFs)—what they are, how they’re recycled, and the role they play in asphalt quality. If you’re working at an asphalt plant or managing dust collection equipment, understanding this topic can help you get more out of your system. Also, in addition to helping the environment, you’re also saving money. Reusing fines cuts down on material costs and can actually make your asphalt stronger and more durable, which means fewer problems down the road and less money spent fixing them.

A Closer Look At Baghouse Fines

Baghouse fines are the fine particles your dust collector captures during asphalt production. They’re often seen as just a byproduct, but they can actually be a valuable resource. With sustainability becoming a bigger priority in construction, more producers are finding ways to reuse these fines in hot mix asphalt (HMA)—without sacrificing pavement performance.

Most asphalt plants today try to reuse as much of the collected dust as possible (around 80–90% of baghouse fines end up back in the mix.)

In fact, most asphalt plants today try to reuse as much of the collected dust as possible. Industry estimates say around 80–90% of baghouse fines end up back in the mix. That not only helps reduce environmental impact but also fills the mineral filler requirements for certain asphalt designs. Still, a small percentage of producers—probably under 10%—are either disposing of the extra fines in settling ponds or returning them to a quarry. And at plants that use wet scrubbers instead of baghouses, the captured material usually gets washed away and discarded.

Physical and Chemical Properties of Baghouse Fines

In batch plants, the aggregates are first dried in a rotary dryer, then screened into different sizes and stored in bins. These materials are then fed, batch by batch, into a pugmill mixer, where asphalt cement is added and mixed with the hot aggregate.

Most BFs are reused on-site, right at the plant where they’re collected. That’s partly because fines can vary a lot from one plant to another. Their characteristics—like particle size, chemical makeup, and specific gravity—depend on things like the type of aggregate being processed, moisture content, and whether it’s a batch or drum plant. The dust collection setup also plays a big role. Plants with cyclones usually collect finer particles, with up to 90–100% passing the No. 200 sieve (0.075 mm). Those without cyclones may end up with coarser material, with less than 50% passing that same sieve.

In general, baghouse fines are made up of particles smaller than 0.6 mm. Some are coarse, some are ultra-fine. Fines collected after a cyclone tend to be better suited for reuse in asphalt. Most BFs have low plasticity—usually a plasticity index (PI) under 4—and low moisture absorption (typically less than 2%). Organic impurities are rare, except sometimes in oil-fired plants.

Chemically, BFs tend to be alkaline, with pH levels ranging from 7.2 to as high as 12.4, depending on the parent aggregate. Their chemical composition basically mirrors whatever aggregate the plant is crushing—granite, limestone, traprock, or something else.

How Are BFs Recycled?

Depending on the setup, the fines can go straight back into the process or be stored in silos for later. When reused, BFs serve as mineral fillers, replacing materials like hydrated lime or stone dust. These fillers are important. If your mix has too little, it can lack cohesion. Too much, and it might get brittle.

That’s why some producers are careful about how much BF they use. Even though they’re a recycled material, BFs can meet AASHTO (American Association of State Highway and Transportation Officials) and other highway specs for mineral fillers—if the parent aggregate is high-quality and the fines are well-graded.

How Do BFs Affect Asphalt Performance?

Using BFs in the mix does affect performance. For example, bumping up the fines-to-asphalt ratio from 0.2 to 0.5 tends to stiffen the mix by decreasing binder penetration and increasing viscosity. Lab tests show that Marshall stability improves with more fines, peaking when fines make up about 55% of the binder’s volume. The resilient modulus also goes up, which means a stiffer, stronger mix. But there’s a limit—too much fine material (especially over half the binder volume) can cause moisture sensitivity and lead to durability problems in the field.

That’s why proper mix design is so important. Most mixes using BFs can be designed using standard methods like the Marshall immersion-compression test (ASTM D1075). Good designs usually keep the fines content below 50% of the binder’s bulk volume, use well-graded particles, and include plenty of very fine material (smaller than 0.010 to 0.020 mm). It’s also key to keep your fines-to-asphalt ratio consistent—any changes in BF composition can affect pavement performance.

If you’re blending cyclone dust with baghouse fines, be sure to know the proportions and mix them properly. The type of aggregate matters, too. Dust from hard, angular rocks like traprock or granite may stiffen the mix more than softer, carbonate-based materials.

In short, BFs aren’t just filler—they actually act like active components of the mix. They need to be accounted for from the start, not thrown in at the end.

Handling and Production Considerations

For structural design purposes, asphalt mixes with BFs can be modeled using standard AASHTO methods—no special tweaks needed, as long as the fines are integrated correctly.

How fines are handled depends on the type of plant. In batch plants, they can be reintroduced at several points, including the hot elevator, hot bin No. 1, or the weigh box. Introducing fines earlier in the process usually leads to better mixing and more consistent properties. In drum plants, they can be added at the cold feed conveyor, drum inlet or outlet, or—ideally—where the liquid asphalt is injected. That last option helps ensure better coating and reduces the risk of fine particles escaping with exhaust gases.

You can stick with standard mixing and compaction techniques, although mixes with a higher filler/asphalt ratio can be tougher to compact due to stiffness. Quality control doesn’t change either: use AASHTO T168 for sampling, ASTM D2726 for specific gravity, and ASTM D2950 for in-place density.

Over the years, plenty of research has been done on how BFs perform in the field. Early studies—like one by PennDOT in the late 1970s—warned of brittle pavement and compaction problems when fines were added inconsistently. But more recent evaluations are much more positive. Caltrans, for example, found that adding up to 2% BFs improved cohesion. The Asphalt Institute concluded that BFs work well as mineral fillers—as long as the aggregate is high-quality. Other studies (like those from West Virginia and NCHRP) also found that very fine fractions of BFs can boost performance, especially when particles smaller than 0.020 mm are present.

How Baghouse.com Can Help

At Baghouse.com, we’re more than just parts suppliers—we’re your partner for keeping your dust collection system running strong. Whether you need a site inspection, troubleshooting, filter replacements, or a full system rebuild, we know how much dust collector performance affects your ability to reuse baghouse fines effectively.

We can help you to:

✧ Make sure your baghouse is collecting fines that meet gradation specs
✧ Spot issues like uneven airflow or leaking bags that mess with BF quality
✧ Retrofit or upgrade your system to boost performance and cut down on downtime
✧ Train your crew on best practices for handling and recycling BFs

Your baghouse it’s part of your production line. When it’s well-maintained, it gives you a steady source of reusable material and helps you control asphalt quality from start to finish.

In the third and last article of this series, we will take a look at the best design and maintenance practices for asphalt dust collectors.

Need help with your dust collector? Let’s talk.

Image Credits

By Silverije – Own work, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=37085244

June 3, 2025/by Andy Biancotti

Baghouse Design, Cement and Construction Materials

Asphalt Production & Dust Control (Part 1)

Asphalt is everywhere. It’s under your tires on the highway, in the parking lot at the grocery store, and lining the roads in your neighborhood. Its use is so widespread that many of us take it for granted, never stopping to consider how it’s made — or the vital role dust collectors play in its production.

In the world of asphalt manufacturing, dust collection systems are essential equipment that protect workers, ensure clean operation, and help keep plants running efficiently and profitably.

Through the years, Baghouse.com has helped many asphalt plants design their systems, maintain, troubleshoot, and upgrade their systems. We have learned many good tips we would like to share with you in a series of three articles:

Asphalt Production & Dust Control (Part 1)
Asphalt Production & Baghouse Fines (Part 2)
Asphalt Production & Dust Collectors Design and Maintenance (Part 3)

Let’s first take a look at how asphalt is produced.

How Is Asphalt Made?

Asphalt is a black, sticky, and highly viscous liquid derived from crude oil.

Asphalt is a black, sticky, and highly viscous liquid derived from crude oil. It acts as a binding agent when mixed with aggregate materials like stone, gravel, or sand. When combined, they form what we commonly refer to as asphalt cement or simply asphalt.

Historically, natural deposits of asphalt were used, but today, virtually all asphalt used for commercial and industrial purposes comes from petroleum refining. The final product is a strong, durable paving material used primarily in road construction. In fact, asphalt is the most widely used material for building roads in the United States — and the country is home to around 3,600 hot mix asphalt plants, producing over 400 million metric tons of asphalt paving material annually.

These plants fall into two major categories: batch plants and drum mix plants.

The asphalt production process begins with the cold aggregate supply system (1), where different sizes of aggregates are fed into the plant. These materials are then transferred to the drum dryer (2), where they are heated by the coal burner (3). Fuel is delivered by the coal feeder (4). During the drying phase, dust generated is captured by the cyclone dust collector (5) and the finer particles are filtered out by the baghouse dust collector (6). The hot aggregates are lifted by the hot aggregate elevator (7) to the top of the tower, where they are sorted by size using the vibrating screen (8). The filler supply system (9) adds mineral fines, and everything is then weighed and blended in the weighing and mixing system (10). The final hot mix asphalt is stored in asphalt storage (11) and the bitumen supply system (12) provides the binder essential for forming the asphalt mix.

Take a look at how an Asphalt Plant works in the following video:

Where Does Dust Collection Come Into the Picture?

To understand where dust collection fits into the asphalt manufacturing process, it helps to walk through how a plant operates.

In drum mix plants, cold aggregates that have already been sized are fed into a rotating drum. Inside, the aggregates are dried, and at the end of the drum, asphalt cement is injected to coat them in a continuous process.

In batch plants, the aggregates are first dried in a rotary dryer, then screened into different sizes and stored in bins. These materials are then fed, batch by batch, into a pugmill mixer, where asphalt cement is added and mixed with the hot aggregate.

Both systems generate a considerable amount of dust during the drying and mixing phases — and that’s where dust collection systems become crucial.

A typical setup includes a drying drum connected via ductwork to a baghouse that captures airborne dust particles generated during the drying and mixing stages. Most systems also include cyclones to collect the larger, heavier particles before they reach the filters.

What Are Baghouse Fines?

Far from being useless, baghouse fines are sometimes reused in the asphalt mix itself as mineral fillers, depending on the mix design and application.

The fine particles collected by baghouses are called baghouse fines, or BFs. These are ultra-fine dust particles removed from the exhaust gas stream. Far from being useless, BFs are sometimes reused in the asphalt mix itself as mineral fillers, depending on the mix design and application.

In the United States alone, asphalt plants generate an estimated 6 to 8 million tons of baghouse fines annually. Proper handling and collection of these fines is not only critical for environmental compliance but also provides an opportunity for recycling and cost savings.

Why Are Collectors So Important?

About 40 to 50 percent of asphalt plants use baghouse systems for dust control. They are used to:

✧ Prevent fine particles from clogging downstream equipment
✧ Protect workers and the environment from harmful emissions
✧ Maintain proper airflow and temperature balance in the drying process
✧ Allow for the reuse of valuable fines in the mix

Without a reliable collector, dust can accumulate rapidly inside the plant, leading to unnecessary wear on machinery, unplanned shutdowns, and even fire hazards. And when an asphalt plant experiences downtime, every minute lost translates to significant revenue loss — especially on tightly scheduled road work projects.

A Team That Helps Asphalt Plants Stay Clean and Productive

Baghouse.com has supported many asphalt plants across North America, helping operators troubleshoot, repair, and upgrade their dust collection systems. From replacing worn-out aramid filters, upgrading to pleated elements for better airflow, to retrofitting baghouses for improved cleaning performance — we’ve seen it all.

Our team of engineers and field technicians has worked hand-in-hand with hot mix asphalt plants across the country, and we understand the challenges asphalt producers face: high temperatures, tight spaces, short timelines, and the constant need to reduce downtime and stay compliant with environmental regulations.

So whether you’re planning your next plant move or struggling with pressure drop or bag failure, we’re here to help you keep your operation clean, safe, and productive.

Stay tuned for the second and third parts of this series of articles!

Need help with your asphalt plant’s dust collection system? Contact us today at Baghouse.com — because your uptime depends on it.

Images Credit:

By Unknown author – http://www.asphaltplant.cn direct link, CC BY 1.0, https://commons.wikimedia.org/w/index.php?curid=36614371

By Trougnouf (Benoit Brummer) – Own work, CC BY 4.0, https://commons.wikimedia.org/w/index.php?curid=77336217

By Lord Mountbatten – Own work, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=23036022

May 27, 2025/by Andy Biancotti

Dust Collector Maintenance, Operation & Optimization, Pollution/Emission Regulation

How to Balance Baghouse Performance vs Reducing Operating Costs

Let’s be honest—everyone’s trying to save money. And in the world of dust collection, that often means stretching your filter life just a little bit longer. Maybe a lot longer.

On paper, it makes sense. Filters aren’t cheap, and if you can get 18 or 24 months out of them (or in some applications even longer), instead of changing them every year, that’s real savings for the maintenance budget. But here’s the catch: filters don’t just slowly deteriorate. They clog, leak, harden, tear, and—if ignored too long—can turn your entire dust collection system into a headache.

So how do you actually strike the right balance between baghouse performance and reducing operating costs? Let’s take a walk through the plant floor and talk through what works (and what really doesn’t).

The Smart Way to Know When It’s Time to Change Your Filters

Here’s what we see a lot: some facilities change filters once a year like clockwork. Others wait until filters start leaking like a sieve. A few smart ones monitor differential pressure (DP) and start planning replacement once the readings begin to creep consistently above normal. And then… there are those who wait for disaster—a fire, visible emissions, or a complete loss of suction—before doing anything.

Monitoring differential pressure (DP) regularly and observing its trends will tell you when is best to start planning a filter changeout

If you’re only using one of those approaches, you’re probably either wasting money or risking performance. The truth is, the best results come when you combine multiple inputs to guide your decision: schedule, DP trends, emissions monitoring, and even basic visual inspections. If you can, throw in a triboelectric monitoring system to catch leaks early and keep track of overall bag performance. It doesn’t have to be expensive tech—it just has to give you enough data to make a smart call.

Read the article:

➤ How Often Should Baghouse Filters Be Changed?

What’s the Real Cost of “Saving Money”?

Yes, filters cost money. But what about:

🔴 Downtime when suction drops and production is interrupted?
🔴 Failed inspections that lead to fines or extra paperwork?
🔴 Product quality issues because dust is settling where it shouldn’t?
🔴 Worker exposure to airborne dust when the suction can’t keep up?

These are real, measurable costs—and they often don’t show up until after you’ve stretched your filter life too far. Old filters mean high DP, and high DP means fans work harder, energy bills go up, suction goes down, and eventually, you’ve got clogged machines or exposed workers.

Not worth it.

A Smart Plan: Use a Combination of Clues

Visually inspect during shutdowns—look for bag hardening, holes, or excessive dust buildup.

There’s no single answer for when to change your filters. But here’s a solid framework that’s worked well for many of our customers:

Set a baseline schedule based on your baghouse size, dust type, and usage patterns.
Track differential pressure. Don’t panic at every spike, but look at the trend.
Visually inspect during shutdowns—look for bag hardening, holes, or excessive dust buildup.
Use leak detection systems to catch issues before they lead to emissions violations, like a triboelectric broken bag detector.

Read the article:

➤ How Can I Tell When I Need to Replace My Baghouse Filters? (FAQ Series)

Use Higher-Quality Filter Media

Upgrading to premium filters might feel like an unnecessary cost at first. Why spend more when the cheap bags “get the job done,” right? But here’s the thing: better filters don’t just last longer—they perform better.

investing in PTFE-membrane bags or pleated filter elements can give you lower operating differential pressure (meaning less energy use), better filtration efficiency (which helps keep emissions low), and longer service life (sometimes 2–3 times longer than standard felt bags).

Investing in pleated filter elements can give you lower operating differential pressure, better filtration efficiency, and longer service life

For example, investing in PTFE-membrane bags or pleated filter elements can give you lower operating differential pressure (meaning less energy use), better filtration efficiency (which helps keep emissions low), and longer service life (sometimes 2–3 times longer than standard felt bags).

We’ve worked with plants that doubled their filter life by switching to a more durable media suited for their application, like a bakery using high-temp aramid bags for greasy exhaust, or a steel plant switching to PTFE for sticky fumes. Yes, the initial cost went up, but their cost-per-month of operation actually dropped, and they had fewer changeouts and shutdowns.

So the takeaway? Take a look at your process, your dust, your temperature, and your emissions goals. Sometimes spending a little more upfront saves a lot more down the line.

Train Your In-House Maintenance Staff

Another often overlooked cost-saver: invest in your team. A lot of plants rely on outside contractors for even basic baghouse maintenance—inspections, troubleshooting, filter changes. And while there’s a time and place for bringing in experts (especially for major rebuilds or testing), training your in-house maintenance team can pay off fast.

They can respond to issues faster and learn to spot small issues (like seal leaks or valve failures) before they snowball into expensive downtime. Even just one or two maintenance techs trained in baghouse basics (like checking DP trends, inspecting filters, and doing minor pulse valve repairs) can dramatically reduce long-term maintenance costs.

Training courses, like Baghouse.com training programs, adapt to the time and pace of your personnel.

Don't Let Cost Cutting Cut Into Performance

If there’s one thing we’ve learned from years in the field, it’s this: your baghouse doesn’t need to be the most expensive part of your plant, but it does need to work properly. Trying to save money by squeezing out a few more months of filter life might feel smart today, but it often backfires tomorrow.

Balance is everything. Monitor multiple indicators, make small adjustments, and plan filter changes like you would any other piece of critical equipment maintenance.

May 7, 2025/by Andy Biancotti

About Andy Biancotti

Entries by Andy Biancotti

🔹 Welcome & Overview

🔹 What is IoT, and how does it apply to your facility?

🔹 IoT Technology Explained In Depth – Interview with Eric Schummer

➡️ What are the building blocks of an IoT platform?

➡️ How data gets collected, transmitted, and visualized? What are the basic steps for implementing IoT tools?

➡️ What are some IoT sensor types relevant to dust collection and other industrial equipment?

➡️ How do IoT platforms interface with existing enterprise systems?

➡️ Review ROI cases for common facility types, and case studies.

🔹 How Can I Implement This Technology In My Facility?

🔹 Conclusion & Q&A

Asphalt Production & Dust Control (Part 1)

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