About Matt Coughlin

Matt Coughlin is an engineer with experience in the medical device, turbomachinery, aerospace & defense, and industrial dust collection industries. He has been with Baghouse.com since 2022.

Entries by Matt Coughlin

Avoid Downtime By Taking Care of Your Baghouse Dust Collector

Downtime or lost production at a manufacturing facility can be incredibly costly.

Plants that operate 24/7 or produce large volumes of goods often know exactly how much each hour of downtime costs them—and it’s usually a number that makes management break into a cold sweat.

Problems with baghouses are a common cause of unplanned downtime, especially when maintenance is overlooked.

Problems with baghouses are a common cause of unplanned downtime, especially when maintenance is overlooked. Many facility managers think they’re saving money by cutting back on dust collection system maintenance. But what they’re really doing is saving a few pennies now only to lose buckets of dollars later when the whole system grinds to a halt.

It’s probably not realistic to expect any plant to run perfectly 24 hours a day, 7 days a week, 365 days a year. (If yours does, please tell us what’s the secret!) That’s why smart plant managers plan regular maintenance windows to keep things running smoothly.

There are two types of downtime: planned and unplanned. Both come with costs, but only one of them is on your schedule.

A survey of automotive industry execs showed that stopping production costs an average of $22,000 per minute. Let that sink in. Another study found that most facilities underestimate their downtime costs by a whopping 300%.

Now, imagine that your industrial dust collector goes down. Odds are, it won’t be going alone—it’ll take related systems with it. In many facilities, dust collectors used for pollution control are required to run at all times. Any malfunction can trigger a mandatory shutdown of the entire operation. When downtime costs tens of thousands per minute, it’s easy to see how skipping routine maintenance on a dust collector can quickly become the most expensive “savings” plan in history.

Yet despite their importance, dust collectors often get minimal attention when it comes to preventive maintenance.

Below are three practical tips to help keep your dust collector—and your production—running like clockwork.

1. Prevent Abrasion from Damaging Your Bags

High compressed air will lead to early bag failure, often creating abrasion problems or even creating holes in the fabric

Abrasion occurs when incoming dust hits the filters at high speed or volume. It can also happen when filter bags rub against each other or other components, like filter cages. This kind of wear is the main cause of early bag failure—and when bags leak, that usually means shutting the system down to find and replace them.

To reduce abrasion:

🔸 Use baffle plates to slow down and evenly distribute incoming air, allowing heavier dust to fall out before reaching the filters.
🔸 Ensure a proper inlet design to keep air from blasting directly onto the bags.
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

🔸 Consider pleated filter technology, which elevates the filters out of the direct path of incoming dust. This gives particles more space to settle before hitting the filter media.

2. Change the Whole Set—Avoid Spot Changing

One of the most common (and most shortsighted) maintenance mistakes is only replacing the individual filters that fail, instead of the entire set. While it might seem like a cost-saving measure, it actually leads to more frequent failures, more emissions, and more downtime—not exactly a win.

Here’s why: when a brand-new filter is installed among older, dust-laden ones, air naturally flows through it more easily. That extra airflow causes the new filter—and those around it—to wear out faster. It’s a domino effect of failure.

Pro tip: If you’ve spot-changed more than 5–10% of the filters in a unit, it’s time to replace the entire set. That prevents the cycle of failure from continuing and helps restore optimal system performance.

3. Use Triboelectric Monitoring

With devices such as opacity meters or triboelectric bag leak detection systems, plants can measure emissions with extreme accuracy

Want to catch bag failures before they catch you off guard? Install a triboelectric monitor. It’s one of the best tools to proactively detect early or end-of-life filter failures.

With a properly installed system, you’ll get an alert at the first signs of a leak, early enough to address it during your next scheduled maintenance window. That means fewer emergency shutdowns and less contamination of nearby filters.

And when a leak does occur, triboelectric monitoring systems can help you pinpoint its exact location, right down to the compartment, row, or even individual bag. Quite impressive, right?

Conclusion

Regular maintenance and smart monitoring of your baghouse dust collector can help you avoid unplanned downtime, reduce emissions, and keep your team focused on production, not chasing leaks. In the end, it’s not just about dust—it’s about dollars.

August 12, 2025/by Matt Coughlin

Baghouse Accessories, Baghouse Design

The Role of Dampers and VFDs in an Efficient Dust Collection System

Every time we visit a new plant and chat with the folks running the dust collectors, we notice that the word “damper” means different things to different people. So we figured it’s a good time to clear things up and explain what dampers actually are, what are VFDs, and how to use them the right way.

What Are Dampers?

As systems increase in size, it may be necessary to use dampers on the ductwork

Ventilation dampers are used in dust collection systems to adjust and control airflow. Air dampers are also used to separate sections of the ductwork that are not currently operated, thus optimizing the operation of the entire system. There are different types of dampers, including manual dampers (adjusted by hand), motorized dampers (controlled by an electric motor), and automatic dampers (responding to changes in temperature or pressure). Dampers provide a way to manually or automatically adjust airflow, but they do not change the speed of the fan or motor.

In the dust collector itself, there are two main types of dampers and they adjust fan capacity with different system effects:

Outlet Damper: This is the least efficient option, as it increases system pressure drop as the air flow decreases.

Inlet Vane Damper (VIV) – Installed on the inlet of the fan, swirls the air in the same direction as the fan rotation. They are commonly modulated with electric or pneumatic actuators. This is the most efficient damper option. Power consumption can be reduced, though not as much as with a VFD.
Outlet Damper – Mounted on the outlet of the fan, simply “throttles” the air leaving the fan. This damper is the least efficient option, as it increases system pressure drop as the airflow decreases.

The Importance of Initial Damper Settings

You might have to readjust the dampers throughout the lifespan of the filters

When a dust collector is first commissioned, a service technician measures the total air volume and duct conveying velocity to ensure proper dust control at the hoods in the process. These measurements are typically taken when the system and filters are new, with a low differential pressure around 1.0 inch of water column. At this point, the technician sets and records the fan damper position.

Most dust collectors have a cleaning system that keeps dust from building up in the filters and helps maintain an average differential pressure. But as time goes on, pressure builds up and airflow drops, so you might have to readjust the damper a bit to keep things working right. This kind of adjustment might need to happen a few times throughout the lifespan of the filters.

When it’s time to replace the filters, the damper must be readjusted to its original position set during commissioning. If you skip that step, you could end up with too much airflow, which wears out the new filters faster, increases costs due to more frequent replacements, and could even cause some downtime in your process.

What is the difference between Dampers and VFDs?

While dampers control airflow by opening or closing to adjust the volume of air passing through ducts, VFDs control the speed of motors to regulate the output of fans.

VFDs (Variable Frequency Drives) are electronic devices used to control the speed of an electric motor by varying the frequency and voltage supplied to it. They are often used with fans to adjust the speed of the motor based on the required airflow. By adjusting the speed of the motor, VFDs can achieve energy savings by matching the output of the fan or pump to the actual demand, rather than running at full speed constantly.

This setup is great for dust collector users because it cuts down on the work needed to keep the system running—no one has to constantly mess with the outlet damper. Plus, the VFD keeps the collector working at the right air-to-cloth ratio all the time. That means there’s no risk of someone accidentally opening the damper too much and throwing things off, which can wear out the filters faster.

But the biggest perk for dust collector owners? Long-term energy savings. Since fans use variable torque, the energy they need depends on how fast they’re running. And it’s not a small difference—if you slow a fan down by 25%, it only uses about 42% of the energy. Cut the speed in half, and it only uses around 12% of the power. That adds up to serious savings over time.

Do I Need a Fan Damper or a VFD?

Simply put, it all depends on the application. What can help you decide?

PROS

In addition to reducing the power, variable frequency drives in fan applications may also result in reduced noise in heating and ventilation ductwork due to the elimination of dampers. When regulating flow rates, dampers can induce unwanted vortexes in the airflow, which create noise and vibration. In a variable frequency drive system, making flow-rate changes generally only results in slight changes to the noise levels, which are normally undetectable to the ear.

CONS

✳️ Full load conditions: in well-optimized applications where the process demand may already closely match the full-load capacity of the motor, then use of a variable frequency drive with its associated energy losses would only add to the overall system losses.
✳️ Equipment speed limitations: some equipment is not designed to operate at reduced speeds, and could be damaged if operated at a reduced speed. Check with equipment suppliers to ensure the equipment is compatible with variable speed operation.
✳️ Another limitation of variable frequency drives is that it is not normally possible to reduce the flow all the way to zero due to a reduction of cooling capacity in the motor; a minimum speed of around 30% is permissible, however this is dependent on the specification of the variable frequency drive and motor.

Which One is the Most Convenient for My System?

Here we have some key factors you should have in mind:

✔ How many hours will the fan be in operation?
✔ What is the cost of power in your area?
✔ Dampers have lower up-front costs than VFD’s, but VFD’s can provide higher long-term savings in energy costs.
✔ Outlet dampers may be a great option if cold-starting the fan is the only concern (when the air’s temperature at start-up is colder than the actual operating temperature).
✔ Dampers can be used to regulate and balance system pressure.

Do you have any additional questions regarding fan dampers and VFD’s? Are you wondering how you can make the switch in your current dust collection system?

July 1, 2025/by Matt Coughlin

Baghouse FAQs, Dust Collection 101, Dust Collector Maintenance, Dust Collector Troubleshooting

Are My Dust Collector Filters Washable?

—”The inside of my dust collector’s filter bag is clogged with a solid layer of dust, and the airflow seems weaker than before. Should I hire a filter cleaning service? Isn’t that cheaper?”

Short answer: “Maybe not…”.

Long answer: Read below!

Pros and Cons of Wet and Dry Cleaning Services For Filters

Cleaned filters need to be replaced more frequently, leading to more change-outs, downtime, and cleaning charges.

Cleaning weakens the filter, reducing its strength, lifespan, and risking structural failure

Many see paying for a wet or dry cleaning service for their cartridge and bag filters as a great deal. But is it really?

The cost of having a filter cleaned is significantly lower than buying a new one. However, the perceived savings quickly diminish when you factor in the resulting shorter filter lifespan and decreased efficiency caused by cleaning.

Cleaned filters need to be replaced more frequently, leading to more change-outs, downtime, and cleaning charges.

Usually, a cleaned filter lasts about half as long as new filters before clogging again. Consequently, cleaned filters require more frequent replacement, resulting in increased change-outs, downtime, and cleaning expenses.

In the following images, you can see the true difference between new filters and filters after it has been wet cleaned or dry cleaned.

As shown in the images, cleaned filters still retain particles. Independent lab tests comparing new and cleaned filter media revealed the following:

● Cleaning weakens the filter, reducing its strength, lifespan, and risking structural failure.
● It can damage filter pores.
● The nanofiber surface layer degrades, reducing efficiency at the submicron level by up to 18%.
● Only about 52.8% of the filter’s overall dust holding ability is recovered, using up over half of its lifespan.
● Wet cleaning may remove flame retardant treatment.
● Aggressive cleaning can cause weak spots or holes in filters.

Wet cleaning on dust collection filters can remove flame retardant treatment.

Wet cleaning can remove flame retardant treatment

Apart from these reasons, consider disposable safety equipment, travel time for service personnel, or downtime costs, which can be double the cost of new filters.

By the end of the year, this average scenario shows that it is actually more expensive to use cleaned filters than new filters. Why spend more money just to compromise the integrity of your dust collection system?

Additional Factors to Consider

● Turnaround time for cleaning can be two to three weeks.
● You need to keep spare filters and packaging available while filters are being cleaned.
● Shipping and handling increase the risk of filter damage.
● Cross-contamination and receiving back another customer’s filter are possibilities.
● Contaminants can migrate during cleaning, introducing them into the plant environment.

Dry-cleaned filters lose almost 53% of their original dust loading capacity

"We thought we could save a bit of money by washing our filters instead of replacing them. I figured it was worth a try. Initially, everything seemed fine — they looked cleaner, and airflow improved. But just a few days later, we noticed the collector wasn’t performing like it used to. The differential pressure started rising and not coming down after the cleaning pulse, and we had buildup inside and outside our facilities. It wasn't a good idea. The filters started clogging up much faster than before, and we had to replace them anyway.

In the end, we lost valuable production time and the costs added up quickly. Looking back, I would have been better off sticking with new filters and avoiding the headaches altogether."

— Mark R., Operations Manager at an Aggregates Plant

So... Should I Wash My Dust Collector Filters?

If you’re debating whether to clean or replace your dust collector filter, the answer is to replace it.

Filters should always be changed when they become blinded and the differential pressure gets consistently high. This is especially important even if the filter media looks undamaged. Materials like polyester, cellulose, or corrugated filters aren’t built for high-pressure cleaning — attempting to do so can cause holes or tears that may be too small to see but will still allow dust particles to pass through the filter. These particles can accumulate in the clean air plenum and continue blowing into your facility, even if the filters seem “clean.”

While a clean filter and a seemingly normal differential pressure reading might suggest everything is working properly, the truth is that the lower dP could be misleading — a result of contaminated air passing through tiny holes created by repeated cleaning.

Our advice: Think twice before cleaning your dust collector filters. What seems like a good deal may not be in the long run.

If your filters are blinded and you are ready for your next filter changeout, click here:

February 12, 2025/by Matt Coughlin

Dust Collection 101, Dust Collector Maintenance, Operation & Optimization, Dust Collector Troubleshooting

Why Set Cleaning Based on Differential Pressure Instead of a Timer Setting?

Dust collector operators typically utilize cleaning systems to help them ensure effective dust control for their process areas while saving compressed air (which is very expensive when you look at your electric bill). And, for as much as some consider that the cleaner the filter is, the better it works, that is not always the case. Although some will suggest cleaning the bags on a regular basis using a timer setting… in this article you will learn why setting up your cleaning system based on the differential pressure is better for you.

In order to understand all the reasons, let’s start with the cleaning basics.

What is Pulse Jet Cleaning?

Graphic showing compressed air dislodging the dust cake from the filters

During pulse jet cleaning, a reverse flow of clean compressed air puffs a row of bags outwards, dislodging the dust cake on each bag’s surface. The bags react to the initial shock of compressed air, followed by a bubble-like expansion that moves along the bag length.

During pulse jet cleaning, a reverse flow of clean compressed air puffs a row of bags outwards, dislodging the dust cake on each bag’s surface. During this cleaning cycle, the bags in the row being pulsed do not inflate all at once, but in a wavelike manner, which enhances cleaning. The bags react to the initial shock of compressed air, followed by a bubble-like expansion that moves along the bag length. During the cleaning procedure, the baghouse remains online, and filtration continues, with no downtime required.

What is Differential Pressure?

During pulse jet cleaning, the compressed air accumulated in the air header reaches the blowpipe with a frequency and strength determined by the controller, the gauge and the diaphragm

Differential pressure in a dust collector is the difference in air pressure between the dirty side of the collector and the clean side (these two sides divided by the tubesheet). When dust particles are collected by the filter, they build up on the filter surface, making it harder for air to pass through. This creates a pressure difference: the air inside the filter becomes more pressurized compared to the clean air outside the filter.

As the dust builds up, the pressure difference increases, which can affect the efficiency of the dust collector. High differential pressure usually means the filter is getting clogged and needs cleaning. Monitoring differential pressure helps ensure the dust collector is working properly and efficiently.

Why is It Important to Monitor Differential Pressure?

Just as blood pressure indicates the health and efficiency of the circulatory system, differential pressure provides a vital measurement of how well the dust collector is functioning.

Differential pressure can warn us when the baghouse needs help. It can be as simple as indicating when it’s time to pulse clean filters or more extensive service, like it’s time to replace the filters. Continuously monitoring pressure drop can reveal problems early, when they are faster, easier and cheaper to fix, and helps extend bag life.

Read here Why Is The Differential Pressure So Important.

Why Set Cleaning Based on Differential Pressure Instead of a Timer?

Setting your cleaning based on differential pressure helps stop wasting compressed air. This is because the filters are cleaned only when the pressure reaches a certain level, which prevents overuse. It’s important to maintain the right amount of dust cake (the layer of dust on the filter) because cleaning too often or not enough can cause problems. Under-cleaning creates high differential pressure, while over-cleaning wears the filters out faster.

DID YOU KNOW?
The primary benefit of differential pressure controllers is their ability to program a high set point (when a filter cleaning system turns on) and a low set point (when the cleaning system turns off). Usually the low and high points for the differential pressure are 3” to 5” respectively. By programming the high and low set points effectively, the controller triggers filter cleaning only within the desired range.

During normal use and operation, these controllers monitor the differential pressure across the filters in the collector. The dust collector operator receives a visual indication of the pressure drop across the filters, indicating how clean or dirty the filters may be. Typically, the lower the indicator value for pressure drop, the cleaner the filters, and the higher the value, the dirtier the filters.

Dirty filters tend to provide better filtration efficiency with their cake of accumulated dust, but they require additional energy from the fan in order to maintain airflow volume.

In summary: Your dust collector’s cleaning system does not need to run continuously or clean in fixed periods of time. Using the differential pressure to control the cleaning will save you lots of money and time, since the system will only clean when is necessary, and your filters will last longer.

How Often Should We Monitor the Differential Pressure?

A good preventive maintenance program should include daily (or per shift) checks of the filter differential pressure on each pulse jet unit. This includes visually inspecting and listening to each collector while it’s running to check the pulsing sound and frequency, as well as checking the compressed air pressure in the cleaning manifold before and after pulses. Weekly, monthly, and longer-term checks should also be included. A simple and effective way to do this is to assign one person per shift to monitor the dust collectors and record that information. After a short time, they will become familiar with the normal differential pressure trends and sounds, helping them quickly identify any issues.

Read here How To Install a Differential Pressure Sensor

What Are The Best Settings For Your Pulse Cleaning System?

Pulse Duration

It’s important to set your pulse time correctly. We recommend a pulse duration between 300 and 500 milliseconds. This is enough time to allow a solid “pop” of air, without an additional “Shhhh” with it. This provides a strong burst of air, without wasting air with additional unnecessary flow. A pulse that lasts too long results in wasted air after the initial “pop,” as the lower pressure doesn’t improve cleaning. If pulses are too short, they might not clean the filters thoroughly, leading to premature wear. You can adjust pulse duration on the timer board or controller.

Pulse Frequency

The key to effective pulsing is giving the manifold enough time to recover the compressed air between pulses. Avoid pulsing too frequently, as this can prevent the manifold from refilling to the correct pressure. If the pressure isn’t high enough, cleaning will be inefficient, leading to wasted compressed air. Always ensure there’s enough delay between pulses to allow the manifold to recover properly. This can also be set on the timer board or controller.

Pulse Sequence

It might seem logical to pulse the filters in row order, but this actually wastes air. When row 1 is cleaned, its lower static pressure allows air to take the path of least resistance, potentially carrying dust back into row 1 during subsequent pulses. This reduces the effectiveness of the cleaning. Instead, we recommend pulsing in a non-sequential order. For example, pulse rows 1, 4, 7, and 10 first, then rows 2, 5, 8, and 3, 6, 9, repeating. This method ensures better cleaning and minimizes air waste. You can change the sequence by adjusting the wiring on the timer board.

Read here How To Troubleshoot False Readings From Your Pressure Sensor

By following these guidelines, you can improve the efficiency of your dust collection system, saving both time and money.

Do you have any additional questions?

December 23, 2024/by Matt Coughlin

Baghouse FAQs, Purchasing Supplies Tips

Should I Buy a Used or New Baghouse?

Key Considerations for Buying Used Baghouse Systems

When businesses look for ways to save money, one option is to buy used equipment instead of new. At first glance, purchasing a used baghouse system may seem like a great deal. The lower upfront cost and quick availability are tempting. However, before jumping into a decision, it’s important to consider more than just the initial savings. There are hidden factors that could make a used baghouse less economical in the long run. Let’s break down the pros and cons to help you make the best decision for your operation.

Key Considerations for Used Baghouse Systems

While a used baghouse may come with a lower price tag, here are a few critical factors you need to evaluate:

Age and Condition

How old is the equipment? It’s common for used systems to need replacement parts such as filters, cages, valves, and gaskets. Depending on how much needs to be replaced, a used system could quickly become more expensive than it first appeared.
Compatibility with Your Needs

Is the system designed for your specific dust collection requirements? Consider:
- The air-to-cloth ratio
- The temperature and pressure it can handle
- The physical and chemical properties of the dust. An improper match could lead to inefficiencies, higher operating costs, or worse—contamination risks.
Unknown History

Before buying a used dust collector, make sure you get a full report of what kind of process it was used for

You might not know what the baghouse was exposed to before. If it handled hazardous or incompatible materials, you could face contamination risks in your own operations, which could harm your products or create a dangerous environment.
Compliance

Does the used system meet today’s OSHA and NFPA standards? Regulations are frequently updated, and an older system might need costly upgrades to comply with current rules.
Transport and Assembly Costs

Large used baghouse systems may need to be disassembled for transport, which can require specialized equipment and labor. Reassembling it at your site could also incur additional costs, potentially outweighing the initial savings.

Hidden Costs to Watch For

Used systems often come with more than just the visible costs of parts and transport. You might also encounter:

— Structural issues: Outdated control systems or worn-out motors could add to your expenses.
— Environmental concerns: Older systems may not include modern technology for efficient dust collection or emission control.
— Higher maintenance: Older systems generally require more frequent repairs and servicing, which increases downtime and operational costs over time.

Benefits of Buying a New Baghouse System

Baghouse.com personnel unloading a dust collector and installing it

A new system offers customization, compliance, low maintenance, and the security of a warranty

While buying a used baghouse system may seem cheaper upfront, purchasing new equipment often saves more in the long run. Here’s why:

Customization: A new system is designed specifically for your operation. Experts take into account the dust properties, airflow needs, temperature, and pressure to create a system that runs efficiently and meets all your requirements.
Compliance and Safety: A new system will meet current OSHA and NFPA regulations right from the start. This helps you avoid fines, legal issues, and costly modifications.
Lower Maintenance Costs: New systems are less likely to break down and come with modern cleaning mechanisms that extend filter life and reduce operating costs.
Warranty and Support: A new baghouse comes with a warranty and the option for ongoing technical support, giving you peace of mind that any issues will be promptly handled.
Higher Resale Value: A new system, when well-maintained, will retain more of its value, making it easier to resell if your production needs change.

Conclusion: Used vs. New—Which is Right for You?

If you’ve evaluated a used baghouse system and determined it can meet your needs, considering factors like disassembly, transport, and the cost of necessary upgrades, it might be a good option. However, keep in mind the potential hidden costs and long-term maintenance issues.

On the other hand, a new system offers customization, compliance, low maintenance, and the security of a warranty, which often makes it a better investment over time.

Before making your decision, we recommend speaking with a dust collection expert at Baghouse.com. Our specialists can help analyze your specific needs and guide you toward the best option for your facility.

October 9, 2024/by Matt Coughlin

Agriculture, Food Processing

Case Study – Operational Improvements at Blue Diamond Growers

Background

Blue Diamond Growers, an almond processing facility in central California, required a large and complex ductwork modification and installation of HEPA filters on several dust collection systems to balance building pressure and improve air quality. The project involved routing return air from their dust collectors back into the building and installing high-efficiency HEPA filters to ensure the return air was dust-free. Additionally, the added HEPA filters required existing dirty air ductwork to be rerouted around the new equipment.

Scope of Work

Blue Diamond Growers needed to balance pressure within their facility to reduce energy costs and maintain air quality. This required significant re-routing of ductwork, designing custom HEPA housings, and transitions. They also needed to install particulate sensors and differential pressure gauges with remote monitoring capability.

Solution

Baghouse.com responded to a request for a quote and developed the final work scope after a job walk and reviewing 3D scans of the facility. The engineering deliverables included 2D layouts, 3D CAD files of the dust collection systems, and general arrangement drawings of the equipment.

Installation Challenges

The project had to be completed within an extremely tight schedule, as the customer could only take their production offline for one week. The existing ductwork’s complexity, with many tight clearances and multiple duct sizes and inlets, posed a challenge. The ductwork had to be re-routed around the new HEPA filter housings logically to minimize static pressure from added elbows and unions.

Outcome

The project was completed within about four months, resulting in a perfectly balanced facility for the first time. Blue Diamond Growers significantly reduced their energy usage, is able to keep their climate-controlled and refrigerated areas cool, and has significantly minimized the risk of pulling in outside dust or contaminants. The upgrade also reduced the overall heating and cooling costs in the facility.

Conclusion

Baghouse.com provided Blue Diamond Growers with a comprehensive solution that improved air quality and facility efficiency. The successful implementation of the dust collection upgrade has led to significant energy savings and operational improvements.

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 30, 2024/by Matt Coughlin

Dust Collector Troubleshooting

The Benefits of Leak Testing for Dust Collection Systems

Even the most efficient and well-maintained dust collection systems will occasionally experience leaks, compromising their effectiveness and putting worker health at risk. A mere ⅛” hole in a single filter bag out of 1000+ bags can cause a system to fail a stack test. This is why implementing effective leak detection strategies is crucial.

A stack test, also known as a performance test or compliance test, measures the emissions from industrial stacks or ducts. While visual checks were common in the past, many facilities now use continuous monitoring systems for more reliable and less labor-intensive measurements. Visual observations still serve as a valuable backup method.

Conducting a dye test is not only for filter bags that have been in operation for an extended period of time. Newly installed ones can (and should) also undergo leak testing. It’s crucial to safeguard your investment in filter bags by performing a dye test on the dust collector after replacing filter bags.

How Leak Testing Is Done

Identify an injection port on the negative side of the gas stream closest to the baghouse inlet for injecting the fluorescent dye powder. (Note: Avoid using hopper doors for injection as it disrupts airflow and may leave some filter bag areas uncoated with dye powder.)
Ensure that the baghouse/compartment hopper is free of any accumulated material.
Deactivate the baghouse cleaning mechanism while keeping the exhaust/ID fan operational.
- —For Pulse Jet Dust Collectors, shut off and lockout the main airline feeding the cleaning system and release all air pressure from the header.
- —For Mechanical Shaker or Reverse-Air Systems, de-energize and perform a LOTO on the appropriate electrical and pneumatic devices.

Tip: Shutting down the shaking or pulse cleaning mechanism for a short period before inserting the leak testing powder will enhance detection results. This allows the dust cakes to build-up, increasing the pressure between the dirty and clean air sides of the baghouse, encouraging the leak testing powder to find the points of least resistance – the leaks.

4. Inject an appropriate amount of fluorescent dye powder into the system based on your baghouse design and application. A general rule of thumb is to use 1 lb of powder for every 1,000 sq/ft of fabric area. For smaller units, a higher ratio is needed.

Leak testing powder can be used in all baghouse types with operating temperatures up to 550°F (288°C). It is important to choose an appropriate color for your specific application, as well as keeping a contrasting color on-hand for repetitive test. The objective is to choose a color that will not blend in with process dust color.

5. Allow up to five minutes for the leak detection powder to circulate through the system after injection.
6. Shut down the exhaust/ID fan.
7. Before entering the baghouse, ensure compliance with all OSHA/MSHA and site-specific company protocols, including LOTO and Confined Space Entry.
8. Enter the clean air side of the baghouse or compartment being tested. Use a black light and UV filtering glasses to inspect the tubesheet, filter bag, snap band/seating surface, and all other areas on the clean air side of the collector that come into contact with the inlet gas stream. Any leaks will cause the fluorescent dye powder to “glow” under the black UV light, pinpointing the affected area. For optimal results, perform the dye test in darkness with minimal light. (On rare occasions, it may be necessary to also inspect the filters from the dirty side as well to locate hard-to-find leaks.)
9. Document all filter bag failures on a grid sheet and retain them for future reference. Recurring bag failures in the same area may indicate dust collector system design or operational issues.

Benefits of leak testing for dust collection systems

1. Maintaining Compliance with Environmental Regulations: Governments have stringent air quality standards in place to protect the environment and public health. In many industries, once a leak becomes large enough to create visual emissions at the stack, companies are required to document and report corrective actions and possibly face fines and sanctions. By being proactive with leak testing and promptly repairing any found, an organization can demonstrate its commitment to environmental responsibility, helping them stay within compliance and avoid fines.

2. Protecting Worker Health and Safety: This is most crucial with systems that recirculate the air after it passes through the dust collector. Dust particles generated during industrial processes often contain toxic compounds or otherwise benign materials that are harmful when inhaled. Additionally, leaks on systems handling combustible dusts can lead to accumulations in the ductwork, process equipment, and on elevated surfaces inside the plant (when recirculated), all of which form a severe fire and/or explosion hazard.

Plants that recirculate the air back into the building are often required to install triboelectric bag leak detection systems. These systems are sensitive enough to detect even minute increases in dust emissions. When installed, they can give early warning about leaks as they form, even before they reach reportable levels. For this reason, many plants find triboelectric bag leak detection systems useful even when their use is not strictly mandated by their operating permits or OSHA.

3. Enhancing Equipment Efficiency and Longevity: Leaks in dust collection systems can impact the overall efficiency and performance of many types of process equipment. By proactively identifying and repairing leaks, industries can ensure that their systems operate at optimal efficiency, reducing energy costs, extending equipment lifespan, and minimizing maintenance costs.
4. Preventing Cross-Contamination and Product Loss: In industries where contamination control is critical, leak detection becomes crucial. Leaks in dust collection systems can introduce foreign particles into the production area, compromising the quality and safety of the final product.

If you believe your dust collection system may be suffering from leaks, consider conducting a dye test or contacting professionals like Baghouse.com for assistance. Remember, the benefits of leak testing far outweigh the risks associated with system failures. Protect your workers, your environment and your investment by making leak detection a priority in your maintenance program.

Want to read more about leak testing? Read the article:

Filter Bags & Leak Testing – How Important is it?

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

May 29, 2024/by Matt Coughlin

Industrial Health and Safety Regulations

Dust Collection System Compliance – Ensure Your System Will Pass an Audit

Industrial dust collection systems are a crucial tool in ensuring workplace safety, sustainability, and environmental compliance. These systems are not just equipment needed for your processes and facilities to produce effectively; they are state-of-the-art safety measures. However, to maintain their effectiveness they require modern validation and certification methods. Regular assessments are essential, especially when process conditions change.

The Consequences of Non-compliance

Extraction systems that handle explosive dust are made up of numerous vital components. These components must work in harmony to provide the expected safety. When a system malfunctions or doesn’t perform as intended, it can lead to a host of issues:

Production Impacts: Malfunctioning extraction can disrupt the production process, resulting in downtime and decreased productivity.
Health Concerns: Operators exposed to dust due to inadequate extraction can face significant short and long-term health problems, leading to absenteeism, reduced workforce efficiency, reduced worker morale and productivity, and sickness and injury among your team. One example is silicosis, a lung disease caused by long-term exposure to fine silica dust.
Increasing Costs: Neglected preventive maintenance, monitoring, and operational tasks result in unplanned costs for repair and replacement of worn and broken equipment.
Safety Risks: Failure to ensure your equipment is up to date increases the risk of dust explosions, which can have catastrophic consequences, endangering lives and property.

Compliance and Inspections

For all ATEX equipment (equipment used in explosive atmospheres), regular inspections are mandatory. The specific intervals and requirements vary based on the manufacturer and notified bodies responsible for type approval. Compliance checks must include the following…

Explosion Isolation System Inspection Requirements:

A clear description of the intended use of the explosion isolation system.
Operational requirements.
Installation requirements.
General arrangement plans.
Commissioning requirements.
Maintenance guidelines.
Periodic Inspections

Regular inspections are crucial to ensure that the explosion isolation system maintains its capability and reacts as originally designed in case of an explosion. Procedures after an explosion are also a vital part of compliance.

Inspection Points

Specific inspection points are listed in user manuals, and in most cases, only authorized engineers can perform these inspections. Even when end users are allowed to inspect, it’s strongly recommended to engage knowledgeable companies like Baghouse.com for an annual inspection. Book Now Your Baghouse System Audit.

Inspectors can identify issues beyond the checkpoints. For instance, they can uncover dust deposits on valve seats, which, if not cleared, can render safety components ineffective in the event of an explosion. Safety is contingent on the entire system functioning correctly, not just individual components.

Documenting the Inspection

A documented inspection or maintenance, conducted by an authorized company, is the formal way to prove compliance with OSHA and NFPA standards. Documentation is essential in case of accidents or incidents to demonstrate that regular maintenance occurred. When individuals without adequate training or authorization conduct inspections, they bear full responsibility for any faults. Conversely, following instructions and maintaining proper documentation shifts responsibility away from the end user.

How Baghouse.com Can Help

We can assist by providing annual safety inspections for Dust Collection Systems in various industrial applications. These inspections include a comprehensive functional test of the entire system and a summary of recommendations based on our on-site survey for each dust collector.

Training for Safety

Regular training for key personnel is crucial. This includes not only personnel directly involved with the equipment but also those responsible for emergency procedures, such as Building Management System (BMS) operators. Having an accessible emergency checklist is vital for quick, effective responses during alarms, ensuring everyone knows what to do in critical situations. Read more about our Training for Maintenance and Safety Personnel.

In conclusion, compliance with safety and environmental regulations is non-negotiable in industrial dust collection systems. Regular inspections, documentation, and expert assistance are your best allies in maintaining a safe, compliant, and efficient dust collection operation. Our experts are ready to help you evaluate, diagnose, and improve the safety and efficiency of your dust collection system, ensuring a secure and sustainable workspace for all.

If you have any questions or need assistance with your dust collection system compliance, feel free to reach out to us. Your safety and peace of mind are our top priorities!

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

September 12, 2023/by Matt Coughlin

Purchasing Supplies Tips

Where to Spend and Where to Save on Dust Collector Components

Regardless of your industry, business size, or region, keeping the air clean and your workers safe is a top priority. This is where dust collection systems come into play. They not only protect your employees from harmful carcinogens and health issues, but they keep your equipment running smoothly and your business compliant and out of the crosshairs of regulatory agencies. With those priorities in mind, it’s important to note that selecting the right parts for your dust collector is more than just looking at the price tag. Let’s dive into the art of making smart decisions – knowing where to invest and where to save when it comes to dust collector components.

Don’t Skimp on Filtration Efficiency

Before we get into the nitty-gritty of costs, remember that filter performance is the most crucial element of your dust collection system. Filters are like the guards at the gate of safety, health, and compliance, and their job should never be compromised. When it comes to dust collector filters, it’s about finding the right one for your application. It’s like cooking a good meal – you need the right ingredients. Once you find the right one, you have to make sure to replace them before they fail and damage your system. Read more: How often should filters be changed?

It is very common for users to look for deals on filters – for example, replacing a high-efficiency nano cartridge filter with a cheaper 80/20 cartridge filter to save on cost. However, in this case the 80/20 cartridge offers roughly half of the filter area of a nano filter of the same size, meaning your system can now handle half of the air flow it was designed for! And the efficiency of the cheaper filter is much less – MERV 11 vs. MERV 15, so there is a good chance that you will be emitting much more dust than expected. Finally, the 80/20 filters will wear out significantly faster than the better filters. So it worth paying more for a better filter with longer life, better efficiency and better performance throughout your system? You bet! The total cost will be lower in the long run (see farther down).

Being Eco-Friendly Matters

Your duty is not only to your workers but also to the environment. In a world of strict rules, your choices should match the limits set for different types of dust. Some dust is just annoying, while others can be harmful. Sometimes, the law requires you to use extra-efficient filters, especially for hazardous dust. Knowing these rules helps you pick the right filter. Learn more about these regulations.

More Than Money: Considering Dust Particles

Look beyond the cost and consider the characteristics of your dust. Is it fine or coarse? Is it combustible? Is it sticky? These things really matter when choosing the right filter. Some may think that obtaining the right filter is very expensive and may look for cheaper alternatives. Check here why this is a dangerous decision: Why Are My Baghouse Filters So Expensive?

The Real Costs: Total Cost of Ownership (TCO)

As any good supply chain professional knows, the up-front price tag doesn’t tell the whole story. There’s more to cost than just buying the item. TCO is a fancy way to say, “How much does this really cost over time?” It includes energy use, how often you change filters and cages, and other hidden expenses. E.g.: Using electricity costs money. Filters need air to flow through them, and that takes energy. But there are smart ways to save energy, like using special fans that don’t waste electricity.

Money-Saving Options

One item that perfectly illustrates the difference between short-term cost and long-term savings is the use of VFD (variable frequency drive) fan controllers. 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. Generally, upgrading your fan controller to include a VFD will cost several thousand dollars, but this cost is easily recouped after a year of running your system more efficiently.

Next Steps: Being a Smart Chooser

Remember, this is more than just a dust collector. It’s about keeping your workers safe, your equipment in shape, and your business running well. So, when you’re thinking about where to spend and where to save, remember that the journey to a better dust collection system goes way beyond just buying stuff. It’s about being smart, safe, and forward-thinking.

Take a deeper dive into our dust collection blog for more helpful articles and insights. Let’s make your dust collection system the best it can be!

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

September 5, 2023/by Matt Coughlin

Dust Collection 101

How Does a Cyclone Dust Collector Work?

What is a Cyclone Dust Collector?

A cyclone dust collector (also referred to as a cyclone separator or simply a cyclone) is a device that is used to remove particulate matter from air or gas streams. It works on the principle of centrifugal force, which is generated by a rapidly rotating cylindrical chamber.

Unlike a standard dust collector or baghouse that uses filters to collect dust from the air, allowing clean air to pass through, a cyclone dust collector uses centrifugal force and the momentum of the dust-laden air to pull out heavier dust from the air stream. They are particularly effective for removing larger or non-uniform particles (strips and of wood, etc.) that might clog a cartridge or baghouse collector.

How Does a Cyclone Dust Collector Work?

Here’s how a cyclone dust collector works:

Dust-laden air or gas enters the cyclone dust collector through an inlet and is directed into a cylindrical chamber.
The chamber is designed to cause the incoming air or gas to spin around its axis. This creates a centrifugal force, causing the heavier particles to move towards the outer walls of the chamber and eventually drop out and settle at the bottom of the collector.
The clean air or gas then exits the collector through an outlet located at the top of the chamber.
The collected particles are collected in a hopper at the bottom of the collector, where they are typically discharged into a bin or other dust discharge method.

When is a Cyclone Separator Needed?

Cyclone dust collectors and baghouse dust collectors are both effective at capturing and removing dust particles from industrial processes, but they are best suited for different applications.

Cyclone dust collectors are typically used for applications that generate large volumes of coarse and heavy dust particles, such as sawdust, wood chips, metal shavings, or granular materials. Cyclones are effective at removing these large particles due to their use of centrifugal force, which causes the particles to be separated from the air stream and collected in a hopper or bin. Cyclones are also relatively simple to operate and maintain, with low maintenance requirements and operating costs.

Baghouse dust collectors, on the other hand, are best suited for applications that generate large volumes of fine and light dust particles, such as welding fumes, chemical dusts, or pharmaceutical powders. Baghouses use a series of fabric filter bags or cartridges to capture the dust particles as they pass through the system. Baghouses are effective at capturing these fine particles due to their high filtration efficiency, which can exceed 99%.

In general, cyclone dust collectors are preferred over baghouse dust collectors for applications where the dust particles are relatively large and heavy, and where the process generates high volumes of material. Baghouse dust collectors are preferred for applications where the dust particles are fine and light, and where high filtration efficiency is required.

Often, a cyclone separator is installed in front (upstream) of a baghouse or other dust collector. The cyclone to remove the heaviest dust particles and the dust collector catches the finer dust. This has the benefit of lowering the dust load on the collector and removing large, sticky, or high-temperature particles before the dust-laden air reaches the collector, improving efficiency and filter life and avoiding the clogging of filters with large dust particles.

Cyclone separator upstream of a baghouse.

Cyclone dust collector upstream of a baghouse dust collector.

However, it is important to consider the static pressure loss of adding a cyclone separator into the air stream as it will increase the required load on the system fan.

It is important to consider the specific requirements of each application when selecting a dust collector to ensure that the system will provide effective dust collection while minimizing operating and maintenance costs.

Are There Different Types of Cyclone Collectors?

Yes, there are different types of cyclone dust collectors, each designed to suit specific applications and operating conditions. Here are a few variations of cyclone dust collectors:

Single-cyclone dust collectors: This is the most basic and common type of cyclone dust collector. It consists of a single cyclonic chamber where the dust-laden air enters and undergoes centrifugal separation. The heavier particles settle at the bottom of the collector, while the cleaned air is discharged.
Multiple-cyclone dust collectors: In this configuration, several cyclone chambers are arranged in parallel or series to achieve higher collection efficiencies. Multiple cyclones increase the surface area available for particle separation, improving the overall dust collection efficiency.
High-efficiency cyclones: These cyclone dust collectors are designed with enhanced geometries and optimized airflow patterns to achieve higher separation efficiencies. They often incorporate modifications such as tapered inlets, vortex finders, and secondary air injection to enhance particle separation and reduce pressure drops.
Reverse-flow cyclones: Reverse-flow cyclones, also known as reverse-flow dust collectors, operate in a reverse flow direction compared to traditional cyclones. The clean air is directed upward through the cyclone chamber, while the dust particles are collected in a downward flow. Reverse-flow cyclones are particularly useful in applications where the collected material is sticky or prone to re-entrainment.
High-temperature cyclones: These cyclone dust collectors are specifically designed to handle high-temperature applications, such as those found in industrial processes involving hot gases or exhaust streams. High-temperature cyclones are constructed with materials that can withstand elevated temperatures and are equipped with proper insulation and cooling mechanisms.

Interested in Purchasing a Cyclone Dust Collector?

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

May 13, 2023/by Matt Coughlin

About Matt Coughlin

Entries by Matt Coughlin

Pulse Duration

Pulse Frequency

Pulse Sequence

Age and Condition

Compatibility with Your Needs

Unknown History

Compliance

Transport and Assembly Costs

The Consequences of Non-compliance

Compliance and Inspections

Explosion Isolation System Inspection Requirements:

Inspection Points

Documenting the Inspection

How Baghouse.com Can Help

Training for Safety

Don’t Skimp on Filtration Efficiency

Being Eco-Friendly Matters

The Real Costs: Total Cost of Ownership (TCO)

Money-Saving Options

Next Steps: Being a Smart Chooser

What is a Cyclone Dust Collector?

How Does a Cyclone Dust Collector Work?

When is a Cyclone Separator Needed?

Are There Different Types of Cyclone Collectors?

Contact Us

Explore Our Filtration Solutions

About Baghouse.com