Andy Biancotti – Page 3

Case Study – Innovative Solutions for Cosmetics Manufacturing

A Dust Collection Success Story at Cosmetics Group USA

Background

Cosmetic Group USA is an ever growing developer and manufacturer of cosmetics and skin care for national and international brands.

Cosmetics Group USA is a California-based maker of a range of beauty products, partnering with the world’s most well-known cosmetics brands. The process of cosmetics manufacturing begins with the careful blending of raw materials to create the desired formulations. These powders are then finely milled and sifted to achieve the right texture and consistency.

Scope of Work

As part of their plans to expand and upgrade their Los Angeles factory, Cosmetics Group leadership recognized two main issues with dust collection that needed to be addressed:

An efficient, central dust collection system with capacity to support planned operations and expansion in the factory.
The air pressure in the building required balancing, as the dust collection system generated significant negative pressure, resulting in slamming doors, potential dust and particulates being pulled into the building through windows and doors, and inefficient heating and cooling of the facility.

Solution

To resolve these challenges, the company partnered with Baghouse.com to design and install a dust collection system that would satisfy their unique challenges.

“Our team worked efficiently to ensure the new dust collection system was up and running ahead of schedule, minimizing any disruptions to the Cosmetics Group’s operations” —said David Dal Santo, Systems Engineer for this project.

Baghouse.com developed a dust collection system using two 4-32 cartridge dust collectors with high-efficiency nano-media cartridge filters and twin 75 HP ground-mount fans. The various process dust pickup points in the lab and production areas were connected to the dust collectors via galvanized steel, clamp-together duct, an economical duct configuration that is perfect for lighter duty applications like cosmetic powder and dust.

“With high-efficiency nano-media cartridge filters and a robust ductwork design, we’re confident that this setup will exceed expectations for years to come” —said David Dal Santo.

Positioned on the clean air side of the unit, the HEPA after-filter acts as a secondary filtration stage, capturing even the tiniest microscopic particles before the air is returned to the facility.

To address the pressure balancing challenge, Baghouse.com designed the dust collection system exhaust to return to the building. Dual HEPA after-filter units were installed on the return air ductwork to meet compliance requirements and ensure the highest filtration efficiency for the filtered air that would be returned to the building. Baghouse.com also supplied and installed a central vacuum system with 30+ vacuum ports with flap valves for easy plug in of hoses where necessary.

In addition to the dust collection system sizing design, and delivery of the equipment, a Baghouse.com team installed the dust collection system and commissioned the units, successfully completing the project.

Conclusion

Baghouse.com developed a dust collection system using two 4-32 cartridge dust collectors with high-efficiency nano-media cartridge filters and twin 75 HP ground-mount fans. The various process dust pickup points in the lab and production areas were connected to the dust collectors via galvanized steel, clamp-together duct, an economical duct configuration that is perfect for lighter duty applications like cosmetic powder and dust.

Newly installed cartridge collectors, ductwork and HEPA After-Filters

“We were excited to take on this challenge and are thrilled with the outcome. Helping Cosmetics Group USA expand their operations while solving their dust collection issues was truly a rewarding experience” —said Matthew Coughlin, Engineer and Owner of Baghouse.com.

Happy with the results of their new dust collection system, Cosmetics Group USA continues to work with Baghouse.com to support additional future expansion plans for their factory.

November 12, 2024/by Andy Biancotti

Dust Collection 101, Dust Collector Maintenance, Purchasing Supplies Tips

Pleated Baghouse Filters: A Smarter, More Cost-Effective Solution!

Traditional Filters vs. Pleated Filters

Made from a variety of materials, filter bags can be used in high temp, high dust loading, abrasive, corrosive and high humidity applications

Traditional baghouse filter bags have been the standard in dust collector for nearly 100 years and they continue to be the most common type of filter used across nearly all industries and applications. Their wide use, and simple construction means they present the lowest cost per filter option.

However, when the time for your next filter replacement comes, are traditional baghouse filters always the most cost effective option when all cost factors are considered? In many applications this is not the case. One choice that should be given more consideration is to replace your existing traditional filter bags and cages with pleated filters.

This article will examine exactly what are pleated baghouse filters and what are their advantages over traditional bags and cages.

What are Pleated Baghouse Filters

Pleated filter elements have many folds of the fabric that provide a greater surface area of filter cloth in a shorter length, allowing for improved air-to-cloth ratios in the same space

As one of the latest technologies in industrial dust collection, pleated filters improve on the design of traditional bags by packing more filter fabric into a smaller space.

Additionally, the shorter overall filter length also creates additional space underneath the bottom of the filters, keeping the filters above the dirty inlet gas stream.

traditional filter bags versus pleated filters

Shorter filter length reduces abrasion problems caused by incoming dust particles striking the filters and further slows the incoming air, which improves filter dust cake release when the filters are pulsed

Another advantage over traditional filters is that they do not require separate cages, as the bag and cage are combined into a one-piece construction. This means no more separate cage purchases and easier storage of filters. Due to these reasons, they are more efficient at removing particulate than traditional bags and last longer, sometimes up to 2 times as long. Pleated filters are designed to operate with today’s high demand production demands and can replace existing bags and cages in most standard pulse jet baghouses without any modifications required.

Why use Pleated Filters Over Traditional Bags and Cages

As noted, there are compelling operational and performance benefits to switch from traditional filters to pleated filter elements. But there are also significant financial advantages. The use of pleated filters in today’s high production demands can reduce costs by up to 60%. How is this the case? Let’s examine some of the benefits of switching to pleated filters.

— Reduction in Total Number of Filters:

The total number of filters required is reduced due to the overall filter cloth area being increased when using pleated filters. Less filters are required for the same filtering efficiency.

Installation can take 50% less time than it takes to replace traditional filters

— Easier Installation:

The reduction in the number of filters being installed results in faster changeouts, less downtime and lower installation costs. Also the one-piece unitary design means there is no cumbersome operation to remove and reinstall the cage and bag together, therefore installation can take 50% less time than it takes to replace traditional filters.

— Reduction in Compressed Air:

With less physical filters and an improved filter area, pleated filters load dust better and are easier to clean. This leads to a significant reduction in the use of compressed air during the cleaning cycle.

— Increased Lifespan:

Shorter length of filters and a reduction in cleaning, results in pleated filters experiencing less wear and tear during operation. This means pleated elements commonly last from 25 to 75% longer than filter bags. Sometimes as much as 2 to 3 times longer. Longer lifespan means replacing filters less often.

— Improved Operation and Greater Capacity Through Increased Filter Area:

Pleated Filter elements can dramatically improve operation costs by increasing capacity, by decreasing emissions, reducing electricity usage. Pleated elements can effectively increase the amount of filter media inside a collector by as much as 700%.

With the greater amount of filter media, operators can either:

Keep the airflow the same and thus increase the air-to-cloth ratio for improved performance and filter life
Increase airflow to have a greater baghouse capacity of a baghouse, possibly allowing for the combination of several dust collection systems into one larger unit and in turn reducing operation costs.

Conclusion - Pleated Filters Provide Significant Advantages In The Right Application

what is cheaper: a filter bag or a pleated filter?

Traditional filters usually mean lowest cost per filter, but with pleated elements the overall short term and long term cost of replacing and maintaining your baghouse can be dramatically reduced

There are many advantages to switching from traditional to pleated filters.

In certain cases however, switching to pleated filters will not be a viable option. For example, pleated filters are not advisable for high temperatures or when the airstream contains highly corrosive gases. Higher temp versions do exist, but they have significantly higher costs per filter and may only be viable in applications where improving dust collector performance will provide significant financial upside and with few to no other options available to do so.

In summary, from cost savings to improved efficiency and longer lifespan, pleated filters can be a game-changer for your dust collection system.

To find out more information on the pleated filters and to discuss the option of converting your baghouse to pleated filters, please contact us at Baghouse.com

October 24, 2024/by Andy Biancotti

Industrial Health and Safety, Industrial Health and Safety Regulations, Safety

Hazardous Dust: Key Risks and Practical Management Solutions

How Harmful is Exposure to Dust in the Workplace?

In many industries, workers can be exposed to high levels of dust, causing breathing problems that could lead to life-threatening respiratory diseases. Most occupational lung diseases are caused by repeated, long-term exposure, but even a severe, single exposure to a hazardous agent can damage the lungs.

In What Industries is Dust a Hazard?

Manufacturing factories, processing facilities, and industrial sites all have the potential to emit dangerous dust.

Dust is a prevalent exposure at workplaces in various industries such as:

— Mining
— Foundries
— Chemical
— Food industries
— Stone working
— Woodwork

While many industries expose workers to dust, not all dust is equally harmful. Excessive exposure to some types of dust has been linked to the development of particular health problems, such as lung cancer or asthma. Different forms of the same substance may present different hazards. For example, a large piece of wood may be safe, but when ground into dust, it can become hazardous.

What Problems Can Exposure to Dust Lead To?

Exposure to any dust in excessive amounts can create respiratory problems. The harmful effects of dust can vary, from skin irritation to lung cancer, depending on the composition of the dust and the type and degree of exposure. Dust is not always an obvious hazard because the particles which cause the most damage are often invisible to the naked eye, and the health effects of exposure can take years to develop.

Safe Materials When Solid, Hazardous in Dust Form

As we mentioned, some materials that are generally safe in their solid form can become hazardous when they are ground into dust and inhaled over long periods. For example, Silica is found in materials like sand, stone, and concrete, silica is harmless in its solid state. However, when these materials are cut, ground, or drilled, they produce respirable crystalline silica dust. Prolonged exposure to this dust can lead to silicosis, a serious lung disease, as well as lung cancer and other respiratory issues.

Inherently Toxic Dusts

Other dusts are inherently toxic and should be avoided as much as possible due to their severe health risks:

— Heavy Metals: Dust from metals like lead, cadmium, and arsenic can be extremely toxic. Inhalation of these dusts can lead to serious health issues, including damage to the nervous system, kidneys, and other organs.
— Asbestos: Asbestos fibers, when inhaled, can cause severe lung diseases, including asbestosis, lung cancer, and mesothelioma. Even small amounts of asbestos dust can be dangerous.
— Mineral Acids: Dusts from mineral acids, such as sulfuric acid, can cause severe respiratory and skin irritation.

How Can We Prevent Dust-Related Diseases?

PTFE filters from Baghouse.com can easily reach sub-micron filtration ranges. In some applications efficiencies are high enough to allow for the recirculation of treated air back into the facility.

In some applications, PTFE membrane filtration efficiencies are high enough to allow for the recirculation of treated air back into the facility.

In normal situations with non-hazardous materials, a simple dust collector with basic filters is often sufficient to meet regulatory requirements. However, when handling hazardous dust, additional steps are necessary to comply with local regulations. For example, hazardous dust might require dust collectors fitted with high-efficiency filters, such as bags or cartridges with nanofiber or PTFE membranes. These filters capture a higher percentage of the smallest particles.

Using HEPA Filters for Extra Safety

HEPA after-filter serves as a powerful ally when searching for cleaner indoor air quality, particularly in industrial settings

If the dust is particularly hazardous, local authorities or safety regulators may require an extra set of filters known as after-filters or HEPA (High-Efficiency Particulate Air) filters. These are usually placed after the primary filters, either before or after the fan. HEPA filters act as a fallback safety measure. In normal operation, the primary filters capture all the dust. However, if there’s a hole or damage to the primary filters, the HEPA filters will capture any escaping dust, preventing it from being released into the environment or recirculated back into the building.

Conclusion

This guide aims to promote safety by educating company owners, managers, environmental personnel and workers about the dangers of hazardous dust and advocating for effective prevention strategies. Remember, a little awareness and action can go a long way in keeping your team safe and healthy.

Would you like to talk to a dust collection expert to determine if you are working with hazardous dust?

Are you wondering what measures should you take to keep your facilities safe?

October 14, 2024/by Andy Biancotti

Baghouse Accessories, Dust Collection News, Dust Collector Maintenance, Operation & Optimization

Introducing the Vacu-Valve: The Economical Dust Discharge Solution

If you’re in industries like foundry, mining, cement, or pharmaceuticals, think of dust management like that one chore you can’t skip—because nobody wants their facilities and equipment to look like it’s been hit by a sandstorm!

That’s where the Vacu-Valve comes in—an economic and reliable solution for continuous dust discharge in systems operating under negative pressure.

How the Vacu-Valve Works

The Vacu-Valve operates without any electrical power, lubrication, or complicated mechanisms. Instead, it uses a simple yet effective method of airlock and vacuum management. Here’s how it works:

— The sleeve inside the valve forms an airtight seal due to the vacuum present in the system.
— As dust particles accumulate above the valve, their weight and the force of gravity eventually force the sleeve to open, allowing particulate to trickle out while maintaining the vacuum.
— The valve then closes automatically, sealing the system again without any external input.

Fine spherical particles, such as sand, pass through most effectively, but the Vacu-Valve can handle a wide variety of particulate sizes and shapes depending on the application.

Industries that Benefit from the Vacu-Valve

The Vacu-Valve is perfect for a wide range of industries, including:

— Foundry
— Mining
— Cement
— Pharmaceutical
— Plastics
— Chemicals
— Manufacturing

Frequently Asked Questions about the Vacu-Valve

— What makes the Vacu-Valve different from a rotary valve?

The Vacu-Valve operates without power or controls, relying on the balance between the vacuum pressure and the weight of particulate matter. Rotary valves require power and regular maintenance, making the Vacu-Valve a more economic and simpler alternative.

— Can the Vacu-Valve handle high temperatures?

Yes! The high-temperature silicone sleeve option can handle temperatures up to 500°F, while the VHT chemical-resistant sleeve is suitable for temperatures up to 400°F.

— What types of dust materials can the Vacu-Valve handle?

The Vacu-Valve works best with free-flowing, dense materials such as sand, industrial powders, coffee, and other small particulates.

— How durable is the Vacu-Valve?

The Vacu-Valve is highly durable and resistant to wear and tear. Its sleeves are available in different materials such as neoprene, nitrile, and silicone, allowing it to be used in abrasive or chemically aggressive environments.

— Does the Vacu-Valve require a lot of maintenance?

No, the Vacu-Valve requires minimal maintenance. Since it doesn’t need lubrication or electrical power, the valve can run continuously with little oversight.

— How quickly can I get a Vacu-Valve after ordering?

Most Vacu-Valves are stocked and can ship within 2-3 business days after placing an order.

Why Choose the Vacu-Valve?

If you’re looking for an efficient, worry-free, and low-cost method of dust discharge, the Vacu-Valve is a very smart investment.

Ready to simplify your dust management system? Contact us today to learn more about how the Vacu-Valve can meet your specific industrial needs.

September 13, 2024/by Andy Biancotti

Baghouse.com News, Dust Collection News, News

New Partnership: Baghouse.com Becomes Authorized Partner for DustVent Equipment

Baghouse.com personnel working on a DustVent equipment.

Baghouse.com personnel servicing a DustVent dust collector.

We are thrilled to announce a new partnership between Baghouse.com and DustVent (Mid-Air Consulting), marking a significant milestone for both companies. Baghouse.com is now the exclusive service partner for all DustVent equipment including their Cyclone Collector, Fabric Collector, and Downdraft Bench. This partnership means that customers who own DustVent equipment can now rely on us for expert on-site service and support, maintenance and repairs for their equipment.

DustVent has a rich history, dating back to the 1970s when it was founded by an innovative engineer whose passion for dust collection systems laid the foundation for what the company is today. William Fitzpatrick (Fitz), the current owner, began his journey with DustVent in 1989, working closely with the company’s founder to redesign and enhance their product offerings. In 2008, the company rebranded as Mid-Air Consulting, and Fitz, along with his dedicated team, has continued to deliver high quality products.

Our team has the capability to service any DustVent collector or downdraft table.

By complementing DustVent’s products with our extensive expertise and on-site service capabilities, we can now ensure that your DustVent equipment continues to meet your production requirements. This collaboration not only enhances our service portfolio but also underscores our commitment to delivering the highest quality support and solutions to our clients.

We are excited about the possibilities this partnership brings and look forward to servicing more DustVent equipment.

Do you have DustVent equipment that needs service?

Are you ready for your next filter changeout?

Give us a call at (702) 848-3990!

September 2, 2024/by Andy Biancotti

Metalworking and Foundries

Case Study – Expansion at Sunshine Minting

Background

Sunshine Minting, a global supplier and processor of precious metals, was looking to upgrade their dust collection system to support new melt lines and future expansion. Their existing small collectors were inadequate for the increased capacity and airflow requirements.

Scope of Work

Sunshine Minting needed a dust collection solution with sufficient capacity and airflow to handle their expanding operations. Additionally, they required improvements in ductwork to connect both new and existing processes to the new system. A spark trap was necessary to mitigate the fire risk from sparks traveling through the ductwork into the collector. Additionally, flame resistant filters were used for extra protection.

Solution

Baghouse.com responded to Sunshine Minting’s needs by dispatching a technician for an on-site inspection. The technician documented the facility layout, the proposed location for the new collector, and the new ductwork configuration. Following this, we installed an ACT 4-48 cartridge collector with a 20,000 CFM fan, a 50 HP motor, and a VFD control panel. A Boss Products Raptor Shield 22″ spark arrestor was also installed, along with connecting ductwork throughout the facility. The turnkey installation included programming of the VFD and airflow measurements to confirm adequate airflow and pressure at pickups and ducts.

What is a VFD?
It stands for Variable Frequency Drive, and is a type of fan controller. A VFD allows the user to run their dust collector fan at a lower or higher rate to manage performance. Rather than simply flipping a switch and running your fan at full speed (think 40kW per hour), the fan motor will run at a lower rate, saving significant energy costs in the long run.

Installation Challenges

Placing the new collector and fan without interfering with existing condensers and other equipment was a challenge. To overcome this, the inlet duct was routed up and over the area, and the fan exhaust was directed away from the facility as requested by the customer. These minor layout modifications are common and easily accomplished with a proper design and layout review.

Outcome

The installation of the modern cartridge-style collector has provided Sunshine Minting with sufficient fan and filter capacity for current processes, and extra capacity for future expansion. The VFD controller on the fan improves power efficiency and allows for easy adjustment to accommodate future changes. The MERV 15 rated nano media filters, upgraded with flame retardant treatment, ensure maximum safety from sparks or hot coals.

Sunshine Minting now enjoys enhanced dust collection efficiency and safety, with the system’s additional capacity supporting their ongoing and future operational growth. The improved power efficiency and safety features represent a significant upgrade from their previous setup.

Conclusion

Baghouse.com successfully addressed Sunshine Minting’s dust collection needs with a comprehensive solution that supports their expanded operations and future growth, enhancing both safety and efficiency in their facility.

Would you like to know how a technical inspection and a system report by Baghouse.com could improve the efficiency of your operations?

Talk now with one of our baghouse experts for more information!

July 24, 2024/by Andy Biancotti

Dust Collector Maintenance

How to Measure Your Baghouse Filters & Cages

When ordering replacement baghouse bag filters, it is extremely important that you order the right size to ensure a proper fit in your baghouse.

Properly fitting bags and cages are integral to achieving long filter bag life and optimum baghouse performance. Filter bags come in a huge variety of sizes and types, to fit many makes and models of baghouses.

Measuring Filter Bags & Cages - Key Terms

Flat Width/Diameter

This is the most critical measurement, and the one people most often get wrong. As we need this size correct down to a ⅛”, it is not possible to measure the diameter of a loose bag accurately enough for ordering. For that reason, we instead rely on a flat width measurement, which we can then convert to an accurate diameter.

Overall Length

For top load pulse jet bags, the bag is the same length as the cage or just 1⁄2” longer. For bottom load pulse jets, where the top of the raw edge bag is folded over the top of the cage, we recommend 4” of overlap, but some OEMs recommend 2”.

Tubesheet Hole Size/Snap Band Size

Often the hardest dimension to confirm, a hole size measurement accurate down to 1/32” is required to ensure proper fit. For best results, measure the hole with calipers or check the OEM drawings for details. Alternatively, you can send a sample bag to confirm the tubesheet hole size or have us make a sample bag/cuff to test fit before releasing the entire order to production.

Size Draft/Accurate Specifications

While it is usually possible to rely on previous bag sizing when reordering, at times, there may be reason to reconfirm all bag and cage sizing choices. Over time, sloppy or copy errors can result in slight variances in sizing making their way into orders and company records. In this way, the original bag sizing can see a slight, but impactful creep over successive orders.

When we suspect this has happened, we may ask you to go back and provide us with the fundamental component sizing that dictates the overall bag and cage sizing. For top load pulse jet, reverse air, and many shaker units this is the tubesheet hole size. For bottom load pulse jets, and some reverse air/shaker units, it is the mounting hub/venturi.

Once we have this fundamental sizing information, we can then recommend the proper bag and cage sizing.

Bag/Cage Fit or “Pinch”

Filters that are too loose or too tight on the cages will severely limit collection efficiency and lead to premature failure. For most felt bag materials (polyester and aramid/nomex being the most common) we generally recommend ¼” to ½” of pinch, meaning the bag diameter is that much larger than the cage. Other specialty fabrics such fiberglass, P84, and fabrics with PTFE membrane applied to them may require tighter tolerances.

Number Cage Vertical Wires and Horizontal Ring Spacing

Proper care must be taken to ensure that the cage construction will properly support the filter bag as well as optimize cleaning and efficiencies. Most fabrics work well with using cages with 10, 12 or 14 vertical wires. However, some specialty fabrics such fiberglass, P84, and fabrics with PTFE membrane applied to them require the additional support of 20 wire cages and possibly tighter spacing on the horizontal rings.

Common Bag and Cage Size Combos

Below we have listed a few common sizes for pulse jet and reverse pulse systems in use today.

Top Load Style

—Bag: 6.25” x ¼” tubesheet hole, 5.875” diameter x 96”/120”/144” long, snap band top, disk bottom – Cage: 5.625” diameter x 96”/120/144” long, turned down flange top (with or without integral venturi), pan bottom, 12 vertical wires, horizontal rings on 8” centers
—Bag: 6.25” x ¼” tubesheet hole, 6” diameter x 96”/120”/144” long, snap band top, disk bottom – Cage: 5.75” diameter x 96”/120/144” long, turned down flange top (with or without integral venturi), pan bottom, 12 vertical wires, horizontal rings on 8” centers
—Bag: 5” x ¼” tubesheet hole, 4.625” diameter x 96”/120”/144” long, snap band top, disk bottom – Cage: 4.5” diameter x 96”/120/144” long, turned down flange top (with or without integral venturi), pan bottom, 12 vertical wires, horizontal rings on 8” centers

Bottom Load Style

—Bag: 5.865” diameter x 100”/124” long, raw top, disc bottom – Cage: 5.625” diameter x 96/120”” long, split collar top, pan bottom, 12 vertical wires, horizontal wires on 8” centers (Flex Kleen style bottom load)
—Bag: 4.625” diameter x 100”/124” long, raw top, disc bottom – Cage: 4.5” diameter x 96/120”” long, split collar top, pan bottom, 10 vertical wires, horizontal wires on 8” centers (Mikropul bottom load and “twistlok” style)

Measuring Filter Bags - Step-By-Step

Top Load, Snap Band Filter Bag

Use a tape measure or ruler and measure the width across the bag.

Flat width/Diameter

Lay the bag out on a table or floor, flatten it completely.
Use a tape measure or ruler and measure the width across the bag.

Length

Measure along the seam running the length of the bag. Start at the center of the snap band and end at the first stitch at the bottom of the bag.

Cage-to-Bag (Bag-to-Cage) fit

Should have ¼” to 3/8” pinch; the bottom of the bag should have about a thumbs width between the bottom of the cage and the disc bottom of the bag.

Top Load, Snap Band Filter Bag – Woven Fiberglass

Flat width: Flatten bag and measure width across.
Length: Measure along the seam running the length of the bag. Start at the center of the snap band and end at the first stitch at the bottom of the bag.
Cage-to-Bag (Bag-to-Cage) fit: Should have 1/8” or less pinch, but shouldn’t be stretched tight around the cage.

Top Load, Snap Band Filter Bag – Felt with membrane

Flat width: Flatten bag and measure width across.
Length: Measure along the seam running the length of the bag. Start at the center of the snap band and end at the first stitch at the bottom of the bag.
Cage-to-Bag (Bag-to-Cage) fit: Should have 1/8” or less pinch, but shouldn’t be stretched tight around cage.

Shaker style Filter Bag

Flat width: Flatten bag and measure width across.
Length: Measure along the seam running the length of the bag. Start at the end of the snap band to the end of the bag, not including the tail.
Length of the tail: Measure along the seam from the end of the bag to the end of the tail
Flat width of the tail: Flatten tail and measure width.
Determine if the tail is 3 ply or 4 ply by pinching the material and feeling for layers.
If there is a wear cuff at the snap band end of the bag, measure length and width.

Measuring Cages - Step-By-Step

Step one: Measure from top to bottom the full length of the cage.

Full length of the cage: Measure from top to bottom.

Measure diameter in the middle of the cage at the widest point between wires. Ideally, using a Pi Tape to determine circumference will yield a preferred measurement.

2. Diameter: Measure diameter in the middle of the cage at the widest point between wires. Ideally, using a Pi Tape to determine circumference will yield a preferred measurement.

Be aware that some OEMs make the bottom pan slightly smaller than the cage body to make it easier to insert the cage into the bag. This is why you should always measure the diameter near the middle of the cage.

3. Bottom construction: Determine if the bottom cup is crimped or if the wires are welded to the cup.

4. Number of rings: Count the number of rings.

5. Space between rings: Measure the space between the rings. Note: the space between the last ring and the bottom of the cup may be different.

6. Number of vertical wires: Count the number of vertical wires running the length of the cage.

7. Material: Plain steel, galvanized, coated, 304 stainless steel, or specify if it is some other material.

8. Determine the top construction of the cage:

- — If the top has a venturi, measure the length of the venturi.

- — If the top has a split top, measure the space between the groove in the split top and the end of the top

Measure across the center of the hole in a straight line from one edge to the opposite edge.

Another important measurement to have in mind when ordering filters or cages, is the size of the tube sheet hole where our filters will be placed. This will ensure there is a perfect seal, extending the life of the filters and not allowing dust to go through.

With a wide range of sizes and types available, it’s essential to select the right filter bags and cages to suit your specific dust collector model. Following these basic steps will help you make informed decisions when ordering replacements, ensuring smooth operation and extended filter bag life for your dust collection system.

Another option to find out the right size of your filters and cages is to send us a used filter or cage so we can measure it for you. Feel free to get in contact with us if you prefer this option and we will be happy to assist you.

If you need assistance with measuring filters or cages, please reach out to one of our experts clicking below:

Contact Us to Speak to One of Our Baghouse Experts

For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

May 30, 2024/by Andy Biancotti

Dust Collection 101

A Brief History of Dust Collectors

Dust collection began during the late 1800s Industrial Revolution in the US, spurred by the rise in manufacturing and the oil industry, which generated increased waste like sawdust, coal dust, and chemicals. This waste polluted the air near factories, leading to health concerns. To tackle this, dust collectors were invented.

The First Dust Collector

The first dust collector is subject to debate, with some attributing it to Wilhelm Beth for his filter-based design, while others credit John Finch for his Cyclone Dust Collector introduced around 1885. Cyclones became popular by 1900 for their effectiveness in collecting coarse dust, and they’re still used today. Operating on centrifugal force, cyclones create a vortex that separates dust from air, depositing it into a collector while letting filtered air out.

The Shaker Dust Collector

In the mid-1920s, a significant advancement in dust collection emerged with the invention of the Shaker Dust Collector by Wilhelm Beth in Germany. Wilhelm introduced a baghouse unit connected to machines via ductwork to collect sawdust and similar materials. The filter elements in this system are self-cleaned using a vibrating motor attached to the frame, which shakes the filter bags to dislodge accumulated dust.

Over time, the design of the Shaker Dust Collector was refined, incorporating better filters capable of capturing smaller particles while maintaining optimal airflow and efficiency. Although still in use today, Shaker Dust Collectors have declined in popularity due to their relatively low air-to-cloth ratio and large footprint, which demands considerable space.

Cartridge Dust Collector

In the early 1970s, the dust collector saw another evolution with the introduction of the cartridge collector. This innovation replaced the fabric in baghouse filters with cartridge media, offering finer filtration. Capable of efficiently filtering particles as small as 0.3 microns, cartridge collectors excel in removing fumes from the air.

New Dust Collection Options

In the mid-1900’s, environmental regulations became more common and major polluters came under pressure to clean up the massive amounts of dust they generated. Shaker bags and basic fabric filters could not handle the task.

Reverse air baghouses were invented around this time, shortly followed by pulse jet baghouses. These provided tremendous improvements in dust collection by setting up an arrangement of filtration bags that could be cleaned by fans or compressed air pulses instead of shaking. These methods kept the bags cleaner and increased the efficiency of the filters.

The invention of baghouses brought a new era in the history of dust collection. Both types of baghouses are still in use today, and they continue to work well. They are especially useful in applications with high temperatures and high humidity. Bags are now made of a wide variety of materials specialized for different needs.

The Future of Dust Collection

As technology continues to evolve, the future of dust collection holds exciting possibilities. Integration with smart devices and cloud-based platforms could enable remote monitoring and control of dust collection systems, empowering operators to manage their systems with unprecedented efficiency and flexibility. Continued research and development efforts may unveil new methods and technologies to further improve dust collection performance, ultimately fostering safer and healthier work environments across various industries.

With ongoing technological advancements, the future holds the promise of even greater strides in optimizing dust collection systems for enhanced workplace safety and environmental stewardship. Here at Baghouse.com we are always researching and implementing the latest cut edge technologies, continuing to make history in dust collection.

Would you like to know how this technology can be applied to your application?

Contact Us to Speak to One of Our Baghouse Experts

For more baghouse related training and information, be sure to check out our Baghouse Online Training page.

May 17, 2024/by Andy Biancotti

Dust Collector Troubleshooting

Troubleshooting Your Dust Collector Pulse Jet Cleaning System

Overview of a pulse jet top load baghouse

For a dust collection system to operate efficiently, the filter cleaning system must be designed, installed and maintained properly. The following troubleshooting basics are intended to help avoid common pitfalls. (Note: Think of these tips as your dust collector’s GPS – they won’t replace the regular check-ups, but when your collector decides to throw a fit and send you through a back road, you will be better prepared to come back on track without losing lots of time or resources…)

When issues arise, it’s essential to troubleshoot effectively. Start by asking, “What has changed?” It could be a worn component or a shift in the operating environment. Even adding a single pickup point can impact the entire system.

Key Steps for Troubleshooting

A correct dP reading is vital for performance tracking.

Check Differential Pressure (dP): Measure with a magnehelic gauge to assess filter media condition. The dP across the filters should slowly increase as dust builds up on the filters, then suddenly decrease when the cleaning system fires a pulse of compressed air, cleaning the filter and reducing pressure across the filter.
Troubleshoot dP Gauge: As part of your periodic inspection process, remove the air lines connected to your dP gauge and ensure there are no obstructions or leaks in the lines. Replace old lines and ensure airtight connections. Even a small amount of dust in the gauge will lead to false readings or foul the gauge.
Listen for Problems: With the cleaning system active, listen to the pulse jets fire. You should hear a tight blast of air. If it sounds “off” – you hear a squeak, a rattle, a click but no air, etc. it is a sign that something requires attention. Most common issues are worn diaphragms (rattle or puff sound), leaks in connecting hoses (hiss sound), and stuck solenoids (a click but no air noise).
Check Compressed Air Pressure: Ensure your system has a compressed air gauge nearby so you can check it as part of your daily or weekly inspection. Review your equipment manual to ensure compressed air is set to the correct pressure. Ensure that your compressed air is clean and dry.
Timer board with lights off indicating no power

Timer Board Settings: Less common issues arise with the timer board, most often due to a surge in electricity or an unauthorized change in the board settings. If you have a ‘clean on demand’ setup, the pulse cleaning system will only fire when the dP reaches a high limit. Equally important is the low limit, where the cleaning shuts off. There are other settings that can be programmed on your control board such as On-Time and Off-Time that control how long the valves are open for and how long it waits between firing the valves. Once set, these should only be changed by authorized personnel. Most timer boards have indicator lights that will flag errors or basic issues. Refer to your equipment manual to ensure all settings are correct.

In the following video, you will see an overview of a system, from the blowpipes and diaphragm, to the control box. Actively listening to how your valves shoot will help you identify the most common issues.

Damaged by rust or out of position blowpipes could affect the operation of a pulse-cleaning system

Blowpipes knocked out of position

6. Other Common Pulse-Cleaning System Issues: Less common (but still important to know) issues include damaged or out of position blowpipes, stuck solenoids, water or oil in compressed air source, and electrical wiring issues.

When to Troubleshoot

Taped up pulse valve connecting tube indicating likely air leak location

High dP without filter life exhaustion is your first indication of a cleaning system malfunction. If the dP seems off, start by listening for the pulse valves to fire, then run through the items above to identify the issue.

Adjust Timer for Medium-Pressure Systems: Lengthen pulse intervals by adjusting the timer to fill the reservoir adequately. Check for leaks and loose connections before replacing components.

Beyond Cleaning System Issues:

Filter Inspection: Assess filter condition and look for moisture or caking issues.
Environmental Conditions: Consider variations in temperature and humidity, especially in colder regions.
Wear and Corrosion: Monitor aging systems, especially if handling abrasive or corrosive materials.
Human Factors: Be aware of unintended actions like shutting off compressed air or adjusting fan dampers.
Long-Term Monitoring: It is a good practice to monitor the system (specifically the dP) over an extended period to identify patterns or external factors affecting performance.

Hopefully, these tips will be able to guide you through unexpected challenges as a GPS, navigating the potential issues and ensuring your operations stay on track without losing valuable time or resources.

You haven’t found the problem yet? Did you find the problem, but you need assistance fixing the issue?

Talk to one of our dust collection experts, and they will be able to help you troubleshoot!

January 18, 2024/by Andy Biancotti

Cement and Construction Materials

Case Study – Dust Collection Optimization in Asphalt Production

When one asphalt plant began experiencing a mix of serious challenges (abrasive dust damaging equipment, fine particles posing health risks, and high temperatures creating cleaning and safety issues) they turned to Baghouse.com for a solution. What followed was a carefully engineered response that tackled each problem head-on and also boosted overall efficiency and compliance. Here’s how we helped them get their dust collection under control and their plant back on track.

Background

Baghouse.com collaborated with an asphalt plant facing some of the following challenges:

Coarse particles cause wear and tear on dust collection equipment and filter bags.
Fine asphalt dust presenting health risks and demanding specialized filtration methods due to varying material compositions.
Elevated temperatures creating difficulties such as dust adherence, cleaning, and the risk of fire and explosion.

Through the years, Baghouse.com has helped many asphalt plants across North America 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:

Scope of Work

Baghouse.com implemented a comprehensive solution featuring a large top-load pulse jet baghouse.

Key components included:

Specialized filter media designed for abrasion and temperature resistance, ensuring effective dust collection and prolonged filter life.
Equipment and filter bags designed to withstand the abrasive nature of particles, minimizing maintenance costs.
Systems equipped to handle high temperatures, preventing issues such as dust sticking, enhancing cleaning efficiency, and minimizing fire and explosion risks.

Outcome

Implementation of effective dust collection not only ensured workplace safety but also controlled emissions harmful to health and the environment, like volatile organic compounds, particulate matter, and carbon monoxide.

Additionally, closed belt systems on aggregate conveyor belts and efficient dust filtering systems contributed to reduced dust emissions.

Conclusion

By combining high-quality filter media, abrasion-resistant systems, and temperature-resilient filtration, the client’s asphalt plant achieved increased efficiency, reduced maintenance costs, and ensured compliance with environmental and safety standards. This case study demonstrates the importance of specialized dust collection strategies in the asphalt industry to mitigate health risks, environmental impact, and operational challenges.

Would you like to know how a thorough technical inspection by Baghouse.com could improve the efficiency of your operations? Talk now with one of our baghouse experts for more information!

December 19, 2023/by Andy Biancotti

About Andy Biancotti

Entries by Andy Biancotti

— Reduction in Total Number of Filters:

— Easier Installation:

— Reduction in Compressed Air:

— Increased Lifespan:

— Improved Operation and Greater Capacity Through Increased Filter Area:

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